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BACKHOE LOADER WORKSHOP MANUAL 6111283M2 — English — January 2008

820 860/880 SX & ELITE 970/980 ELITE TX760B TX860B TX970B TX980B

TABLE OF CONTENTS GENERAL INFORMATION GENERAL INFORMATION GENERAL SAFETY

ACCESSORIES REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET FROM A QUICK ATTACH UNIT REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET FROM A QUICK ATTACH UNIT REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT HYDRAULIC CYLINDER SPECIFICATIONS — ACCESSORIES DESCRIPTION AND OPERATION — HOSE BURST VALVES REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDERS BURST VALVES REMOVAL AND INSTALLATION — LOADER BUCKET CROWD HYDRAULIC CYLINDER BURST VALVE REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM CYLINDER BURST VALVE REMOVAL AND INSTALLATION — BACKHOE BOOM CYLINDER BURST VALVE SPECIFICATIONS — HOSE BURST VALVES

BUCKETS REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET CLAMPING CYLINDER SPECIFICATIONS — BUCKETS

DIGGER QUICK ATTACH REMOVAL AND INSTALLATION — QUICK ATTACH BACKHOE BUCKET REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT CONTROL VALVE REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY — QUICK ATTACH HYDRAULIC CYLINDER SPECIFICATIONS — DIGGER QUICK ATTACH

DIGGER BOOM AND DIPPERSTICK REMOVAL AND INSTALLATION — STANDARD BACKHOE BUCKET REMOVAL AND INSTALLATION — BACKHOE BOOM REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM REMOVAL AND INSTALLATION — BOOM SWING TOWER DISASSEMBLY AND ASSEMBLY — EXTENDABLE DIPPER ARM HYDRAULIC CYLINDER GENERAL PROCEDURE — BACKHOE CONTROL LEVER ADJUSTMENT GENERAL PROCEDURE — AUXILIARY FUNCTION/TELESCOPIC DIPPER CONTROL PEDAL ADJUSTMENT SPECIFICATIONS — DIGGER BOOM AND DIPPERSTICK

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — MAST CASTING

0 0–01–2 0–01–19

A01 A01–01–1 A01–01–3 A01–01–5 A01–01–9 A01–01–11 A01–02–1 A01–02–3 A01–02–5 A01–02–9 A01–02–11 A01–02–13

B02 B02–01–1 B02–01–3 B02–01–7 B02–01–9 B02–01–15 B02–01–19

C03 C03–01–1 C03–01–3 C03–01–5 C03–01–7 C03–01–9 C03–01–13

D04 D04–01–1 D04–01–3 D04–01–7 D04–01–11 D04–01–15 D04–01–19 D04–01–23 D04–01–25

E05 E05–01–1

TABLE OF CONTENTS

REMOVAL AND INSTALLATION — MAST CASTING CLAMP SEALS REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT) REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT) CYLINDER REMOVAL AND INSTALLATION — STABILIZER LEG (SIDESHIFT) REMOVAL AND INSTALLATION — STABILIZER LEG HYDRAULIC CYLINDER (SIDESHIFT) DISASSEMBLY AND ASSEMBLY — DIPPER HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY — BACKHOE BUCKET HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY — BOOM HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY — SLEW HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY — STABILIZER HYDRAULIC CYLINDER (SIDESHIFT) DISASSEMBLY AND ASSEMBLY — STABILIZER LEG HYDRAULIC CYLINDER (CENTREMOUNT) GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER LOWER EXTERNAL WEAR PADS GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER EXTERNAL WEAR PADS GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER INTERNAL WEAR PADS GENERAL PROCEDURE — STABILIZER LEG WEAR PADS (SIDESHIFT) GENERAL PROCEDURE — STABILIZER LEGS CONTROL LEVER ADJUSTMENT GENERAL PROCEDURE — BOOM LATCH CABLE ADJUSTMENT SPECIFICATIONS — DIGGER SWING SYSTEM

MAIN HYDRAULICS HYDRAULIC SYSTEM DIAGRAM DIAGNOSING AND TESTING — HYDRAULICS/PRESSURE TESTING DIAGNOSING AND TESTING — HYDRAULIC OIL CONTAMINATION REMOVAL AND INSTALLATION — HYDRAULIC OIL RESERVOIR REMOVAL AND INSTALLATION — OIL COOLER REMOVAL AND INSTALLATION — HYDRAULIC PUMP REMOVAL AND INSTALLATION — HYDRAULIC PUMP 2007 REMOVAL AND INSTALLATION — BACKHOE CONTROL VALVE BANK REMOVAL AND INSTALLATION — LOADER CONTROL VALVE REMOVAL AND INSTALLATION — CHANGEOVER VALVE REMOVAL AND INSTALLATION — STEERING PRIORITY/UNLOADER VALVE REMOVAL AND INSTALLATION — RIDE CONTROL VALVE REMOVAL AND INSTALLATION — SERVO CONTROL VALVE REMOVAL AND INSTALLATION — SERVO CONTROL CONFIGURATION CHANGEOVER VALVE. DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP — 2007 DISASSEMBLY AND ASSEMBLY — BACKHOE CONTROL VALVE DISASSEMBLY AND ASSEMBLY — LOADER CONTROL VALVE DISASSEMBLY AND ASSEMBLY — CHANGEOVER VALVE DISASSEMBLY AND ASSEMBLY — RIDE CONTROL VALVE DISASSEMBLY AND ASSEMBLY — SERVO CONTROL VALVE GENERAL PROCEDURE — HYDRAULIC CYLINDER INSPECTION GENERAL PROCEDURE — CLEANING THE HYDRAULIC SYSTEM GENERAL PROCEDURE — FLUSHING WATER FROM THE HYDRAULIC SYSTEM GENERAL PROCEDURE — RELEASING THE HYDRAULIC SYSTEM PRESSURE GENERAL PROCEDURE — HYDRAULIC CYLINDER RING LUG EXTRACTION SPECIFICATIONS — MAIN HYDRAULIC SYSTEM

LOADER REMOVAL AND INSTALLATION — FRONT LOADER BEAM REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDER

E05–01–5 E05–01–9 E05–01–11 E05–01–13 E05–01–17 E05–01–21 E05–01–25 E05–01–29 E05–01–33 E05–01–37 E05–01–41 E05–01–45 E05–01–49 E05–01–51 E05–01–57 E05–01–61 E05–01–65 E05–01–67

F06 F06–01–1 F06–01–5 F06–01–19 F06–01–21 F06–01–23 F06–01–25 F06–01–29 F06–01–33 F06–01–39 F06–01–43 F06–01–45 F06–01–47 F06–01–49 F06–01–51 F06–01–55 F06–01–59 F06–01–63 F06–01–75 F06–01–81 F06–01–83 F06–01–85 F06–01–87 F06–01–89 F06–01–91 F06–01–95 F06–01–97 F06–01–99

G07 G07–01–1 G07–01–7

TABLE OF CONTENTS

REMOVAL AND INSTALLATION — FRONT LOADER HYDRAULIC CROWD CYLINDER REMOVAL AND INSTALLATION — LOADER BUCKET POTENTIOMETER DISASSEMBLY AND ASSEMBLY — LOADER BUCKET HYDRAULIC CYLINDER GENERAL PROCEDURE — ANTI ROLLBACK ADJUSTMENT GENERAL PROCEDURE — RETURN TO DIG ADJUSTMENT SPECIFICATIONS — LOADER

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB REMOVAL AND INSTALLATION — CAB HEATER AIR DUCTING REMOVAL AND INSTALLATION — CAB HEATER MOTOR REMOVAL AND INSTALLATION — CAB HEATER MATRIX REMOVAL AND INSTALLATION — DRIVER SEAT (ALL MODELS) REMOVAL AND INSTALLATION — CAB DOOR GLAZING PANEL REMOVAL AND INSTALLATION — AIR CONDITIONING EVAPORATOR REMOVAL AND INSTALLATION — REAR WINDOW OPEN POSITION LATCH REMOVAL AND INSTALLATION — SERVO CONTROL JOYSYICK REMOVAL AND INSTALLATION — CONTROLS TILT PEDAL REMOVAL AND INSTALLATION — HOSE REMOVAL AND INSTALLATION GENERAL PROCEDURE — AIR CONDITIONING RECOVERY AND CHARGING SPECIFICATIONS — OPERATORS ENVIRONMENT

ELECTRICS DIAGNOSING AND TESTING — STARTING SYSTEM DIAGNOSING AND TESTING — CHARGING SYSTEM DIAGNOSING AND TESTING — BATTERY REMOVAL AND INSTALLATION — BATTERY (SINGLE) REMOVAL AND INSTALLATION — BATTERY (TWIN) REMOVAL AND INSTALLATION — STARTER MOTOR REMOVAL AND INSTALLATION — STARTER MOTOR SOLENOID REMOVAL AND INSTALLATION — ALTERNATOR REMOVAL AND INSTALLATION — FRONT WIPER MOTOR REMOVAL AND INSTALLATION — REAR WIPER MOTOR REMOVAL AND INSTALLATION — INDICATOR SWITCH REMOVAL AND INSTALLATION — FORWARD/REVERSE SWITCH GENERAL PROCEDURE — BATTERY ISOLATION GENERAL PROCEDURE — BATTERY CHARGING SPECIFICATIONS — ELECTRICS GENERAL ELECTRICAL INFORMATION FUSE AND RELAY INFORMATION CONNECTOR INFORMATION COMPONENT LOCATIONS WIRING DIAGRAMS — POWER SUPPLY WIRING DIAGRAMS — ENGINE WIRING DIAGRAMS — TRANSMISSION WIRING DIAGRAMS — DIFFERENTIAL LOCK WIRING DIAGRAMS — STEERING WIRING DIAGRAMS — CONSOLE PANELS WIRING DIAGRAMS — LIGHTING WIRING DIAGRAMS — WARNING FUNCTIONS WIRING DIAGRAMS — OPERATORS ENVIRONMENT WIRING DIAGRAMS — HYDRAULIC SYSTEMS WIRING DIAGRAMS — SERVO LEVER CONTROL CONNECTOR LOCATIONS

G07–01–9 G07–01–13 G07–01–15 G07–01–19 G07–01–21 G07–01–23

H08 H08–01–1 H08–01–13 H08–01–17 H08–01–19 H08–01–23 H08–01–25 H08–01–27 H08–01–31 H08–01–33 H08–01–37 H08–01–41 H08–01–45 H08–01–49

J09 J09–01–1 J09–01–5 J09–01–7 J09–01–11 J09–01–13 J09–01–15 J09–01–17 J09–01–19 J09–01–21 J09–01–25 J09–01–27 J09–01–29 J09–01–33 J09–01–35 J09–01–43 J09–02–1 J09–02–5 J09–02–9 J09–02–33 J09–02–47 J09–02–51 J09–02–53 J09–02–57 J09–02–61 J09–02–63 J09–02–69 J09–02–83 J09–02–87 J09–02–93 J09–02–103 J09–02–105

TABLE OF CONTENTS CHASSIS AND BODYWORK REMOVAL AND INSTALLATION — REAR FENDER REMOVAL AND INSTALLATION — HARDNOSE / TOOL BOX REMOVAL AND INSTALLATION — HOOD REMOVAL AND INSTALLATION — FRONT FENDER SPECIFICATIONS — CHASSIS AND BODYWORK

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — TWO-WHEEL DRIVE FRONT AXLE DIAGNOSING AND TESTING — TWO-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — TWO-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP GENERAL PROCEDURE — TOE-IN ADJUSTMENT SPECIFICATIONS — TWO-WHEEL DRIVE FRONT AXLE DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP DISASSEMBLY AND ASSEMBLY — PINION GROUP GENERAL PROCEDURE — TOE-IN ADJUSTMENT GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE DESCRIPTION AND OPERATION — FOUR-WHEEL STEER FRONT AXLE DIAGNOSING AND TESTING — FOUR-WHEEL STEER FRONT AXLE REMOVAL AND INSTALLATION — FOUR-WHEEL STEER FRONT AXLE DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — FRONT WHEEL HUB GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER) GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT (FOUR-WHEEL STEER) GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL (FOUR-WHEEL STEER) GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER) SPECIFICATIONS — FOUR WHEEL STEER FRONT AXLE DESCRIPTION AND OPERATION — TWO-WHEEL STEER DESCRIPTION AND OPERATION — FOUR-WHEEL STEER REMOVAL AND INSTALLATION — STEERING COLUMN

K10 K10–01–1 K10–01–3 K10–01–5 K10–01–7 K10–01–9

L11 L11–01–1 L11–01–3 L11–01–5 L11–01–9 L11–01–11 L11–01–13 L11–01–21 L11–01–25 L11–01–27 L11–02–1 L11–02–3 L11–02–9 L11–02–13 L11–02–17 L11–02–19 L11–02–23 L11–02–33 L11–02–37 L11–02–49 L11–02–53 L11–02–61 L11–02–63 L11–02–65 L11–02–67 L11–02–69 L11–03–1 L11–03–3 L11–03–9 L11–03–13 L11–03–15 L11–03–21 L11–03–31 L11–03–37 L11–03–47 L11–03–53 L11–03–63 L11–03–65 L11–03–67 L11–03–69 L11–03–71 L11–04–1 L11–04–3 L11–04–9

TABLE OF CONTENTS

REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR UP TO 2007 REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR 2007 ONWARDS REMOVAL AND INSTALLATION — FOUR-WHEEL STEER (4WS) CHANGEOVER VALVE REMOVAL AND INSTALLATION — TIE ROD END GENERAL PROCEDURE — FOUR-WHEEL STEER MISALIGNMENT CORRECTION SPECIFICATIONS — STEERING DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP DISASSEMBLY AND ASSEMBLY — PINION GROUP GENERAL PROCEDURE — TOE-IN ADJUSTMENT GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE

WHEELS AND TYRES SAFETY PRECAUTIONS — WHEELS AND TYRES REMOVAL AND INSTALLATION — FRONT WHEEL REMOVAL AND INSTALLATION — REAR WHEEL REMOVAL AND INSTALLATION — INNER TUBE REMOVAL AND INSTALLATION — TYRE SPECIFICATIONS — WHEELS AND TYRES

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — POWERSHIFT TRANSMISSION DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION PRESSURE TESTING REMOVAL AND INSTALLATION — POWERSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — POWERSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — FORWARD LOW CLUTCH DISASSEMBLY AND ASSEMBLY — 1ST CLUTCH DISASSEMBLY AND ASSEMBLY — REVERSE CLUTCH DISASSEMBLY AND ASSEMBLY — 2ND CLUTCH DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY — DISCONNECT SHAFT DISASSEMBLY AND ASSEMBLY — CHARGING PUMP DRIVE SHAFT DISASSEMBLY AND ASSEMBLY — INPUT SHAFT DISASSEMBLY AND ASSEMBLY — TRANSMISSION CONTROL VALVE GENERAL PROCEDURE — CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR GENERAL PROCEDURE — POWERSHIFT TRANSMISSION CLUTCH CALIBRATION SPECIFICATIONS — POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION — TURNER DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION DIAGNOSING AND TESTING — SYNCHROSHIFT TRANSMISSION PRESSURE TESTING REMOVAL AND INSTALLATION — SYNCHROSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — SYNCROSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — INPUT SHAFT

L11–04–15 L11–04–19 L11–04–21 L11–04–23 L11–04–25 L11–04–27 L11–05–1 L11–05–3 L11–05–9 L11–05–13 L11–05–17 L11–05–19 L11–05–23 L11–05–35 L11–05–39 L11–05–51 L11–05–55 L11–05–63 L11–05–65 L11–05–67 L11–05–69 L11–05–71

M12 M12–01–1 M12–01–3 M12–01–5 M12–01–7 M12–01–11 M12–01–13

N13 N13–01–1 N13–01–19 N13–01–35 N13–01–45 N13–01–53 N13–01–77 N13–01–89 N13–01–101 N13–01–113 N13–01–125 N13–01–135 N13–01–139 N13–01–143 N13–01–149 N13–01–151 N13–01–153 N13–01–157 N13–02–1 N13–02–10 N13–02–13 N13–02–15 N13–02–23 N13–02–47

TABLE OF CONTENTS

DISASSEMBLY AND ASSEMBLY — COUNTERSHAFT DISASSEMBLY AND ASSEMBLY — REVERSE IDLER SHAFT DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY — HYDRAULIC MULTIPLATE CLUTCH FOUR-WHEEL DRIVE SHAFT DISASSEMBLY AND ASSEMBLY — DIRECTION CONTROL VALVE DISASSEMBLY AND ASSEMBLY — GEAR LEVER HOUSING SPECIFICATIONS — SYNCHROSHIFT TRANSMISSION DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM SAFIM REMOVAL AND INSTALLATION — MASTER CYLINDER (POWER BRAKES) REMOVAL AND INSTALLATION — MASTER CYLINDER (SAFIM BRAKES) REMOVAL AND INSTALLATION — BRAKE FLUID RESERVOIR (SAFIM BRAKES) REMOVAL AND INSTALLATION — PARKING BRAKE CALIPER REMOVAL AND INSTALLATION — PARKING BRAKE DISC REMOVAL AND INSTALLATION — DIFFERENTIAL LOCK SOLENOID VALVE GENERAL PROCEDURE — BRAKE BLEEDING POWER BRAKES GENERAL PROCEDURE — BRAKE BLEEDING SAFIM BRAKES SPECIFICATIONS — POWER BRAKES SPECIFICATIONS — BRAKES — SAFIM DESCRIPTION AND OPERATION — TWO-WHEEL STEER REAR AXLE DIAGNOSING AND TESTING — TWO-WHEEL STEER REAR AXLE REMOVAL AND INSTALLATION — TWO WHEEL STEER REAR AXLE DISASSEMBLY AND ASSEMBLY — BRAKE CALIPER DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP DISASSEMBLY AND ASSEMBLY — HALF SHAFT AND BRAKE GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP DISASSEMBLY AND ASSEMBLY — PINION GROUP DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL HOUSING GROUP GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL SPECIFICATIONS — TWO-WHEEL STEER REAR AXLE DESCRIPTION AND OPERATION — FOUR-WHEEL STEER REAR AXLE DIAGNOSING AND TESTING — FOUR-WHEEL STEER REAR AXLE REMOVAL AND INSTALLATION — FOUR-WHEEL STEER REAR AXLE REMOVAL AND INSTALLATION — STEERING CYLINDER (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — PARKING BRAKE CALIPER (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR WHEEL-STEER) DISASSEMBLY AND ASSEMBLY — REAR WHEEL HUB GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — AXLE BEAM TRUMPETS AND BRAKE GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER) DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER) GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL (FOUR-WHEEL STEER) GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER) SPECIFICATIONS — FOUR-WHEEL STEER REAR AXLE DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION – CARRARO DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO PRESSURE TESTING REMOVAL AND INSTALLATION — SYNCHROSHUTTLE TRANSMISSION — CARRARO

N13–02–65 N13–02–67 N13–02–69 N13–02–77 N13–02–89 N13–02–93 N13–02–95 N13–03–1 N13–03–3 N13–03–5 N13–03–7 N13–03–11 N13–03–13 N13–03–15 N13–03–17 N13–03–19 N13–03–21 N13–03–23 N13–03–25 N13–04–1 N13–04–3 N13–04–9 N13–04–13 N13–04–15 N13–04–19 N13–04–25 N13–04–33 N13–04–41 N13–04–51 N13–04–67 N13–04–69 N13–05–1 N13–05–3 N13–05–9 N13–05–13 N13–05–15 N13–05–17 N13–05–23 N13–05–31 N13–05–41 N13–05–49 N13–05–59 N13–05–61 N13–05–63 N13–05–65 N13–06–1 N13–06–11 N13–06–15 N13–06–19

TABLE OF CONTENTS

DISASSEMBLY AND ASSEMBLY — PLUGS AND FILTERS DISASSEMBLY AND ASSEMBLY — TRANSMISSION OIL PUMP DISASSEMBLY AND ASSEMBLY — HYDRAULIC CONTROL VALVE DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SOLENOID VALVE DISASSEMBLY AND ASSEMBLY — TRANSMISSION HOUSING DISASSEMBLY AND ASSEMBLY — INPUT SHAFT AND IDLER SHAFT DISASSEMBLY AND ASSEMBLY — SHAFTS C AND B DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SHAFT (E) DISASSEMBLY AND ASSEMBLY — SPEED CONTROLS SPECIFICATIONS — SYNCHROSHUTTLE TRANSMISSION — CARRARO DESCRIPTION AND OPERATION — CARRARO POWERSHIFT TRANSMISSION DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION PRESSURE TESTING REMOVAL AND INSTALLATION — CARRARO POWERSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT FORWARD AND REVERSE CLUTCHES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 2ND SPEED CLUTCH DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 1ST CLUTCH DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 3RD AND 4TH SPEED CLUTCHES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 4WD CLUTCH DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT HYDRAULIC PUMP DRIVE SHAFT DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION CONTROL VALVE GENERAL PROCEDURE — CARRARO POWERSHIFT CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR SPECIFICATIONS — CARRARO POWERSHIFT TRANSMISSION

ENGINE DESCRIPTION AND OPERATION — ENGINE REMOVAL AND INSTALLATION — ENGINE REMOVAL AND INSTALLATION — ENGINE REMOVAL AND INSTALLATION — RADIATOR REMOVAL AND INSTALLATION — FUEL TANK REMOVAL AND INSTALLATION — AIR CLEANER REMOVAL AND INSTALLATION — EXHAUST PIPE REMOVAL AND INSTALLATION — EXHAUST SILENCER GENERAL PROCEDURE — THROTTLE ADJUSTMENT GENERAL PROCEDURE — DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM SPECIFICATIONS — ENGINE

N13–06–31 N13–06–39 N13–06–43 N13–06–61 N13–06–65 N13–06–83 N13–06–105 N13–06–129 N13–06–139 N13–06–145 N13–07–1 N13–07–19 N13–07–29 N13–07–33 N13–07–43 N13–07–49 N13–07–67 N13–07–79 N13–07–85 N13–07–103 N13–07–113 N13–07–117 N13–07–121 N13–07–123

P14 P14–01–1 P14–01–3 P14–01–15 P14–01–27 P14–01–31 P14–01–33 P14–01–35 P14–01–37 P14–01–39 P14–01–41 P14–01–43

GENERAL INFORMATION

0

SECTION

GENERAL INFORMATION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 0–01–1 GENERAL SAFETY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 0–01–19

GENERAL INFORMATION GENERAL INFORMATION

BHA0001IA

Publication Date

Revision Number

January 2008

02.00.00

0–01–1

GENERAL INFORMATION Service Techniques General The words ’front’, ’rear’, ’right-hand’ and ’left-hand’ used in this manual refer to the different parts of the machine as viewed from the Operator’s seat, when facing the steering wheel. Clean the exterior of all components before starting any type of repair. Dirt and abrasive dust can reduce the efficient working life of a component and lead to costly replacement. Time spent on the preparation and cleanliness of working surfaces will pay dividends in making the job easier and safer and will result in overhauled components being more reliable and efficient in operation. Use cleaning fluids which are known to be safe. Certain types of fluid can cause damage to O-rings and cause skin irritation. Solvents should be checked that they are suitable for the cleaning of components and also there is no risk to the personal safety of the user. When replacing component parts, use the correct tool for the job. Cleaning

•

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

Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and agitated until all old lubricant and foreign material is dissolved and the parts are thoroughly cleaned. Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying . Bearings may be rotated slowly by hand to facilitate the drying process. Housings

•

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

Thoroughly clean interior and exterior of housings, bearing caps, etc. Cast parts may be cleaned in hot solution tanks with mild alkali solutions, provided these parts do not have ground or polished surfaces. Parts should remain in the solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water.

Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with a steam cleaner. All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft lint—free absorbent wiping rags, free of abrasive materials such as metal filings, contaminated oil or lapping compound. Inspection The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. Bearings Carefully inspect all rollers, cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, lubricate the bearings with suitable clean oil and wrap in clean lint—free cloth or paper to protect them until installed. Oil Seals, Gaskets, Etc. Replace O-rings, seals or gaskets whenever they are disturbed. Never mix new and old seals or O-rings, regardless of condition. Always lubricate new seals and O-rings with suitable clean oil before installation. Replacement of spring-load oil seals, O-rings, metal sealing rings, gaskets and snap rings is more economical when the unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn oil seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching or curling under the lips of seals seriously reduces their efficiency. When assembling new metal type sealing rings, these should be lubricated with a light grease to stabilise rings in their grooves for ease of assembly of mating members. Gears and Shafts Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening is worn through or cracked, replaced with new gear. Small nicks may be removed with a suitable hone. Inspect shafts and quills to make certain they are not sprung, bent or spline-twisted, and that shafts are not bent. Housings, Covers, Etc. Inspect housings, covers and bearing cups to ensure that they are thoroughly clean and that mating surfaces, bearing bores, etc. are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions that would cause subsequent oil leaks or failures.

0–01–2

GENERAL INFORMATION Hoses and Tubes Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connection. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing. After hose replacement to a moving component, check the hose does not foul by moving the component through the complete range of travel. Make sure any hose which has been installed is not kinked or twisted. Hose connections which are damaged, dented, crushed or leaking, restrict oil flow and the productivity of the component being served. Connectors which show signs of movement from the original swagged position have failed and will ultimately separate completely. A hose with a chafed outer cover will allow water to enter. Concealed corrosion of the wire reinforcement will subsequently occur along the hose length with resultant hose failure. Ballooning of the hose indicates an internal leakage due to structural failure. This condition rapidly deteriorates and total hose failure will soon occur. Kinked, crushed, stretched or deformed hoses generally suffer internal structural damage which can result in oil restriction, a reduction in the speed of operation and ultimately hose failure. Free moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.

TV040375

TV040376

Installing Flexible Hoses TV040377

TV040374

TV040378

0–01–3

GENERAL INFORMATION VIN Definition Item

Digit

Description/Values

Example

Manufacturer ID

S

Registered with BSI

S

M

M

F

F

Product Variants

X

H =Terex/TCE, G =Fermec

H

Transmission

X

4 =4 Speed Synchro Shuttle, 3 =3 Speed Syncro Shuttle, 6 =4 Speed Power Shift, 5 =3 Speed Power Shift

5

Drive

X

4 =4WD, 2 =2WD

4

Digging Length

X

S =4.5 Std, T =4.5 Ext, L =4.9 Std, E =4.9 Ext, N =None

T

Operator Compartment

X

C =Cab, R =ROPS

C

Loader Element Function

X

0 =Mechanical, N =None

0

Production Year

X

BSA U175 Model Year, 1 =2001, 2 =2002, 3 =2003, 4 =2004 etc..

4

Chassis Type

X

See Table 1 Below

C

Engine Type

X

F =68.5 kW, G =74.5kW

G

Digging Element Function

X

M =Mechanical, N =None

M

Serial Number

X

Machine Serial Number

3, 6, 5, 7

Table 1 — Chassis Type Digit

Type

A

2WS/Base/Sideshift (820)

B

2WS/Base/Centre Mount (820)

C

2WS/Main/Side Shift (860)

D

2WS/Main/Centre Mount (860)

E

4WS/Side Shift (970)

F

4WS/Centre Mount (970)

For additional information, refer to the Operator’s Manual.

0–01–4

GENERAL INFORMATION Fluids and Lubricants Specifications System

Engine Turbocharged – 1100 Series 820/860/970

Temperatures

Viscosity

Specifications

Capacities (Litres)

Notes

7.3

If sulphur content in fuel is above 0.2% of mass (2000ppm), change oil and filter every 250 hours)

From

To

-40°C

+40°C

0W – 40

-30°C

+40°C

5W – 40

-10°C

+50°C

15W – 40

EMA DHD-1 or CH-4 API CH-4 ACEA E3 or E5

Transmission Synchro Shuttle 820/860

ALL

10W

ATF

22 (Total System)

Check oil level with engine running at idle. Clean suction strainer at oil change

Transmission Powershift 860/970

ALL

10W

ATF

23 (Total System)

Check oil level with engine running at idle: Approved oils: ATF Elfmatic G3 Esso D (21611)

Front Axle 820/860

ALL

80W – 90

API GL5 MIL-L-2105D

6.5 + 1 + 1

As Alternative: Agip Rotra Multi THT Esso Torque Fluid 62 Mobil Fluid 422 or 424

Front Axle 970

ALL

80W – 90

API GL5 MIL-L-2105D

7.5 + 1 + 1

As Alternative: Agip Rotra Multi THT Esso Torque Fluid 62 Mobil Fluid 422 or 424

Rear Axle 820/860

ALL

80W

API GL4 M1135

14.5 + 1.5 + 1.5

Approved oils: Agip Rotra Multi THT Esso Torque Fluid 62 Mobil Fluid 422 or 424

Rear Axle 970

ALL

80W

API GL4 M1135

14.5 + 1.5 + 1.5

Approved oils: Agip Rotra Multi THT Esso Torque Fluid 62 Mobil Fluid 422 or 424

Up to +30°C

ISO VG 46

DIN 51524

Up to +50°C

ISO VG 68

143 (Total System)

Tank Capacity = 85 Litre

Greasing – General

ALL

EP-NLGI

Grade 2

EP-Lithium based

Greasing Backhoe swing

ALL

EP–NLGI

Grade 2

EP-Lithium based with Molybdenum disulphide (MoS2)

Hydraulics

0–01–5

GENERAL INFORMATION ALL

Greasing Propeller Shafts

EP–NLGI

EP-Lithium based with Molybdenum disulphide (MoS2)

Grade 2

Greasing — Dive Shafts U.J Greasing — Axle(s) King Pins Coolant

Up to -33°C

BS 6580-1992 ASTM D3306

Up to -50°C Fuel

16 (Total System)

ALL

130

Air Conditioning

Antifreeze=50% Cetane: Minimum 45 Sulphar content: Maximum 0.2% (of mass)

1200 gr (Initial Charge)

CFC 134 A

Antifreeze=33%

Recharge=900 – 1000gr

Service Schedule System

Service Schedule (Hours) 10

Engine Turbocharged – 1100 Series 820/860/970

50

250

500

1000

Yearly

R

C

Filter 2654403

R

Transmission Synchro Shuttle 820/860

R

C

Filter 6190810M1

R

Transmission Powershift 860/970

R

C

Filter 6193480M91

R

Front Axle 820/860

C

R

Front Axle 970

C

R

Rear Axle 820/860

C

R

Rear Axle 970

C

R

Hydraulics

R

C

Filter 3515328 M92

R

Greasing – General

G

Greasing — Backhoe swing

G

Greasing — Propeller Shafts

G

Greasing — Dive Shafts U.J

G

Greasing — Axle(s) King Pins

G

Coolant

C

C

Fuel

D (Tank)

Filter 26560201

R

Air Conditioning

C

C=Check, D=Drain, G=Grease, R=Replace NOTE: Synchro Shuttle Transmission oil level is checked with the engine running at idle and hot oil. NOTE: Distance from the flat on top of dipstick to the ’H’ and ’L’ marks 929mm respectively. Total length 952mm.

0–01–6

GENERAL INFORMATION Sealing and Locking Fluids Type

Description

Loctite 242

Medium strength thread lock

Loctite 243

Medium strength oil tolerant sealant

Loctite 270

Maximum strength stud lock

Loctite 496

Instant Adhesive

Loctite 510

High temperature flange sealant

Loctite 542

Fine thread sealant

Loctite 638

Maximum strength retaining compound

Loctite 648

High strength/rapid cure retaining compound

General Specifications Engine Engine

Low Power (820)

High Power (860 – 970)

Make

Perkins

Model

1104C–44T

Bore and Stroke

105x127mm 4400 cc

Capacity

16.5:1

Compression Ratio Firing Order

1 3 4 2

Type

2164/2200

2166/2200

Build List (With Air Con)

RG38043

RG38044

Build List (Without Air Con)

RG38100

RG38099

Power @ 2200rpm

68.5kW (92 HP)

74.5kW (100 HP)

Torque @ 1400rpm

395Nm

415Nm

Turbocharger

Garrett GT 25, with wastegate 2674A226

Perkins P/N Wastegate beginning to operate pressure

1.0 +/- 0.05bar

Injection Pump

Delphi

Model Type

DP210 1398/2644H013

1405/2644H023

Setting Code

XR/2/2350

DT/2/2350

Perkins Type

9320A212G

9320A342G

Perkins P/N

2644H002

2644H003

Injection Advance

0.5° BTDC

Timing

Pin Timed 0° ATDC

Speed at which cut off starts under full load

2200 +/- 25rpm

Maximum No Load Speed

2350 +/- 25rpm

Idle Speed

700 – 1200rpm

0–01–7

GENERAL INFORMATION Injectors

Delphi

Type

LJBX6921101 2645K611

Perkins P/N (Nozzle) Opening Pressure

290 +/- 8bar Yellow

Colour Code Fuel Feed Pump Pressure

0.1 – 0.7bar

Valve Lash (Cold) – Inlet

0.20mm

Valve Lash (Cold) – Exhaust

0.45mm

Valve Arrangement

IE IE IE IE

Cold Start System

Glow Plugs (4)

Make

Beru

Perkins P/N

2666A016

Initial Current

30A Immediately Reduced to 21A

After 8 sec

14A

After 20 sec

10A

After 60 sec

9A

Cold Start Sensor

Normally Open

Perkins P/N

2848A127

Closes at

50 +/- 3°C

Re–opens at

40 +/- 3°C

Radiator Cap Pressure

110kPa

Thermostat

Wax Element By-pass Blanking

Perkins P/N

2485C041P

Nominal Temperature Stamped on Thermostat

82°C

Start to Open Temperature

79 – 84°C

Fully Open Temperature

93°C

Minimum Valve Lift Fully Open

10mm

Lubrication

Rotor Pump

Minimum Oil Pressure at Max rpm

3.0bar

0–01–8

GENERAL INFORMATION Transmission Transmission

Synchro Shuttle

Power Shift

Make

Turner

Dana

Model

COM-T4-2032

121-4FT 16000-22

Fermec P/N

6108873M91

6108875M91

3.01:1

2.60:1

Pump Pressure

18.0bar

20.5 – 23.5bar

Clutch Pressure

16bar

20.5 – 23.0bar

–

4.9 – 5.0bar

6.5 – 7.5bar

9.0bar

Solenoid Pressure

–

9.5bar

860 Transmission Control Unit

–

4503428

970 Transmission Control Unit

–

4503427

1.5 – 3.0bar

0.4 – 0.5bar

Torque Converter Stall Ratio

Torque Converter Working Pressure Torque Converter Safety Valve Pressure

Lubrication Pressure Brakes Brakes

Oil Immersed Disk Type in the Rear Axle

Booster

Transmission Pressure Activated

Boost ratio

2.60:1

Master Cylinders Diameter

31.75mm (1 1/4”)

Master cylinder seals

Specific for Mineral Oil

Brake Disks Friction Discs (820–860)

2 Each Side

Friction Disks (970)

3 Each Side

Brake Piston Seals

Specific for Mineral Oil

0–01–9

GENERAL INFORMATION Axles Axles

Synchro Shuttle

Make

Power Shift Carraro

26.18LP

–

Carraro P/N

148092

–

Fermec P/N

6109000M91

–

28.43M

–

Carraro P/N

146157

–

Fermec P/N

6109183M91

–

26.18LP

–

Carraro P/N

148093

–

Fermec P/N

6109144M91

–

28.43M

–

Carraro P/N

146157

–

Fermec P/N

6109183M91

–

–

26.28LP

Carraro P/N

–

1480648

Fermec P/N

–

6109145M91

–

28.43M

Carraro P/N

–

143739

Fermec P/N

–

6109184M91

970 Front Axle – Type

–

26.28LP

Carraro P/N

–

148930

Fermec P/N

–

6109146M91

970 Rear Axle – Type

–

26.43LP

Carraro P/N

–

148405

Fermec P/N

–

6109185M91

820 Front Axle – Type

820 Rear Axle – Type

860 Front Axle – Type

860 Rear Axle – Type

860 Front Axle – Type

860 Rear Axle – Type

Steering Steering Orbitrol

Closed Center Type

Make

Rexroth 160cc

Dispaced Oil per Revolution MRV Setting Pressure

175bar (170min – 178max)

Antishock Valves Opening Pressure

240bar +/-5

MRV Adjustment

+1 Turn=+26.6bar

Antishock Valves Adjustment

+1 Turn=+105bar

Special Tool for Adjusting MRV / Rexroth P/N

E35/:36064

Special Tool for Adjusting AS Valves / Rexroth P/N

E35/:36949

0–01–10

GENERAL INFORMATION Hydraulics Hydraulics

820

860 – 970

Tandem Gear Pump Make

Commercial

Pump 1 Flow

80 l/min

80 l/min

Pump 2 Flow

62 l/min

80 l/min

Pump 1 Pressure

225bar (225min – 232max)

225bar (225min – 232max)

Pump 1 Pressure

207bar (207min – 214max)

207bar (207min – 214max)

Control Valves

Closed Center Type and Inlet Compensator

Make

Rexroth

Loader Control Valve Type

SX14 – 3 Spool

Backhoe Control Valve Type

SX14 – 7 Spool

Spool Leakage Oil Flow @ 100bar

11cc/min

Compensator Pressure (Engine @ 1800rpm)

20bar (20min – 21max)

Spool Stroke

+/- 8.0mm

Tie Rod Nuts Tightening Torque

42Nm +/-4 Nitrogen

Ride Control System Gas

25bar

Gas Charge Pressure Electrics System Voltage

12V Negative Ground

Battery Capacity (Single)

105Ah

Battery Capacity (Double)

70Ah

Alternator

14V

Make

Denso

Type

A115i 75A

Capacity (Without Air Con)

2871A302

Perkins P/N Capacity (With Air Con)

100A 2871A304

Perkins (P/N) Starter Motor Make

Denso

Type

P95RL

Power

3kW Hydraulic Control Valve

Clamp Solenoid Resistance

7.6Ω at 20°C

Industrial Equipment Extendable Dipper Top Bolt Torque

920Nm +/- 120

Bottom Bolt Torque

140Nm +/- 5

Clearance between Inner and Outer Member

Less than 1.0mm

0–01–11

GENERAL INFORMATION Stall Speeds 820

860 SX

860 PS

970

RPM Max Engine RPM No Load

2350 +/- 25

2350 +/- 25

2350 +/- 25

2350 +/- 25

Stall against Hydraulics @ 225bar

2300 +/- 25

2300 +/- 25

2300 +/- 25

2300 +/- 25

Stall against Transmission

2150 +/- 25

2200 +/- 25

2200 +/- 25

2200 +/- 25

Stall against Transmission and Hydraulics

1575 +/- 25

1625 +/- 25

2000 +/- 25

2000 +/- 25

Stall against Transmission, Hydraulics and Steering

1575 +/- 25

1625 +/- 25

2000 +/- 25

2000 +/- 25

0–01–12

GENERAL INFORMATION Torque Values Use the following torques when specifications are not given in the procedures.

Grade Identification of Metric Fasteners 9.8

10.9

4.8

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

5

B

10

10

10

5

5

12

10

A

12.9

8.8

10

12

4.8

10

12

TV041088

A — Grade and head markings of Retaining Bolts and Cap Screws B — Grade and head markings of Retaining Nuts Torque Values For Metric Fasteners (Zinc Coated) These torque values are applicable to threaded fasteners assembled with coarse and fine threaded retaining nuts, threaded holes with or without flat washers or lock washers, full height weld nuts. Grade of Metric Fasteners Size

4.6

8.8

10.9

12.9

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

M3

0.5

0.5

1

1

2

1

2

1

M4

1

1

4

3

5

4

6

4

M5

2

1

7

5

10

7

12

9

M6

5

4

12

9

17

13

20

15

M8

11

8

30

22

41

30

48

35

M10

22

16

60

44

84

62

97

72

M12

38

28

105

77

140

103

162

119

M16

97

72

230

170

350

258

406

299

M20

185

136

490

361

700

516

812

599

M24

320

236

840

620

1150

848

1334

984

M30

630

465

1600

1180

2450

1807

2096

1546

M36

1100

811

2900

2139

4200

3098

3594

2651

0–01–13

GENERAL INFORMATION Torque Values For Metric Fasteners These torque values are applicable to threaded fasteners assembled with zinc coated and waxed lock nuts, phosphate coated retaining nuts or bolts, reduced height “jam” nuts, reduced height weld nuts. Grade of Metric Fasteners Size

4.6

8.8

10.9

12.9

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

M3

0.5

0.5

1

1

1.5

1

2

1

M4

1

1

3

2

4

3

5

4

M5

2

1

6

4

8

6

9

7

M6

4

3

10

7

14

10

16

12

M8

9

7

24

18

33

24

38

28

M10

18

13

48

35

67

49

78

151

M12

30

22

84

62

115

85

133

98

M16

78

58

185

136

280

207

325

240

M20

150

111

395

291

560

413

650

479

M24

260

192

670

494

920

679

1067

787

M30

500

369

1300

959

1950

1438

2262

1668

M36

880

649

2300

1696

3350

2471

3886

2866

Grade Identification of Inch Fasteners 1/2*

5

5.1

5.2

8

8.2

A 2

5

8

B TV041089

A — S.A.E. Grade and head markings of Retaining Bolts B — S.A.E. Grade and head markings of Retaining Nuts

* — Grade 2 applies for hex cap screw (not hex bolts) up to 152mm (6 inches) long. Grade 1 applies for hex cap screws over 152mm (6 inches) long, and for all other types of retaining bolts and screws of any length.

Note: • Grades 1 and 2 have no markings.

0–01–14

GENERAL INFORMATION Torque Values For Inch Fasteners (Zinc Coated) These torque values are applicable to threaded fasteners assembled with coarse and fine threaded retaining nuts, threaded holes with or without flat washers or lock washers, full height weld nuts. Grade of Inch Fasteners Size

S.A.E. 1

S.A.E. 5

S.A.E. 8

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

1/4

7

5

13

10

19

14

5/16

14

10

26

19

37

27

3/8

26

19

46

34

65

48

7/16

41

30

75

55

105

77

1/2

63

46

115

85

160

118

5/8

125

92

230

170

325

240

3/4

220

162

405

299

575

424

7/8

360

266

660

487

930

686

1

540

398

980

723

1400

1033

1 1/8

560

413

1220

900

1950

1438

1 1/4

790

583

1750

1291

2800

2065

1 1/2

1400

1033

3000

2213

4750

3504

Torque Values For Inch Fasteners These torque values are applicable to threaded fasteners assembled with zinc coated and waxed lock nuts, phosphate coated retaining nuts or bolts, reduced height “jam” nuts, reduced height weld nuts. Grade of Inch Fasteners Size

S.A.E. 1

S.A.E. 5

S.A.E. 8

Nm

Lb.ft

Nm

Lb.ft

Nm

Lb.ft

1/4

6

4

10

7

16

12

5/16

11

8

21

15

30

22

3/8

21

15

37

27

52

38

7/16

33

24

60

44

84

62

1/2

50

37

92

68

125

92

5/8

100

74

185

136

260

192

3/4

175

129

325

240

460

339

7/8

290

214

530

391

745

550

1

435

321

785

579

1120

826

1 1/8

450

332

970

715

1560

1151

1 1/4

630

465

1400

1033

2240

1652

1 1/2

1130

833

2400

1770

3800

2803

0–01–15

GENERAL INFORMATION Torque Values For JIC Hydraulic Hose Fittings

Hex. Size A/F

Thread Size UNF

Termination Dash Size

mm

inch

—

9/16

04

—

5/8

—

Machines Built With “Gates/Global” Hydraulic Hoses

Machines Built With “Manuli” Hydraulic Hoses

Nm

Lb.ft

Nm

Lb.ft

7/16”-20

14

10

15

11

05

1/2”-20

18

13

20

15

11/16

06

9/16”-18

22

16

35

26

—

7/8

08

3/4”-16

41

30

50

37

24

—

10

7/8”-14

60

44

80

59

—

1

10

7/8”-14

60

44

80

59

27

—

10

7/8”-14

60

44

80

59

—

1 1/4

12

1 1/16”-12

90

66

100

74

—

1 1/2

16

1 5/16”-12

130

96

150

111

Torque Values For O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value

Termination Dash Size

Inch Size

Thread Size UNF

Nm

Lb.ft

04

1/4

9/16–18

15

11

06

3/8

11/16–16

26

19

08

1/2

13/16–16

45

33

10

5/8

1–14

65

48

12

3/4

1 3/16–12

92

68

16

1

1 7/16–12

130

96

20

1 1/4

1 11/16–12

180

133

24

1 1/2

2–12

215

159

Torque Values For Split Flange Retaining Bolts Size

Torque Value Nm

Lb.ft

5/16–18

24

18

3/8–16

45

33

7/16–14

54

40

1/2–13

81

60

5/8–11

197

145

0–01–16

GENERAL INFORMATION Torque Values For Dryseal Pipe (NPTF or Equivalent) Steel Fittings Torque Value

Size Inch

Nm

Lb.ft

1/8

25

18

1/4

45

33

3/8

70

52

1/2

125

92

3/4

180

132

1

240

177

1 1/4

280

206

0–01–17

GENERAL INFORMATION

Note: This page intentionally left blank.

0–01–18

GENERAL INFORMATION GENERAL SAFETY

BHA0002IA

General Safety Considerations Throughout this workshop manual you will see various WARNINGS, CAUTIONS and NOTES. Always read and obey the instructions in these wherever they appear.

•

•

Warning: Warning is used to indicate that failure to follow this instruction may result in personal injury. Caution: Caution is used to indicate that failure to follow this instruction may result in damage to machine or the equipment being used.

Note: • Note is used to provide the technician with additional essential information required to carry out a complete and satisfactory repair. Before carrying out any maintenance on this machine, always carry out the following: 1. Park the machine on flat, level ground. 2. Lower the loader and backhoe attachments until they are resting on the ground. 3. Stop the engine and remove the starter switch key. 4. Engage the parking brake. 5. Lock the loader attachment controls (if equipped). 6. Block the wheels to prevent any machine movement. If a procedure requires the loader attachment to be raised (e.g. working on the engine), install the loader attachment control strut. 7. Removing the isolator key from the switch is recommended, especially when carrying out work on the electrical system. Read and obey the following before carrying out a repair: • Do not carry out any maintenance operations until you have read and understood the instructions and warnings given in the manual. • Always wear suitable clothing when working on the machine. • Always wear suitable eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper for installing pins. • Unauthorized modifications of the machine can cause serious injury. Do not carry out any unauthorized modification on the machine. Any modification carried out must be in conformity with the machines technical specifications and must conform to current safety regulations. • Do not carry out any welding operation without prior authorization. • Some of the machines components are subject to type approvals. It is mandatory when replacing these components to ensure they are in conformity with regulations. Always use genuine parts.

•

•

•

• •

• • •

• •

• •

•

Hydraulic fluid, diesel fuel or grease under pressure which penetrates the skin can cause serious injury. Take the necessary safety precautions (protective clothing and face and hand protection) to prevent such risks. In addition, before handling these products, read the manufacturers specific instructions for their use. If hydraulic fluid, diesel fuel or grease penetrates the skin, seek medical attention immediately. When carrying out an authorized welding operation on the machine, disconnect the alternator plug and connect the welding set earth lead to the component on which the welding is to be carried out. Never connect the earth lead to a hydraulic system component. When checking tyre pressures or during an inflation operation, never stay facing the tyre but always facing the tread surface. Always use an inflation cage when the wheel is removed from the machine. keep all other persons away from the area. Never weld near a tyre. It is essential to remove the tyre before any welding operation. Take the necessary safety precautions to protect your face when using compressed air. The machines structure is in conformity with the ’FOPS’ and ’ROPS’ protection standards. Any modification (drilling, welding etc.) may cause that conformity to be invalidated. Always follow the specified repair and maintenance procedures outlined in this manual. Never carry out any repairs to the machine while someone is sitting in the operator seat, unless they are assisting in the procedure being carried out. Do not perform any repair on the machine while the engine is running, unless stated. Stop the engine and make sure all pressure is released from hydraulic circuits before removing any caps, covers, valves etc. Always use lifting equipment of appropriate capacity to lift or move heavy components. When performing a repair, disconnect the battery(s) and label the controls to warn the machine is being worked on. Block the machine and any implements which may be in the raised position. Only operate the machine or attachments when in the Operator’s seat, do not attempt to operate the controls from outside of the cab. Do not wear rings, wristwatches, jewellery, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could become caught on moving parts. Use approved safety clothing such as anti-slipping footwear, gloves, safety goggles, hard hat etc. Lift and handle all heavy components using suitable lifting equipment of adequate capacity. Make sure that parts are supported by appropriate

0–01–19

GENERAL INFORMATION

• • •

• • • •

slings and hooks. Use lifting eyes provided for this purpose. Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas recirculation. Never bring your head, body, arms, legs, feet, hands or fingers near fans or rotating belts. Always loosen the radiator cap very slowly before removing to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped. Do not fill the fuel tank when the engine is running. Never adjust the fuel injection pump when the machine is running. Never lubricate the machine when the engine is running. Fluid coming out from a very small port may be invisible and strong enough to penetrate the skin. Never use your hands to check for leaks, always use a piece of cardboard or wood for this purpose.

Precautions During Work

• • • •

• • •

• • • • • • • •

Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only. Always keep the machine handrails and access steps free of oil, grease or dirt to prevent falls or slips. When entering or leaving the cab, always face the machine. Never turn your back. When carrying out operations at hazardous heights (greater than three metres from the ground), always use type-approved safety belts or fall preventing devices. Do not enter or leave the machine when the engine is running. Allow the engine to cool before servicing. Do not work on the machine when under or between the wheels when the engine is running. If work is required while in this position, stop the engine, apply the parking brake and chock the wheels to prevent accidental movement of the machine. Do not carry out any maintenance or repairs without adequate lighting. Do not connect wet plugs or sockets. Signs or safety decals should never be removed, obscured or unreadable. Always stop the engine and disconnect the battery before maintenance or service. Do not lubricate or clean any components while still moving. Before carrying out operations on hydraulic lines under pressure, always make sure the line has been depressurized and does not contain hot fluid. Do not carry out any repairs to the fuel system with the engine running. Handle all flammable or dangerous substances with care.

• •

Make sure that no tool, cloth or other objects have been left within compartments with moving parts or in which suction and cooling air circulates. After work , never leave the machine in a potentially dangerous state.

Fire Prevention Engine fuel can cause an explosion or fire: — Never fill with fuel when the engine is running. — Do not smoke during re-fuelling. — Take all necessary safety measures when welding, grinding or when working near a naked flame. • Use a non flammable product for cleaning parts. A spark or flame can cause the hydrogen in the battery to explode. To prevent any risk of explosion, obey the following instructions: — Remove the battery isolator key (optional). — When disconnecting the battery cables, always disconnect the negative (-) cable first. — To connect the battery cables, always connect the negative (-) cable last. — Never short circuit the battery terminals with metal objects. — Do not weld, grind or smoke near a battery. • The electrical system or engine exhaust may produce sparks. Before using the machine in an area which may contain inflammable vapours, make sure there is adequate ventilation. • Clean the machine and remove all debris and material which may catch fire. • Check for leaks. Replace damaged hoses, pipes and unions. Clean the machine after any repair work before operating.

Burn Prevention

•

•

•

•

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with skin, eyes or clothing. If contact is EXTERNAL, rinse with water. If contact is INTERNAL, drink large quantities of water or milk. Seek medical assistance immediately. If contact is with in the EYES, rinse with water for 15 minutes. Seek medical assistance immediately. When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery. Always keep the battery charged to prevent the electrolyte freezing. Batteries produce explosive gases. Keep all flames, sparks, and cigarettes away. Provide adequate ventilation when charging a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery. Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap, allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

Personal Safety Considerations Wearing wrong clothes or carelessness in dress can cause accidents. Make sure to wear suitable clothing when servicing the machine.

0–01–20

GENERAL INFORMATION Some jobs require special protective equipment, always use protective equipment when required. Skin Protection Used oil may cause skin cancer. Follow work practises that minimize the amount of skin exposed and length of time used oil remains on the skin. Eye Protection Eye injury may cause loss of vision. Always wear suitable eye protection when chiselling, grinding, welding, painting or working on any pressurized fuel or oil system. Breathing Protection Fumes, dust and paint spray may be harmful. Always wear suitable breathing apparatus when these are present. Hearing Protection Loud noises may damage hearing and the greater the exposure the greater the damage. If the noise level is excessive, wear suitable ear protection. Lifting Protection Avoid injury by correct handling of components. Make sure you are capable of lifting the object, if in doubt seek assistance. Hand Protection It is advisable to use a protective cream before work to prevent irritation and skin contamination. After work, clean hands with soap and water. Solvents such as mineral spirit and kerosene may harm the skin. Foot Protection Substantial or protective foot wear with reinforced toe caps will protect feet from falling objects. Oil resistant soles will assist in avoiding slippage. Special Clothing For certain work it may be necessary to wear flame or acid resistant clothing.

Equipment Safety Considerations Machine Guards Before using any machines, make sure the machine guards are in position and are serviceable. These guards prevent anything from coming into contact with any moving parts and prevent injury from any flying debris. Lifting Devices Make sure lifting equipment such as chains, slings, hooks and eyes are thoroughly inspected for damage before use. If in any doubt about the weight capacity required, use stronger equipment than is necessary.

Do not use compressed air to blow dust, filings or dirt from the area being worked in unless the correct nozzle is fitted. Hand Tools Injuries may result from using defective tools. Always use the correct tools for the job, use of incorrect tools mat result in damage to the machine or personal injury. When removing or installing hardened pins, use a copper or brass drift. Do not use a hard faced hammer. When carrying out a repair procedure, always use the Special Tools recommended.

General Considerations Solvents Use cleaning fluids and solvents that are known to be safe. Certain types of fluids may cause damage to components such as seals and may cause skin irritation. Solvents should be checked that they are suitable for the cleaning of components and individual parts and will not affect the personal safety of the user. Fire Fire has no respect for persons or property. The destruction a fire may cause is not always fully realized. Always be on guard against fire hazards. Do not smoke when working on the machine. Work cleanly and dispose of waste material into suitable containers. Identify the location of the nearest fire extinguisher and know how to operate it. In the event of a fire, do not panic, warn those near and raise the alarm. Do not use a naked flame near the fuel tank, battery or any other components. First Aid Dirt, grease and fine dust may settle on the skin and clothing. If a cut, burn or abrasion is left unattended, infection may occur. Seek medical attention immediately. Cleanliness Cleanliness of the hydraulic system is essential for optimum performance. When carrying out service and repairs, plug all hose ends and connections to prevent contamination. Clean the exterior of all components before carrying out any repairs. Dirt and abrasive dust can reduce the efficiency and working life of a component. Use of a high pressure washer or steam cleaner is recommended.

Compressed Air The pressure from a compressed air line can often exceed 100PSI (690 kPa). This is safe to use but incorrect use may cause injury.

0–01–21

ACCESSORIES

A01 SECTION

REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET FROM A QUICK ATTACH UNIT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . A01–01–1 REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET FROM A QUICK ATTACH UNIT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . A01–01–3 REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . A01–01–5 REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT HYDRAULIC CYLINDER . .. .. . A01–01–9 SPECIFICATIONS — ACCESSORIES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..A01–01–11 DESCRIPTION AND OPERATION — HOSE BURST VALVES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . A01–02–1 REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDERS BURST VALVES .. . A01–02–3 REMOVAL AND INSTALLATION — LOADER BUCKET CROWD HYDRAULIC CYLINDER BURST VALVE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . A01–02–5 REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM CYLINDER BURST VALVE .. .. .. .. .. . A01–02–9 REMOVAL AND INSTALLATION — BACKHOE BOOM CYLINDER BURST VALVE. .. .. .. .. .. .. .. .. ..A01–02–11 SPECIFICATIONS — HOSE BURST VALVES . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..A01–02–13

ACCESSORIES REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET FROM A QUICK ATTACH UNIT Operation: Removing and Installing the Standard Loader Bucket from a Quick Attach Unit None

BHA0101RA

Job Code: 01 08 13 xx Standard tools

Removal

1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Press and hold the loader quick attach switch down to unlock the loader quick attach.

TV040624

4. Operate the loader auxiliary service lever until the loader bucket retaining pins are fully retracted. Note: • The Indicator (1) raised clear of the tube (2).

1

2

TV040623

5. Carefully reverse the machine away from the loader bucket whilst crowding forward to disengage the quick attach hook from the loader bucket retaining pins.

A01–01–1

ACCESSORIES Installation 1. To install, reverse the removal procedure. Note: • Make sure the top of the indicator (1) is flush with the top of the tube (2).

1

2

TV040623

A01–01–2

ACCESSORIES REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET FROM A QUICK ATTACH UNIT Operation: Removing and Installing the Multi Purpose Loader Bucket from a Quick Attach Unit None

Job Code: 01 09 13 xx Standard tools

Removal Note: • Make a note of the position of the hydraulic hoses prior to disconnection to aid installation. Note: • Install blanking contamination.

plugs

to

avoid

1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Place the forks in the stowed position and secure them using the pins (if equipped). 4. Release the pressure from the hydraulic system. For additional information, refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . Note: • Make sure the connections are clean and free from obstructions. 5. Disconnect the hydraulic hoses from the loader bucket.

TV040621

6. Connect the hydraulic hoses to the quick attach control valve connectors.

TV040622

A01–01–3

BHA0101RB

ACCESSORIES 7. Start the engine, press and hold the quick attach switch down to unlock the loader quick attach.

TV040624

8. Operate the loader auxiliary service lever until the loader bucket retaining pins are fully retracted. Note: • The Indicator (1) raised clear of the tube (2).

1

2

TV040623

9. Carefully reverse the machine away from the loader bucket whilst crowding forward to disengage the quick attach hook from the loader bucket retaining pins.

Installation 1. To install, reverse the removal procedure. 2. Make sure the top of the indicator (1) is flush with the top of the tube (2).

1

2

TV040623

A01–01–4

ACCESSORIES REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT

BHA0101RC

Operation: Removing and Installing the Quick Attach Loader Unit Suitable Lifting Equipment

Job Code: 01 10 13 xx Standard tools

Removal Note: • Make a note of the position of the hydraulic hoses prior to disconnection to aid installation. Note: • Install blanking contamination.

plugs

to

avoid

1. Remove the loader bucket. For additional information, refer to STANDARD LOADER BUCKET FROM A QUICK ATTACH UNIT, PAGE A01–01–1 or MULTI PURPOSE BUCKET FROM A QUICK ATTACH UNIT , PAGE A01–01–3 in this section. 2. Position the quick attach loader unit flat on the ground. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system. For additional information, refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 5. Disconnect the loader unit auxiliary service hydraulic hoses.

TV040210

A01–01–5

ACCESSORIES 6. Disconnect the electrical connector (1), hose clamp (2), detach the quick attach control valve (3) and position it to one side.

1

2

3 TV040629

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

7. Using suitable lifting equipment, support the hydraulic crowd cylinder. 8. Remove the crowd hydraulic cylinder pivot pin retaining bolt (1). 9. Remove the pivot pin (2). 10. Detach the crowd hydraulic cylinder. 11. Remove the crowd hydraulic beam pivot pin retaining bolt (3). 12. Remove the crowd hydraulic beam pin (4). 13. Detach the crowd hydraulic beam.

1

2

3 4

TV040632

14. Remove the pivot pin retaining bolts (1). 15. Remove the pivot pins (2). 16. Remove the quick attach loader unit.

1

TV040633

A01–01–6

2

2

1

ACCESSORIES Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (1) to 10Nm (7 lb.ft).

1

2

2

1

TV040633

3. Tighten (1) and (3) to 10Nm (7 lb.ft).

1

2

3 4

TV040632

A01–01–7

ACCESSORIES

Note: This page intentionally left blank.

A01–01–8

ACCESSORIES REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT HYDRAULIC CYLINDER Operation: Removing and Installing the Quick Attach Loader Unit Hydraulic Cylinder None

Job Code: 01 11 13 xx Standard tools

Removal Note: • Make a note of the position of the hydraulic hoses prior to disconnection, to aid installation. Note: • Install blanking contamination.

plugs

to

avoid

1. Remove the loader bucket. For additional information, refer to STANDARD LOADER BUCKET FROM A QUICK ATTACH UNIT, PAGE A01–01–1 or MULTI PURPOSE LOADER BUCKET FROM A QUICK ATTACH UNIT , PAGE A01–01–3 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the quick attach loader unit status indicator.

TV040625

4. Disconnect the quick attach loader unit hydraulic cylinder supply and return hoses.

TV040626

A01–01–9

BHA0101RE

ACCESSORIES 5. Remove the split pin (1) and remove the quick attach loader unit hydraulic cylinder pivot pin (2).

2

TV040627

6. Remove the quick attach loader unit hydraulic cylinder.

TV040628

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

A01–01–10

1

ACCESSORIES SPECIFICATIONS — ACCESSORIES

BHA0101SA

Torque Values Description

Nm

Lb.ft

Pivot Pin Retaining Nut

10

7

A01–01–11

ACCESSORIES

Note: This page intentionally left blank.

A01–01–12

ACCESSORIES DESCRIPTION AND OPERATION — HOSE BURST VALVES

BHA0102OA

General Description These valves are installed within the hydraulic circuit, they are specifically designed to be used on machinery that handles a suspended load. They are installed to prevent the backhoe boom / loader arm dropping or lowering in an uncontrolled manner if a hose fails in the hydraulic circuit.

•

Warning: No attempt should be made to repair or adjust these valves failure to follow this instruction may result in personal injury.

3

2

1

A01–02–1

4

ACCESSORIES Item

Description

Position

1

Loader bucket crowd hydraulic cylinder burst valve

Top of the crowd hydraulic cylinder

2

Loader beam hydraulic cylinder burst valves

Below the loader beam hydraulic cylinder

3

Backhoe dipper arm hydraulic cylinder burst valve

Mounted to the dipper arm hydraulic cylinder

4

Backhoe boom arm hydraulic cylinder burst valve

Inside the top of the boom arm

A01–02–2

ACCESSORIES REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDERS BURST VALVES Operation: Removing and Installing the Loader Beam Hydraulic Cylinders Burst Valves None

Job Code: xx xx xx xx Standard tools

Removal 1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE . 4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Note: • Left-hand side shown, right-hand side similar. 5. Disconnect the electrical connector.

A01–02–3

BHA0102RA

ACCESSORIES

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. 6. Detach and reposition the hydraulic hoses.

7. Detach the hydraulic pipe.

TV074043

8. Detach the hydraulic fitting and remove the burst valve.

TV074044

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

A01–02–4

ACCESSORIES REMOVAL AND INSTALLATION — LOADER BUCKET CROWD HYDRAULIC CYLINDER BURST VALVE Operation: Removing and Installing the Loader Bucket Crowd Hydraulic Cylinder Burst Valve None

Job Code: XX XX XX XX Standard tools

Removal

1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE .

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Make a note of the position of the hydraulic hoses prior to disconnection to aid installation.

•

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

5. Detach and reposition the hydraulic hose.

A01–02–5

BHA0102RB

ACCESSORIES 6. Remove the hydraulic pipe.

TV074045

7. Detach and reposition the hydraulic hose.

TV074061

8. Remove the burst valve.

TV074046

A01–02–6

ACCESSORIES Installation 1. To install, reverse the removal procedure. 2. Tighten to 60Nm (44lb.ft).

TV074046

3. Check and adjust the hydraulic oil level as required.

A01–02–7

ACCESSORIES

Note: This page intentionally left blank.

A01–02–8

ACCESSORIES REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM CYLINDER BURST VALVE Operation: Removing and Installing the Backhoe Dipper Arm Cylinder Burst Valve Suitable Lifting Equipment

Job Code: XX XX XX XX Standard tools

Removal

1. Park the machine on firm level ground. 2. Position the backhoe bucket flat on the ground to gain access to the valve. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE .

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Make a note of the position of the hydraulic hoses prior to disconnection to aid installation.

•

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

5. Detach and reposition the hydraulic hose.

A01–02–9

BHA0102RC

ACCESSORIES 6. Detach the hydraulic pipes.

TV074047

7. Remove the burst valve.

TV074048

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

A01–02–10

ACCESSORIES REMOVAL AND INSTALLATION — BACKHOE BOOM CYLINDER BURST VALVE Operation: Removing and Installing the Backhoe Boom Cylinder Burst Valve None

BHA0102RD

Job Code: xx xx xx xx Standard tools

Removal

1. Park the machine on firm level ground. 2. Position the backhoe bucket flat on the ground to gain access to the valve. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE .

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Make a note of the position of the hydraulic hoses prior to disconnection to aid installation.

•

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

5. Detach and reposition the hydraulic hose.

A01–02–11

ACCESSORIES 6. Detach the hydraulic pipes.

7. Remove the burst valve.

9

Installation 1. To install, reverse the removal procedure. 2. Tighten to 60Nm (44lb.ft).

9

3. Check and adjust the hydraulic oil level as required.

A01–02–12

ACCESSORIES SPECIFICATIONS — HOSE BURST VALVES

BHA0101SA

Torque Values Torque Values For JIC Hydraulic Hose Fittings

Hex. Size A/F

Thread Size UNF

Termination Dash Size

mm

inch

—

9/16

04

—

5/8

—

Machines Built With “Gates/Global” Hydraulic Hoses

Machines Built With “Manuli” Hydraulic Hoses

Nm

Lb.ft

Nm

Lb.ft

7/16”-20

14

10

15

11

05

1/2”-20

18

13

20

15

11/16

06

9/16”-18

22

16

35

26

—

7/8

08

3/4”-16

41

30

50

37

24

—

10

7/8”-14

60

44

80

59

—

1

10

7/8”-14

60

44

80

59

27

—

10

7/8”-14

60

44

80

59

—

1 1/4

12

1 1/16”-12

90

66

100

74

—

1 1/2

16

1 5/16”-12

130

96

150

111

Torque Values For O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value

Termination Dash Size

Inch Size

Thread Size UNF

Nm

Lb.ft

04

1/4

9/16–18

15

11

06

3/8

11/16–16

26

19

08

1/2

13/16–16

45

33

10

5/8

1–14

65

48

12

3/4

1 3/16–12

92

68

16

1

1 7/16–12

130

96

20

1 1/4

1 11/16–12

180

133

24

1 1/2

2–12

215

159

Torque Values For Split Flange Retaining Bolts Size

Torque Value Nm

Lb.ft

5/16–18

24

18

3/8–16

45

33

7/16–14

54

40

1/2–13

81

60

5/8–11

197

145

A01–02–13

ACCESSORIES Torque Values For Dryseal Pipe (NPTF or Equivalent) Steel Fittings Torque Value

Size Inch

Nm

Lb.ft

1/8

25

18

1/4

45

33

3/8

70

52

1/2

125

92

3/4

180

132

1

240

177

1 1/4

280

206

A01–02–14

ACCESSORIES

Note: This page intentionally left blank.

A01–02–15

BUCKETS

B02 SECTION

REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . B02–01–1 REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . B02–01–3 REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . B02–01–7 DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET . .. .. .. .. .. .. .. .. .. .. .. .. .. . B02–01–9 DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET CLAMPING CYLINDER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..B02–01–15 SPECIFICATIONS — BUCKETS. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..B02–01–19

BUCKETS REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET

BHB0201RA

Operation: Removing and Installing the Standard Loader Bucket Suitable lifting equipment

Job Code: 02 10 13 xx Standard tools

Removal 1. Park the machine on firm, level ground. 2. Lower the loader beam and position the loader bucket flat on the ground. 3. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 .

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

5. Using suitable lifting equipment, support the hydraulic crowd cylinder.

TV040693

6. Remove the hydraulic crowd cylinder pin retaining bolt (1). 7. Detach the hydraulic crowd cylinder from the loader (2). 8. Remove the hydraulic crowd beam pin retaining bolt (3). 9. Detach the hydraulic crowd beam from the loader (4).

TV040615

B02–01–1

BUCKETS 10. Remove the loader pivot pin retaining bolts (1). 11. Remove the loader pivot pins and remove the loader bucket(2).

TV040616

Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (1) to 10Nm (7 lb.ft).

TV040616

3. Tighten (1) and (3) to 10Nm (7 lb.ft).

TV040615

B02–01–2

BUCKETS REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET

BHB0201RB

Operation: Removing and Installing the Multi Purpose Loader Bucket Suitable lifting equipment

Job Code: 02 09 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm, level ground. 2. Close the clam shell. 3. Lower the loader beam and position the loader bucket flat on the ground. 4. Place the forks in the stowed position and secure them using the pins (if equipped). 5. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 6. Isolate the battery ground cable. For additional information, refer to J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 7. Disconnect the loader auxiliary service hydraulic hoses.

TV040210

B02–01–3

BUCKETS

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

8. Using suitable lifting equipment, support the hydraulic crowd cylinder.

TV040693

9. Remove the hydraulic crowd cylinder pin retaining bolt (1). 10. Detach the hydraulic crowd cylinder from the loader bucket (2). 11. Remove the hydraulic crowd beam pivot pin retaining bolt (3). 12. Detach the hydraulic crowd beam from the loader bucket (4).

TV040211

13. Remove the loader bucket pivot pin retaining bolts (1). 14. Remove the loader bucket pivot pins and remove the loader bucket (2).

TV040220

B02–01–4

BUCKETS Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (1) to 10Nm (7 lb.ft).

TV040220

3. Tighten (1) and (3) to 10Nm (7 lb.ft).

TV040211

B02–01–5

BUCKETS

Note: This page intentionally left blank.

B02–01–6

BUCKETS REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER Operation: Removing and Installing the Multi Purpose Loader Bucket Clamping Cylinder None

BHB0201RC

Job Code: 02 02 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Park the machine on on firm, level ground. 3. Close the clam shell. 4. Lower the loader beam and position the loader bucket flat on the ground. 5. Release the pressure from the hydraulic system. For additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 6. Disconnect the hydraulic hoses from the loader bucket clamping cylinder (1). 7. Remove the loader bucket clamping cylinder pivot pin retaining bolts (2). 8. Remove the loader bucket clamping cylinder pivot pins and remove the loader bucket clamping cylinder (3).

2 1 3

1

TV040630

B02–01–7

2

BUCKETS Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (3) to 10Nm (7 lb.ft).

2 1 3

1

TV040630

B02–01–8

2

BUCKETS DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET

BHB0201DB

Operation: Disassembling and Assembling the Multi-Purpose Loader Bucket Suitable lifting equipment

Job Code: 02 09 17 xx Standard tools

2 1 4

5

3

6 8

7

9 12

10 11 13 TV040943

B02–01–9

BUCKETS 1

Bush

2

Cutting Edge

3

Clamp Assembly

4

Lower Cutting Edge

5

Bucket

6

Clamping Cylinder

7

Retaining Pin

8

Retaining Bolt

9

Grease Nipple

10

Retaining Bolt

11

Retaining Pin

12

Grease Nipple

13

Bush

Disassembly

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: Always install blanking plugs to any open ports to avoid contamination.

•

1. Remove the clamping cylinder. For additional information, refer to Section B02-01 MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER . Note: Discard the locking nut.

•

2. Remove the clamshell pivot pin retaining bolt (1).

•

Warning: Support the multi-purpose loader bucket and clamshell. Failure to follow this instruction may result in personal injury.

3. Using a suitable drift, remove the clamshell pivot pin (2). 4. Repeat steps 2 to 4 for the remaining side of the bucket.

B02–01–10

BUCKETS 5. Remove the clamshell from the multi purpose loader bucket.

1 2

TV051454

6. Remove the right-hand clamshell hydraulic supply hoses.

TV051455

7. Detach the left-hand clamshell hydraulic supply hoses.

TV051456

8. Remove the left-hand clamshell hydraulic supply hoses brackets retaining bolts and remove the brackets. 9. Remove the left-hand clamshell hydraulic supply hoses.

TV051457

B02–01–11

BUCKETS Assembly 1. Install the left-hand clamshell hydraulic supply hoses. 2. Install the left-hand clamshell hydraulic supply hoses brackets and install the bracket retaining bolts.

TV051457

3. Install the left-hand clamshell hydraulic supply hoses.

TV051456

4. Install the right-hand clamshell hydraulic supply hoses.

TV051455

•

Warning: Support the multi-purpose loader bucket and clamshell. Failure to follow this instruction may result in personal injury.

5. Install the clamshell to the multi purpose loader bucket. 6. Using a suitable drift, Install the clamshell pivot pin (2). Note: Install a new locking nut.

•

7. Install the clamshell pivot pin retaining bolt (1).

B02–01–12

BUCKETS 8. Tighten to 98Nm (72 lb.ft).

1 2

TV051454

9. Install the clamping cylinder. For additional information, refer to Section B02-01 MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER . 10. Repeat steps 6 to 9 for the remaining side of the bucket.

B02–01–13

BUCKETS

Note: This page intentionally left blank.

B02–01–14

BUCKETS DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET CLAMPING CYLINDER Operation: Disassembling and Assembling the Multi-Purpose Loader Bucket Clamping Cylinder None

Job Code: 02 02 17 xx

Standard tools, Suitable vice equipment

B02–01–15

BHB0201DC

BUCKETS 1

Tube

2

Cap

3

Piston

4

Piston rod eye

5

Piston rod

6

Screw

7

Cylinder gland

8

O-ring

9

O-ring

10

Back-up ring

11

Seal

12

Wiper

13

Gland bearing

14

Sealing ring

15

Bushing

16

Grease nipple

17

Cap

18

Ring

Disassembly Clean the outside of the cylinder. 1. Fasten the tube (1) in a vice. Be careful to prevent damage to the tube (1). 2. Use the gland wrench OEM 6202, to loosen and remove the cap (2) from the tube (1). 3. Pull the piston rod (5) straight out of the tube (1) to prevent damage to the tube (1). 4. Fasten the piston rod eye (4) in a vice and put a support below the piston rod (5) near the piston (3). 5. Remove the screw (6) securing the piston (3) to the piston rod (5). 6. Loosen and remove the piston (3) from the piston rod (5). Use a torque multiplier for pistons that have a high torque value. 7. Remove the cylinder gland (7) from the piston rod (5). 8. Remove the cap (2) from the piston rod (5). 9. Remove the O-rings (8) and (9), back-up ring (10), and seal (11) from the cylinder gland (7). 10. Remove the gland bearing (13) from the piston (3). 11. Remove the wiper (12) from the cap (2).

Assembly 1. Install a new wiper (12) in the cap (2). Orientate the wiper (12) with the lip pointing towards the cap (2). 2. Install the wide seal (11) in the cylinder gland (7). The side of the seal (11) with the lip must be towards the small end of the cylinder gland (7). The seal (11) can be difficult to install. 3. Install the O-ring (9) next to the back-up ring (10) in the groove on the outside of the cylinder gland (7). 4. Install a new O-ring (8) in the cylinder gland (7).

B02–01–16

BUCKETS 5. Fasten the piston rod eye (4) in the vice. 6. Remove any marks and sharp edges on the chamfer at the end of the piston rod (5). 7. Install the cap (2) on the piston rod (5). 8. Lubricate the bore of the cylinder gland (7) with clean oil. 9. Push the cylinder gland (7) onto the piston rod (5). If necessary, use a soft hammer to drive the cylinder gland (7) onto the piston rod (5). 10. Put a support below and near the end of the piston rod (5). Use a shop cloth between the support and the piston rod (5) to prevent damage to the piston (3). 11. Put the piston (3) on the end of the piston rod (5). 12. Tighten the piston (3) for the cylinder that is being repaired. A torque multiplier can be used to help tighten the piston (3). 13. Install a new screw (6) securing the piston (3) to the piston rod (5). 14. Lubricate the inside of the tube (1) and the piston (3) with the clean oil. 15. Push the tube (1) straight onto the piston (3). 16. Lubricate the O-ring (9) on the cylinder gland (7) with clean oil. 17. Install the cylinder gland (7) in the tube (1). 18. Apply Loctite 242 to the threads of the tube (1) and the cap (2). 19. Tighten the cap (2).

B02–01–17

BUCKETS

Note: This page intentionally left blank.

B02–01–18

BUCKETS SPECIFICATIONS — BUCKETS

BHB0201SA

Torque Values Description

Nm

Lb.ft

Pivot Pin Lock nut

10

7

Loader Bucket Cylinder Piston

2400

1770

Loader Bucket Cylinder Gland

320–550

236–405

23

17

Lock Screw

B02–01–19

DIGGER QUICK ATTACH

C03 SECTION

REMOVAL AND INSTALLATION — QUICK ATTACH BACKHOE BUCKET. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . C03–01–1 REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . C03–01–3 REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT CONTROL VALVE .. .. .. .. .. . C03–01–5 REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT HYDRAULIC CYLINDER . .. . C03–01–7 DISASSEMBLY AND ASSEMBLY — QUICK ATTACH HYDRAULIC CYLINDER. .. .. .. .. .. .. .. .. .. .. .. . C03–01–9 SPECIFICATIONS — DIGGER QUICK ATTACH .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..C03–01–13

DIGGER QUICK ATTACH REMOVAL AND INSTALLATION — QUICK ATTACH BACKHOE BUCKET

BHC0301RA

Operation: Removing and Installing the Quick Attach Backhoe Bucket None

Job Code: 03 08 13 xx Standard tools

Removal

•

Warning: Never place your hands inside the quick coupler if the engine is running. Failure to follow this instruction may result in personal injury.

1. Park the machine on firm, level ground. 2. Place the backhoe bucket on firm, level ground. 3. Remove the quick attach backhoe bucket safety pin (if equipped).

TV040634

4. Press and hold the backhoe quick attach release switch.

TV040635

5. Remove the bucket.

TV040636

C03–01–1

DIGGER QUICK ATTACH Installation 1. To install, reverse the removal procedure.

C03–01–2

DIGGER QUICK ATTACH REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT

BHC0301RB

Operation: Removing and Installing the Backhoe Quick Attach Unit Suitable axle stand, Suitable trolley jack

Job Code: 03 09 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the quick attach backhoe bucket. For additional information, refer to QUICK ATTACH BACKHOE BUCKET, PAGE C03–01–1 in this section. Note: • Make sure the axle stand is only supporting the backhoe arm and is not resting on the quick attach unit. 2. Using a suitable axle stand, support the backhoe. 3. Release the pressure from the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 4. Disconnect the quick attach unit supply and return hydraulic hoses.

TV040765

5. Using a suitable trolley jack, support the quick attach unit. 6. Remove the pivot pin locking pins (1).

C03–01–3

DIGGER QUICK ATTACH Note: • Recover the pivot pin washers. 7. Remove the pivot pins (2) and remove the quick attach unit.

TV040766

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

C03–01–4

DIGGER QUICK ATTACH REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT CONTROL VALVE Operation: Removing and Installing the Backhoe Quick Attach Unit Control Valve None

BHC0301RC

Job Code: 03 10 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. Release the pressure from the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 3. Disconnect the backhoe quick attach unit control valve electrical connector (1). 4. Disconnect the backhoe quick attach unit control valve hydraulic hoses (2).

TV040775

5. Remove the backhoe quick attach unit control valve.

TV040776

Installation 1. To install, reverse the removal procedure.

C03–01–5

DIGGER QUICK ATTACH 2. Tighten to 12Nm (9 lb.ft).

TV040776

3. Check and adjust the hydraulic oil level as required.

C03–01–6

DIGGER QUICK ATTACH REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT HYDRAULIC CYLINDER Operation: Removing and Installing the Backhoe Quick Attach Unit Hydraulic Cylinder Suitable axle stand, Suitable trolley jack

BHC0301RD

Job Code: 03 11 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the quick attach backhoe bucket. For additional information, refer to QUICK ATTACH BACKHOE BUCKET, PAGE C03–01–1 in this section. Note: • Make sure the axle stand is only supporting the backhoe arm and is not resting on the quick attach unit. 2. Using a suitable axle stand, support the backhoe. 3. Disconnect the quick attach unit supply and return hydraulic hoses.

TV040765

4. Using a suitable trolley jack, support the quick attach hydraulic cylinder. 5. Remove the roll pins (1). 6. Remove the quick attach hydraulic cylinder retaining pins (2).

1

2 2 TV041087

C03–01–7

DIGGER QUICK ATTACH 7. Remove the quick attach hydraulic cylinder from the quick attach unit.

TV040786

8. Remove the pivot pin grub screw (1). 9. Remove the pivot pin (2). 10. Remove the hydraulic hoses (3).

TV040787

Installation Note: • Install new roll pins. 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

C03–01–8

DIGGER QUICK ATTACH DISASSEMBLY AND ASSEMBLY — QUICK ATTACH HYDRAULIC CYLINDER

BHC0301DA

Operation: Disassembling and Assembling the Quick Attach Hydraulic Cylinder

Job Code: 03 11 17 xx

None

Standard tools

14 13 12 15

11 10 9 8 7

5 4

3 2

1

TV041146

C03–01–9

6

DIGGER QUICK ATTACH 1

Piston Rod

2

Wiper Seal

3

Rod Seal

4

Gland Nut

5

Gland Back—Up Ring

6

Gland O-Ring

7

Piston O-Ring

8

Piston Head

9

Piston Ring Bearing

10

Rod Seal

11

Cylinder Assembly

12

Adaptor

13

Dowty Washer

14

Check Valve

15

Adaptor

Disassembly Note: • Note the orientation of all components as they are removed to aid installation. 1. Clean the outside of the hydraulic cylinder. 2. Securely clamp the ram asembly horizontaly in a vice.

•

Caution: Be careful to prevent damage to the cylinder.

3. Loosen the gland nut (4). 4. Withdraw the piston rod assembly from the cylinder. 5. Secure the eye end of the piston rod (1) in a vice. 6. Remove the piston locking screw (not illustrated). Note: This is staked and may require the deformed area to be filed off.

•

7. Remove the piston head (8). 8. Remove the gland nut (4) from the piston rod (1). 9. Remove the rod seal (10), piston ring bearing (9) and O-ring seal (7) from the piston head . 10. Remove the gland O-ring (6) and the gland back-up ring (5) from the gland nut (4). 11. Remove the ram seal (3) and the wiper (2) from the gland nut (4). 12. Remove the check valve (14). Note: • Removing the check valve will aid in assembly allowing air trapped inside the cylinder to escape. Note: • There are no servicable componenets within the check valve.

C03–01–10

DIGGER QUICK ATTACH 13. Remove the adaptors (12) and (15) if damaged. Collect the dowty washer (13).

Assembly Note: • Install new O-ring seals, seals and back-up rings. Note: Clean all internal componenets thoroughly.

•

1. Install the gland nut back-up ring (5) and gland O-ring (6) into the gland nut (4). 2. Install the rod seal (3) and wiper (2) into the gland nut (4). 3. Install the piston O-ring seal (7) into the piston head (8). 4. Install the gland nut assembly onto the piston rod (1). 5. Install the piston ring bearing (9) and the rod seal (10) into the piston head. 6. Apply Loctite 242 to the thread and install the piston head assembly onto the piston rod. Tighten to 100 to 150Nm (74 to 111 lb.ft). Ensure the dog point locates correctly into the locating groove and stake to prevent back-off.

•

Caution: Ensure there is no damage to any componenet during assembly as this may cause premature failure of the componenet.

7. Lightly lubricate the piston assembly with hydraulic oil and install the piston rod asembly into the hydraulic cylinder (11). 8. Tighten the gland nut to 150 to 200Nm (111 to 148 lb.ft). 9. Ensure the piston is in the fully retracted position and install the check valve (14)into the cylinder assembly (11). 10. Install the adaptor (15). 11. Install the adaptor (12) using a new dowty washer (13).

C03–01–11

DIGGER QUICK ATTACH

Note: This page intentionally left blank.

C03–01–12

DIGGER QUICK ATTACH SPECIFICATIONS — DIGGER QUICK ATTACH

BHC0301SA

Torque Values Description

Nm

Lb.ft

Backhoe Quick Attach Unit Control Valve

12

9

C03–01–13

DIGGER BOOM AND DIPPERSTICK

D04 SECTION

REMOVAL AND INSTALLATION — STANDARD BACKHOE BUCKET.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . D04–01–1 REMOVAL AND INSTALLATION — BACKHOE BOOM .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . D04–01–3 REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . D04–01–7 REMOVAL AND INSTALLATION — BOOM SWING TOWER.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..D04–01–11 DISASSEMBLY AND ASSEMBLY — EXTENDABLE DIPPER ARM HYDRAULIC CYLINDER . .. .. ..D04–01–15 GENERAL PROCEDURE — BACKHOE CONTROL LEVER ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. ..D04–01–19 GENERAL PROCEDURE — AUXILIARY FUNCTION/TELESCOPIC DIPPER CONTROL PEDAL ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..D04–01–23 SPECIFICATIONS — DIGGER BOOM AND DIPPERSTICK . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..D04–01–25

DIGGER BOOM AND DIPPERSTICK REMOVAL AND INSTALLATION — STANDARD BACKHOE BUCKET

BHD0401RA

Operation: Removing and Installing the Standard Backhoe Bucket None

Job Code: 04 19 13 xx Standard tools

Removal 1. Park the machine on firm, level ground. 2. Lower the stabilizers until the rear wheels are just clear of the ground. 3. Lower the backhoe bucket on firm, level ground. 4. Stop the engine and engage the park brake. 5. Remove the snap ring and remove the pivot pin.

6. Start the engine and retract the bucket hydraulic cylinder. 7. Operate the attachment controls so the dipper/bucket linkage pin is not under load. 8. Stop the engine. 9. Remove the snap ring and remove the pivot pin.

10. Start the engine and operate the attachment controls to disconnect the dipper from the bucket.

Installation

•

Caution: Make sure the bucket is in a safe position on firm, level ground.

1. Start the engine and extend the bucket hydraulic cylinder rod to bring the connecting rod into the housing.

D04–01–1

DIGGER BOOM AND DIPPERSTICK 2. Stop the engine and install the pivot pin and the snap ring.

3. Start the engine. 4. Carefully raise the attachment and operate the bucket and dipper control to bring the dipper lugs in line with the bucket lugs. 5. Stop the engine and install the pivot pin and the snap ring.

D04–01–2

DIGGER BOOM AND DIPPERSTICK REMOVAL AND INSTALLATION — BACKHOE BOOM

BHD0401RB

Operation: Removing and Installing the Backhoe Boom Suitable lifting equipment 3000Kg

Job Code: 04 01 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine of firm level ground. 2. Remove the Backhoe dipper arm. For additional information, refer to BACKHOE DIPPER ARM, PAGE D04–01–7 in this section. 3. Disconnect the right-hand auxiliary service hose (1). 4. Remove the auxiliary service hose right-hand bracket retaining bolts (2).

2

2

1 TV040116

5. Disconnect the left-hand auxiliary service hose (2). 6. Remove the auxiliary service hose left-hand bracket retaining bolts (1).

1

1

2 TV040117

D04–01–3

DIGGER BOOM AND DIPPERSTICK 7. Remove the auxiliary service hose upper bracket retaining bolt and position to one side.

TV040118

8. Remove the hydraulic hose bracket (1). 9. Disconnect the hydraulic hoses from the boom (2).

2

2

2 1

1

TV040119

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Support the hydraulic cylinder.

•

10. Using suitable lifting equipment, support the boom.

TV040120

11. Remove the hydraulic cylinder pivot pin retaining bolt (1).

D04–01–4

DIGGER BOOM AND DIPPERSTICK 12. Remove the hydraulic cylinder pivot pin (2).

1

2 TV040121

13. Remove the boom pivot pin circlip (1). 14. Remove the boom pivot pin (2). 15. Remove the boom.

2

1

TV040122

Installation Note: • Install a new pivot pin lock nut. 1. To install, reverse the removal procedure. 2. Tighten (1) to 10Nm (7 lb.ft).

1

TV041128

3. Check and adjust the hydraulic fluid level as required.

D04–01–5

DIGGER BOOM AND DIPPERSTICK

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D04–01–6

DIGGER BOOM AND DIPPERSTICK REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM

BHD0401RC

Operation: Removing and Installing the Backhoe Dipper Arm Suitable lifting equipment, Suitable trolley jack

Job Code: 04 04 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. Note: Secure the bucket linkage to prevent movement.

•

1. Remove the backhoe bucket. For additional information, refer to STANDARD BACKHOE BUCKET, PAGE D04–01–1 or QUICK ATTACH BACKHOE BUCKET, PAGE C03–01–1 in this section. 2. Park the machine on firm level ground and lower the stabilizer legs. Make sure the machine is not raised from the ground. 3. Position the backhoe bucket straight behind the machine and fully extend the dipper. 4. Release the pressure from the hydraulic system. For additional information, refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE . 5. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Disconnect the bucket hydraulic cylinder hoses (1).

D04–01–7

DIGGER BOOM AND DIPPERSTICK 7. Disconnect the auxiliary service hydraulic hoses (2).

1

2

TV040111

Vehicles with Extendable Dipper 8. Disconnect the extendable dipper cylinder hoses.

hydraulic

TV040112

All Vehicles

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

9. Using suitable lifting equipment, support the backhoe dipper arm. 10. Using a suitable trolley jack, support the boom. Note: • Support the hydraulic cylinder. 11. Remove the hydraulic cylinder pivot pin retaining bolts (1).

D04–01–8

DIGGER BOOM AND DIPPERSTICK 12. Remove the hydraulic cylinder pivot pin (2).

1

2

TV040113

13. Remove the backhoe dipper arm pivot pin retaining bolt.

TV040114

14. Remove the backhoe dipper arm pivot pin retaining bolt and remove the rear backhoe dipper arm pivot pin. 15. Remove the backhoe dipper arm.

TV040115

D04–01–9

DIGGER BOOM AND DIPPERSTICK Installation Note: • Install new pivot pin retaining bolt lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (1) to 10Nm (7 lb.ft).

1

TV041130

3. Tighten to 10Nm (7 lb.ft).

TV040114

4. Tighten to 10Nm (7 lb.ft).

TV040115

5. Check and adjust the hydraulic oil level as required.

D04–01–10

DIGGER BOOM AND DIPPERSTICK REMOVAL AND INSTALLATION — BOOM SWING TOWER

BHD0401RD

Operation: Removing and Installing the Boom Swing Tower Suitable lifting equipment

Job Code: 04 20 13 xx Standard tools

Removal

1. Park the machine on firm level ground. 2. Remove the backhoe boom. For additional information, refer to Section D04-01 BACKHOE BOOM . 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Remove the backhoe locking cable pin (1). 5. Detach the backhoe locking cable (2).

1 2

TV040123

6. Remove the circlips (1). 7. Remove the pivot pins (2). 8. Remove the backhoe locking plate (3).

3

1

2 2 TV040124

D04–01–11

DIGGER BOOM AND DIPPERSTICK 9. Remove the retaining bolts and remove the slew pins locking plate.

TV040125

10. Using a suitable drift, remove the slew pins.

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

11. Using suitable lifting equipment, support the boom swing tower.

12. Remove the boom swing tower lower pivot pin retaining bolt (1) and remove the pivot pin (2).

2

1

TV040127

D04–01–12

DIGGER BOOM AND DIPPERSTICK 13. Remove the boom swing tower upper pivot pin.

TV040128

Note: • Withdraw the hydraulic hoses through the boom swing tower. 14. Remove the boom swing tower. Note: Note the position of the boom swing tower wear washers.

•

15. Recover the boom swing tower wear washers.

TV040129

Installation Note: • Apply the correct specification grease to the boom swing tower upper and lower pivot pins. 1. To install, reverse the removal procedure.

D04–01–13

DIGGER BOOM AND DIPPERSTICK

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D04–01–14

DIGGER BOOM AND DIPPERSTICK DISASSEMBLY AND ASSEMBLY — EXTENDABLE DIPPER ARM HYDRAULIC CYLINDER Operation: Disassembling and Assembling the Extendable Dipper Hydraulic Cylinder

BHD0401DA

Job Code: 04 12 17 xx

Suitable lifting equipment

Standard tools, Suitable vice, Suitable piston ring compressor

1

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2

17

D04–01–15

DIGGER BOOM AND DIPPERSTICK 1

Cylinder

2

Wiper

3

Retaining Bush

4

O-Ring

5

Bearing

6

Seal

7

Ring

8

O-Ring

9

Ring

10

O-Ring

11

Piston

12

Ring

13

Seal

14

Ring

15

O-Ring

16

Lock Nut

17

Piston Rod

Disassembly

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder. 2. Fasten the cylinder (1) in a vice. Be careful to prevent damage to the cylinder (1). 3. Loosen the retaining bush (3). 4. Pull the piston rod (17) straight out of the cylinder (1) to prevent damage to the cylinder (1). 5. Position horizontally and fasten the piston rod eye in a vice. Position a support below the piston rod (17) near the piston (11). 6. Remove the piston lock nut (16). 7. Remove the piston (11) from the piston rod (17). 8. Remove the O-ring (15), the ring (14), the seal (13), and the ring (12) from the piston (11). Note: • Discard the O-ring seal. 9. Remove the retaining bush (3) from the piston rod (17). 10. Remove the O-ring (10), the ring back-up (9), the O-ring (8), the ring (7), the seal (6), the bearing (5), and the O-ring (4) from the retaining bush (3). Note: • Discard the O-ring seal.

D04–01–16

DIGGER BOOM AND DIPPERSTICK Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the O-ring (4), the bearing (5), the seal (6), the ring (7), the O-ring (8), the ring back-up (9) and the O-ring (10) to the retaining bush (3). Note: • To aid installation of the bush, lubricate the bore of the bush with clean oil. 2. Install the retaining bush (3) onto the piston rod (17). 3. Install the ring (12), the seal (13), the ring (14), the O-ring (15) to the piston (11). Note: • To aid installation of the piston, lubricate the bore of the piston with clean oil. 4. Install the piston assembly onto the piston rod (17). 5. Install the piston lock nut (16) and tighten to 800Nm (590 lb.ft). 6. Using a suitable piston ring compression tool to hold the new rings in place, start the tube onto the piston tube assembly. Push the tube onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. 7. Install the retaining bush (3).

D04–01–17

DIGGER BOOM AND DIPPERSTICK

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D04–01–18

DIGGER BOOM AND DIPPERSTICK GENERAL PROCEDURE — BACKHOE CONTROL LEVER ADJUSTMENT

BHD0401GA

Adjustment Procedure 1. Park the machine on firm, level ground. 2. Switch off the engine. 3. Check that the distance from the cab frame (E) to the top of the backhoe control levers corresponds to (A). 4. Check that the distance between the top of each backhoe control lever and the centre line (D) of the machine corresponds to (B). 5. Adjust the control rods at the backhoe valve assembly until the distances are correct. Lever Adjustment Parameters Version

A

B

C

Standard mm (in)

254mm (10in)

143.5mm (5.65in)

287mm (11.3in)

I.S.O. mm (in)

254mm (10in)

143.5mm (5.65in)

287mm (11.3in)

X Pattern mm (in)

251mm (9.88in)

153.5mm (6.04in)

307mm (12.08in)

D04–01–19

DIGGER BOOM AND DIPPERSTICK Standard Version

D04–01–20

DIGGER BOOM AND DIPPERSTICK I.S.O. Version

D04–01–21

DIGGER BOOM AND DIPPERSTICK X Pattern Version

D04–01–22

DIGGER BOOM AND DIPPERSTICK GENERAL PROCEDURE — AUXILIARY FUNCTION/TELESCOPIC DIPPER CONTROL PEDAL ADJUSTMENT Adjustment Procedure 1. Park the machine on firm, level ground. 2. Stop the engine. 3. Operate the auxiliary function control pedal over its full range of movement. Make sure that the spool on the backhoe control valve bank operates over its full travel. 4. If the stroke of the spool is not correct, loosen the locknuts (1). 5. Adjust the length of the connecting rod (2) at the backhoe control valve bank as required and tighten the locknuts (1).

1

Lock Nuts

2

Connecting Rod

D04–01–23

BHD0401GB

DIGGER BOOM AND DIPPERSTICK

Note: This page intentionally left blank.

D04–01–24

DIGGER BOOM AND DIPPERSTICK SPECIFICATIONS — DIGGER BOOM AND DIPPERSTICK

BHD0401SA

Torque Values Description

Nm

Lb.ft

Pivot Pin Lock nut

10

7

Piston Lock Nut

800

590

Slew Pin Plate Retaining Bolts

98

72

Boom Swing Tower Upper Pivot Pin Retaining Bolt

58

43

D04–01–25

DIGGER SWING SYSTEM

E05 SECTION

REMOVAL AND INSTALLATION — MAST CASTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . E05–01–1 REMOVAL AND INSTALLATION — MAST CASTING CLAMP SEALS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . E05–01–5 REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . E05–01–9 REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT) CYLINDER . .. .. .. .. .. .. .. E05–01–11 REMOVAL AND INSTALLATION — STABILIZER LEG (SIDESHIFT) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–13 REMOVAL AND INSTALLATION — STABILIZER LEG HYDRAULIC CYLINDER (SIDESHIFT).. .. ..E05–01–17 DISASSEMBLY AND ASSEMBLY — DIPPER HYDRAULIC CYLINDER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–21 DISASSEMBLY AND ASSEMBLY — BACKHOE BUCKET HYDRAULIC CYLINDER . .. .. .. .. .. .. .. ..E05–01–25 DISASSEMBLY AND ASSEMBLY — BOOM HYDRAULIC CYLINDER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–29 DISASSEMBLY AND ASSEMBLY — SLEW HYDRAULIC CYLINDER. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–33 DISASSEMBLY AND ASSEMBLY — STABILIZER HYDRAULIC CYLINDER (SIDESHIFT). .. .. .. .. ..E05–01–37 DISASSEMBLY AND ASSEMBLY — STABILIZER LEG HYDRAULIC CYLINDER (CENTREMOUNT) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–41 GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER LOWER EXTERNAL WEAR PADS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–45 GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER EXTERNAL WEAR PADS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–49 GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER INTERNAL WEAR PADS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–51 GENERAL PROCEDURE — STABILIZER LEG WEAR PADS (SIDESHIFT) .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–57 GENERAL PROCEDURE — STABILIZER LEGS CONTROL LEVER ADJUSTMENT . .. .. .. .. .. .. .. ..E05–01–61 GENERAL PROCEDURE — BOOM LATCH CABLE ADJUSTMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–65 SPECIFICATIONS — DIGGER SWING SYSTEM.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..E05–01–67

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — MAST CASTING

BHE0501RA

Operation: Removing and Installing the Mast Casting Suitable lifting equipment

Job Code: 05 06 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. Remove the boom swing tower. For additional information, refer to Section D04-01 BOOM SWING TOWER, PAGE D04–01–11 . 3. Detach the auxiliary service hoses from the mounting bracket and position to one side.

TV040102

4. Disconnect the mast casting clamp pipe.

TV040103

E05–01–1

DIGGER SWING SYSTEM 5. Disconnect the right-hand slew hydraulic cylinder pipe.

TV040104

6. Disconnect the left-hand slew hydraulic cylinder pipe.

TV040105

7. Remove the mast casting lower retaining bolts.

TV040106

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

8. Using suitable lifting equipment, support the mast casting.

E05–01–2

DIGGER SWING SYSTEM 9. Detach the mast casting assembly.

TV040107

10. Remove the backhoe hydraulic hose clamps (1). 11. Detach the hydraulic hose guides (2).

2

2 1 TV040108

Note: • Withdraw the hydraulic hoses through the mast casting. 12. Remove the mast casting.

TV040109

Installation Note: • Ensure the clamp seals do not become dislodged from the mast assembly. 1. To install, reverse the removal procedure.

E05–01–3

DIGGER SWING SYSTEM 2. Tighten to 1067Nm (787 lb.ft).

TV040106

3. Check and adjust the hydraulic oil level as required.

E05–01–4

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — MAST CASTING CLAMP SEALS

BHE0501RB

Operation: Removing and Installing the Mast Casting Clamp Seals Suitable lifting equipment, Suitable trolley jack

Job Code: 05 07 13 xx Standard tools, Seal tool BC001.

Removal 1. Park the machine on firm level ground. 2. Extend the backhoe to between half and three quarters full reach. 3. Position the backhoe bucket straight behind the machine with the backhoe bucket resting on the floor. 4. Engage the backhoe transport lock. 5. Release the sideshift clamps. Note: • Do not raise the wheels from the ground. 6. Lower the stabilizer legs and stop the engine. 7. Release the pressure from the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 .

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

8. Using suitable lifting equipment, support the boom and dipper assembly.

9. Using a suitable trolley jack, support the mast casting.

TV040732

E05–01–5

DIGGER SWING SYSTEM 10. Remove the mast casting lower retaining bolts.

TV040733

11. Using suitable lifting equipment, support the mast casting. 12. Raise the stabilizer legs. 13. Raise the mast casting until the upper lip of the mast casting clears the backframe. 14. Carefully drive the machine forward until there is approximately 125mm clearance between the mast casting and the backframe. 15. Stop the engine.

•

Warning: Make sure the backhoe dipper assembly is secure. Failure to follow this instruction may result in personal injury.

16. Remove the mast casting upper retaining bolts.

TV041135

17. Remove the mast casting clamp pistons and seals.

TV041136

Installation Note: • Ensure the clamp seals do not become dislodged from the mast casting. 1. To install, reverse the removal procedure.

E05–01–6

DIGGER SWING SYSTEM Note: • Clean the mast casting faces before installing new pistons and seals. 2. Using the special tool BC001 , install the seals in to the mast casting.

TV051526

3. Tighten to 1067Nm (787 lb.ft).

TV041135

4. Tighten to 1067Nm (787 lb.ft).

TV040733

E05–01–7

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–8

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT)

BHE0501RC

Operation: Removing and Installing the Stabilizer Leg (Centremount) Suitable lifting equipment

Job Code: 05 15 13 xx Standard tools

Removal 1. Park the machine on firm, level ground. Lower the stabilizer leg to the horizontal position to aid removal of the stabilizer leg. 2. Release the pressure from the hydraulic system. For further information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE., PAGE F06–01–95

•

Warning: These components are very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

3. Using suitable lifting equipment, support the stabilizer leg foot. 4. Using suitable lifting equipment, support the stabilizer leg. 5. Remove the stabilizer leg lower pivot pin retaining bolts (1). 6. Using suitable circlip pliers, remove the stabilizer leg lower pivot pin circlip (2). 7. Remove the stabilizer leg lower pin (3) and remove the stabilizer foot.

2

3

1 TV040450

8. Using suitable lifting equipment support the stabilizer leg hydraulic cylinder. 9. Using suitable circlip pliers, remove the stabilizer leg upper pivot pin circlip (1). 10. Remove the stabilizer leg retaining pin (2).

E05–01–9

DIGGER SWING SYSTEM 11. Remove the stabilizer leg (3).

1

2 3 TV040452

Installation 1. To install, reverse the removal procedure.

E05–01–10

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — STABILIZER LEG (CENTREMOUNT) CYLINDER Operation: Removing and Installing the Stabilizer Leg (Centremount) Cylinder Suitable lifting equipment

BHE0501RD

Job Code: 05 16 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. Lower the stabilizer leg to the horizontal position to aid removal of the stabilizer leg. 2. Release the pressure from the hydraulic system. Refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 .

•

Warning: These components are very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

3. Using suitable lifting equipment, support the Stabilizer leg foot. 4. Using suitable lifting equipment, support the stabilizer leg. 5. Remove the stabilizer leg lower pivot pin retaining bolts (1). 6. Using suitable circlip pliers, remove the stabilizer leg lower pivot pin circlip (2). 7. Remove the stabilizer leg lower pivot pin (3) and remove the stabilizer foot.

2

3

1 TV040450

E05–01–11

DIGGER SWING SYSTEM

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

8. Using suitable lifting equipment, support the stabilizer leg hydraulic cylinder.

TV040451

9. Disconnect the hydraulic hoses from the stabilizer leg ram cylinder (1). 10. Using the suitable circlip pliers, remove the pivot pin circlip (2). 11. Remove the pivot pin (3) and recover the stabilizer leg ram cylinder.

1

2

3 TV040453

Installation Note: • Install new pivot pin lock nuts 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

E05–01–12

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — STABILIZER LEG (SIDESHIFT)

BHE0501RE

Operation: Removing and Installing the Stabilizer Leg (Sideshift) Suitable lifting equipment, Suitable trolley jack

Job Code: 05 17 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. Lower the stabilizer leg sufficiently to allow removal of the stabilizer leg lower pin. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 5. Using a suitable trolley jack, support the stabilizer leg foot. 6. Install an M10x1.5 bolt into the stabilizer post and clamp the stabilizer leg to the stabilizer post.

TV040168

7. Remove the stabilizer leg lower retaining pin retaining bolt (1). 8. Remove the stabilizer leg lower retaining pin (2) and remove the stabilizer foot (3).

TV040169

E05–01–13

DIGGER SWING SYSTEM 9. Disconnect the license plate lamp electrical connector (1). 10. Remove the retaining bolts (2). 11. Remove the license plate mounting bracket (3).

TV040170

12. Disconnect the stabilizer leg hydraulic cylinder supply and return lines.

TV040171

13. Using suitable lifting equipment, support the stabilizer leg hydraulic cylinder. 14. Using suitable circlip pliers, remove the circlip (1). 15. Remove the stabilizer leg hydraulic cylinder upper retaining pin (2).

TV040172

E05–01–14

DIGGER SWING SYSTEM Note: • Recover the stabilizer leg hydraulic cylinder upper retaining pin spacers. 16. Remove the stabilizer leg hydraulic cylinder.

TV040173

17. Using a suitable hoist and strap/chain, thread through the middle of the stabilizer leg and secure with a suitable pin.

TV040174

18. Remove the bolt from the stabilizer post.

TV040168

19. Remove the stabilizer leg upper wear pads (1). 20. Remove the stabilizer leg (2).

TV040175

E05–01–15

DIGGER SWING SYSTEM 21. Remove the stabilizer leg lower wear pads.

TV040176

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

E05–01–16

DIGGER SWING SYSTEM REMOVAL AND INSTALLATION — STABILIZER LEG HYDRAULIC CYLINDER (SIDESHIFT) Operation: Removing and Installing the Stabilizer Leg Hydraulic Cylinder (Sideshift) Suitable lifting equipment, Suitable trolley jack

Job Code: 05 18 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Park the machine on firm level ground. Lower the stabilizer leg sufficiently to allow removal of the stabilizer leg lower pin. 3. Release the pressure from the hydraulic system F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 4. Using a suitable trolley jack, support the stabilizer leg foot. 5. Install a suitable bolt into the stabilizer post and clamp the stabilizer leg to the stabilizer post.

TV040168

6. Remove the stabilizer leg lower retaining pin retaining bolt (1). 7. Remove the stabilizer leg lower retaining pin (2) and remove the stabilizer foot (3).

TV040169

E05–01–17

BHE0501RF

DIGGER SWING SYSTEM 8. Disconnect the license plate lamp electrical connector (1). 9. Remove the retaining bolts (2). 10. Remove the license plate mounting bracket (3).

TV040170

11. Remove the stabilizer leg hydraulic cylinder supply and return lines.

TV040171

12. Using suitable lifting equipment, support the stabilizer leg hydraulic cylinder. 13. Using suitable circlip pliers, remove the circlip (1). 14. Remove the stabilizer leg hydraulic cylinder upper retaining pin (2).

TV040172

E05–01–18

DIGGER SWING SYSTEM Note: • Recover the stabilizer leg hydraulic cylinder upper retaining pin spacers. 15. Remove the stabilizer leg hydraulic cylinder.

TV040173

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic oil level as required.

E05–01–19

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–20

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — DIPPER HYDRAULIC CYLINDER

BHE0501DA

Operation: Disassembling and Assembling the Dipper Hydraulic Cylinder

Job Code: 05 09 17 xx

Suitable lifting equipment

Standard tools, Suitable piston ring compressor

2

3

1

15

19 18

15

17 16

9

10

11

12

8 7 6 5 4

21

22 20 TV040502

E05–01–21

13

14

DIGGER SWING SYSTEM 1

Cylinder

2

Bushing

3

Grease Point

4

Ring

5

Seal

6

Ring

7

Bush

8

Ring

9

O-ring

10

Back-up Ring

11

O-Ring

12

Piston Ring

13

Back-up ring

14

Piston

15

Lock Screw

16

Guide Ring

17

Ring

18

Seal

19

Guide Ring

20

Bushing

21

Grease Point

22

Piston Rod

Disassembly

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder. 2. Fasten the cylinder (1) in a soft jaw vice. Be careful to prevent damage to the cylinder (1). 3. Remove the lock screw from the bush (7) and cylinder (1). 4. Remove the bush (7) from the cylinder (1). 5. Pull the piston rod (22) straight out of the cylinder (1). 6. Fasten the piston rod eye (22) in a vice and put a support below the piston rod (22) near the piston. 7. Remove the locking screw (15), and unscrew the piston (14) from the piston rod (22). 8. Remove the bush (7) from the piston rod (22). 9. Remove the guide ring (19), seal (18), ring (17), guide ring (16) and the back-up ring (13) from the piston (14). 10. Remove the ring (12), O-ring (11), back-up ring (10), O-ring (9), ring (8), ring (6), seal (5) and wiper seal (4) from the bush (7).

E05–01–22

DIGGER SWING SYSTEM Assembly Note: • Install new O-ring seals, seals and rings. Note: lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (4), seal (5), ring (6), ring (8), O-ring (9), back-up ring (10), O-ring (11) and ring (12) to the bush (7). 2. Install the back-up ring (13), guide ring (16), ring (17), seal (18) and guide ring (19) to the piston (14). Note: • To aid installation of the bush, lubricate the bore of the bush with clean oil. 3. Install the bush (7) onto the piston rod (22).

•

Caution: Do not apply Loctite to the first 7mm of the piston rod threads. Failure to follow this instruction may result in damage to the piston.

4. Clean the threads on the end of the piston rod. Apply Loctite 242 to the piston rod threads from the open end of the piston rod. 5. Install piston (14) onto the piston rod (22) and install the locking screw (15) and tighten to 2.3Nm (1.7 lb.ft). 6. Lubricate the inside of the cylinder (1) and the piston (14) with clean oil. Use a piston ring compression tool to hold the new carrier rings in place. 7. Start the cylinder (1) onto the piston rod assembly. Push the tube onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. Be careful not to damage the carrier rings and seal. 8. When the piston (14) is in the smooth part of the cylinder (1), start the bush (7) into the cylinder (1). 9. Tighten the bush (7) to a torque between 400 and 450 Nm (295 and 332 lb.ft). When the lock screw (2) holes become aligned in this torque range, install the lock screw (2). Tighten the lock screw (2) to 23 Nm (17 lb.ft).

E05–01–23

DIGGER SWING SYSTEM

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E05–01–24

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — BACKHOE BUCKET HYDRAULIC CYLINDER

BHE0501DB

Operation: Disassembling and Assembling the Dipper Hydraulic Cylinder

Job Code: 05 11 17 xx

Suitable lifting equipment

Standard tools, Suitable piston ring compression tool

2

3

1

15

19 18

15

17 16

9

10

11

12

8 7 6 5 4

21

22 20 TV040502

E05–01–25

13

14

DIGGER SWING SYSTEM 1

Cylinder

2

Bushing

3

Grease Nipple

4

Ring

5

Seal

6

Ring

7

Cylinder Gland

8

Bush

9

O-ring

10

Back-up Ring

11

O-Ring

12

Piston Ring

13

O-Ring

14

Piston

15

Locking Screw

16

Guide Ring

17

Ring

18

Seal

19

Guide Ring

20

Bushing

21

Grease Nipple

22

Piston Rod

Disassembly

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (1) in a soft jawed vice. 3. Remove the locking screw from the cylinder gland (7) and cylinder (1). 4. Remove the cylinder gland (7) from the cylinder (1). 5. Pull the piston rod (22) straight out of the cylinder (1). 6. Fasten the piston rod eye (22) in a vice and put a support below the piston rod (22) near the piston. 7. Remove the locking screw (15), and unscrew the piston (14) from the piston rod (22). 8. Remove the bush (7) from the piston rod (22). 9. Remove the guide ring (19), seal (18), ring (17), guide ring (16) and the O-ring (13) from the piston (14). 10. Remove the ring (12), O-ring (11), back-up ring (10), O-ring (9), back-ring (8), ring (6), seal (5) and wiper seal (4) from the cylinder gland (7).

E05–01–26

DIGGER SWING SYSTEM Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (4), seal (5), ring (6), bush (8), O-ring (9), back-up ring (10), O-ring (11) and ring (12) to the cylinder gland (7). 2. Install the O-ring (13), guide ring (16), ring (17), seal (18) and guide ring (19) to the piston (14). Note: • To aid installation of the bush, lubricate the bore of the bush with clean oil. 3. Install the cylinder gland (7) onto the piston rod (22).

•

Caution: Do not apply Loctite to the first 7mm of the piston rod threads. Failure to follow this instruction may result in damage to the piston.

4. Clean the threads on the end of the piston rod. Apply Loctite 242 to the piston rod threads from the open end of the piston rod. 5. Install piston (14) onto the piston rod (22) and install the locking screw (15) and tighten to 2.3Nm (1.7 lb.ft). 6. Lubricate the inside of the cylinder (1) and the piston (14) with clean oil. Use a piston ring compression tool to hold the new carrier rings in place. 7. Start the cylinder (1) onto the piston rod assembly. Push the tube onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. Be careful not to damage the sealing rings and seal. 8. When the piston (14) is in the smooth part of the cylinder (1), start the cylinder gland (7) into the cylinder (1). Note: • Install a new locking screw. 9. Tighten the cylinder gland (7) to a torque between 400 and 450 Nm (295 and 332 lb.ft). When the locking screw holes become aligned in this torque range, install the locking screw (2). Tighten the locking screw (2) to 23Nm (17 lb.ft).

E05–01–27

DIGGER SWING SYSTEM

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E05–01–28

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — BOOM HYDRAULIC CYLINDER

BHE0501DC

Operation: Disassembling and Assembling the Boom Hydraulic Cylinder Suitable lifting equipment

Job Code: 05 13 17 xx Standard tools, Suitable piston ring compression tool

2 3

1

21

15

20 19 18

9

17 16 14 13 12 11 10 8

7 6 5 4 23

24

22 TV040503

E05–01–29

DIGGER SWING SYSTEM 1

Cylinder

2

Bush

3

Grease Nipple

4

Wiper Seal

5

Seal

6

Ring

7

Ring

8

Cylinder Gland

9

Locking Screw

10

O-Ring

11

Back-up Ring

12

O-Ring

13

O-Ring

14

Piston

15

Locking Screw

16

Guide Ring

17

Ring

18

Seal

19

Guide Ring

20

Retaining Nut

21

Snap Ring

22

Bush

23

Grease Nipple

24

Piston Rod

Disassembly

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (1) in a soft jawed vice. 3. Remove the locking screw (9) from the cylinder gland (8) and cylinder (1). 4. Remove the cylinder gland (8) from the cylinder (1). 5. Pull the piston rod (24) straight out of the cylinder (1). 6. Fasten the piston rod eye (24) in a vice and put a support below the piston rod (24) near the piston. 7. Remove the snap ring (21) and the retaining nut (20) from the piston rod. 8. Remove the locking screw (15), and unscrew the piston (14) from the piston rod (24). 9. Remove the cylinder gland (8) from the piston rod (24).

E05–01–30

DIGGER SWING SYSTEM 10. Remove the guide ring (19), seal (18), ring (17), guide ring (16) and the O-ring (13) from the piston (14). 11. Remove the ring (12), O-ring (11), back-up ring (10), O-ring (9), ring (8), ring (6), seal (5) and wiper seal (4) from the cylinder gland (8).

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (4), seal (5), ring (6), ring (8), O-ring (9), back-up ring (10), O-ring (11) and ring (12) to the cylinder gland (8). 2. Install the O-ring (13), guide ring (16), ring (17), seal (18) and guide ring (19) to the piston (14). Note: • To aid installation of the bush, lubricate the bore of the bush with clean oil. 3. Install the cylinder gland (8) onto the piston rod (24).

•

Caution: Do not apply Loctite to the first 7mm of the piston rod threads. Failure to follow this instruction may result in damage to the piston.

4. Clean the threads on the end of the piston rod. Apply Loctite 242 to the piston rod threads from the open end of the piston rod. Note: • Install a new locking screw. 5. Install the piston (14) onto the piston rod (24) and install the locking screw (15) and tighten to 23Nm (17 lb.ft). 6. Install the retaining nut (20) and the snap ring (21) onto the piston rod. 7. Lubricate the inside of the cylinder (1) and the piston (14) with clean oil. Use a piston ring compression tool to hold the new carrier rings in place. 8. Start the cylinder (1) onto the piston rod assembly. Push the tube onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. 9. When the piston (14) is in the smooth part of the cylinder (1), start the cylinder gland (8) into the cylinder (1). Note: Install a new locking screw.

•

10. Tighten the cylinder gland (8) to a torque between 500 and 550Nm (369 and 406 lb.ft). When the locking screw holes become aligned in this torque range, install the locking screw. Tighten the locking screw to 23Nm (17 lb.ft).

E05–01–31

DIGGER SWING SYSTEM

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E05–01–32

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — SLEW HYDRAULIC CYLINDER

BHE0501DD

Operation: Disassembling and Assembling the Slew Hydraulic Cylinder

Job Code: 05 03 17 xx

Suitable lifting equipment

Standard tools, Piston ring compression tool

1

2

14

17

13 20 19 18

16 15

6 5

12

4 11

3 10 9 8 7

21

23 22

E05–01–33

DIGGER SWING SYSTEM 1

Cylinder

2

Plug

3

Wiper Seal

4

Seal

5

Sealing Ring

6

Bush

7

Cylinder Gland

8

Retaining Ring

9

O-Ring

10

Back-up Ring

11

O-Ring

12

O-Ring

13

Piston

14

Locking Screw

15

Guide Ring

16

Seal

17

Back-up Seal

18

Guide Ring

19

Ring

20

Snap Ring

21

Bush

22

Piston Rod

23

Grease Nipple

Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (1) in a soft jawed vice. 3. Using a suitable tool, remove the cylinder gland (7) from the cylinder (1). 4. Pull the piston rod (22) straight out of the cylinder (1). 5. Remove the locking screw (14) from the piston (13). Note: • Discard the locking screw . 6. Remove the snap ring (20) and the retaining nut (19) from the piston rod (22). 7. Remove the piston (13) from the piston rod (22). 8. Remove the cylinder gland (7) from the piston rod (22).

E05–01–34

DIGGER SWING SYSTEM 9. Remove the guide ring (18), back-up seal (17), seal (16), guide ring (15) and the O-ring (12) from the piston (13). 10. Remove the O-ring (11), back-up ring (10), O-ring (9), retaining ring (8), bush (6), sealing ring (5), seal (4) and the wiper seal (3) from the cylinder gland (7).

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (3), seal (4), sealing ring (5), bush (6), retaining ring (8), O-ring (9), back-up ring (10) and ring (11) to the cylinder gland (7). 2. Install the O-ring (12), guide ring (15), seal (16), back-up seal (17) and the guide ring (18) to the piston (13). 3. Install the cylinder gland (7) onto the piston rod (22). 4. Install the piston (13) onto the piston rod (22). 5. Tighten the piston (13) to 1075Nm. Note: • Install a new locking screw. 6. Apply Loctite NR275 to the locking screw (14) threads and install the locking screw (14) in the piston (13). Tighten the locking screw (14) to a torque between 23Nm. 7. Install the ring (19) and the snap ring (20) onto the piston rod (22). 8. Lubricate the bore of the cylinder gland (7) with clean oil. 9. Lubricate the inside of the cylinder (1) and the piston (13) with clean oil. Use a piston ring compression tool to hold the new carrier rings in place. 10. Start the cylinder (13) onto the piston rod assembly (22). Push the cylinder onto the piston rod (22) assembly until the compression tool is pushed off the piston rod assembly. Be careful not to damage the carrier rings and seal.

E05–01–35

DIGGER SWING SYSTEM 11. Using a suitable tool, install the cylinder gland (7) into the cylinder (1). 12. Tighten the gland (7) to 395Nm (291 lb.ft).

E05–01–36

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — STABILIZER HYDRAULIC CYLINDER (SIDESHIFT) Operation: Disassembling the Stabilizer Hydraulic Cylinder (Sideshift)

BHE0501DE

Job Code: 05 18 17 xx

Suitable Lifting Equipment

Standard Tools, Piston Ring Compression Tool

1

17 16 15 14 13 12 10 9 8 7 6 5 4 3 2

11

18

TV040506

E05–01–37

DIGGER SWING SYSTEM 1

Cylinder

2

Wiper Seal

3

Seal

4

Ring

5

Bush

6

Cylinder Gland

7

Locking Screw

8

O-Ring

9

Back-up Ring

10

Seal

11

O-Ring

12

Piston

13

Guide Ring

14

Ring

15

Ring

16

Guide Ring

17

Lock Nut

18

Piston Rod

Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (1) in a soft jawed vice. 3. Remove the locking screw (7) from the cylinder gland. Note: • Discard the locking screw 4. Using a suitable tool, remove the cylinder gland (6) from the cylinder (1). 5. Pull the piston rod (18) straight out of the cylinder (1). 6. Fasten the piston rod eye (18) in a vice and put a support below the piston rod (18) near the piston. 7. Remove the lock nut (17) from the piston rod (18). 8. Remove the piston (12) from the piston rod (18). 9. Remove the cylinder gland (6) from the piston rod (18). 10. Remove the guide ring (16), ring (15), ring (14), guide ring (13) and the O-ring (11) from the piston. 11. Remove the seal (10), back-up ring (9), O-ring (8), bush (5), ring (4), seal (3) and the wiper seal (2) from the cylinder gland (6).

E05–01–38

DIGGER SWING SYSTEM Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (2), seal (3), ring (4), bush (5), O-ring (8), back-up ring (9) and the seal (10) to the cylinder gland (6). 2. Install the O-ring (11), guide ring (13), ring (14) ring (15) and the guide ring (16) to the piston (6). Note: • To aid installation of the cylinder gland , lubricate the bore of the gland with clean oil. 3. Install the cylinder gland (6) onto the piston rod (18). 4. Install the piston (12) onto the piston rod (18). 5. Apply Loctite HTS 915 066 to the threads of a new lock nut (17) and install the new lock nut (17) in the piston rod (18). Tighten the lock nut (17) to 825Nm (608 lb.ft). 6. Lubricate the inside of the cylinder (1) and the piston (12) with clean oil. Use a piston ring compression tool to hold the new carrier rings in place. 7. Start the cylinder (1) onto the piston rod (18) assembly. Push the cylinder onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. Be careful not to damage the carrier rings and seals. 8. Tighten the cylinder gland (6) to a torque between 320 and 350Nm (236 and 258 lb.ft). When the locking screw holes become aligned in this torque range, install the locking screw (7). Tighten the locking screw (7) to 23Nm (17 lb.ft).

E05–01–39

DIGGER SWING SYSTEM

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E05–01–40

DIGGER SWING SYSTEM DISASSEMBLY AND ASSEMBLY — STABILIZER LEG HYDRAULIC CYLINDER (CENTREMOUNT)

BHE0501DF

Job Code: 05 16 17 xx

Operation: Disassembling and Assembling the Stabilizer Leg Hydraulic Cylinder (Centremount) Suitable lifting equipment

Standard tools, Suitable piston ring compressor

11 10 9 12

8

7

13

6 5

4 3

14

2 1 25

22 20 19

24

16 23 21 15

18 17

TV040507

E05–01–41

DIGGER SWING SYSTEM 1

O-Ring

2

Ring

3

Seal

4

Ring

5

Cylinder Gland

6

Locking Screw

7

Cylinder

8

O-Ring

9

Nut

10

Tube Assembly

11

Bolt

12

Washer

13

Bush

14

Grease Nipple

15

Piston Rod

16

Grease Nipple

17

Retaining Nut

18

Snap Ring

19

Wiper Seal

20

Seal

21

Retaining Ring

22

Back-up ring

23

O-Ring

24

Bush

25

Cylinder Gland

Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (7) in a soft jawed vice. 3. Remove the cylinder gland (25) from the cylinder (7). 4. Pull the piston rod (15) straight out of the tube (7) to prevent damage to the tube (7). 5. Fasten the piston rod eye (15) in a vice and put a support below the piston rod (15) near the piston (5). 6. Remove the snap ring (18) and the retaining nut (17) from the piston rod (15). 7. Remove the locking screw (6) from the piston (7). Note: • Discard the locking screw (6).

E05–01–42

DIGGER SWING SYSTEM 8. Remove the piston (5) from the piston rod (15). 9. Remove the cylinder gland (25) from the piston rod (15). 10. Remove the ring (4), seal (3), ring (2) and the O-ring (1) from the piston (5). 11. Remove the bush (24), O-ring (23), back-up ring (22), retaining ring (21), seal (20), wiper seal (19) from the cylinder gland (25). 12. Loosen the nut (9) on the tube assembly (23). 13. Remove the bolt (11) and washer (12) from the tube assembly (10). 14. Remove the tube assembly (10) from the cylinder (7). Note: • Discard the O-ring seal.

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the O-ring (8) to the tube assembly (10). 2. Install the tube assembly (10) onto cylinder (7) and install the washer (12) and the bolt (11). 3. Tighten the nut (9). 4. Install the wiper seal (19), seal (20), retaining ring (21), back-up ring (22), O-ring (23) and the bush (24) to the cylinder gland (5). 5. Install the O-ring (1), ring (2), seal (3) and ring (4) to the piston (25). 6. Lubricate the bore of the cylinder gland (25) with clean oil. 7. Push the cylinder gland (25) onto the piston rod (15). 8. Put the piston (5) on the end of the piston rod (15). 9. Tighten the piston (5) to 675Nm (498 lb.ft). Note: • Install a new locking screw. 10. Apply Loctite 648 to the threads of the locking screw (6) and install the locking screw (6) into the piston (5). Tighten the locking screw (6) to 23Nm (17 lb.ft). 11. Install the retaining nut (17) and the snap ring (18) onto the piston rod (15). 12. Lubricate the inside of the tube (1) and the piston (4) with clean oil. Use a piston ring compression tool to hold the new sealing rings in place. 13. Push the cylinder (7) straight onto the piston (5). 14. Push the cylinder onto the piston rod (15) assembly until the compression tool is pushed off the piston rod assembly (15). Be careful not to damage the sealing rings and seals. 15. Lubricate the O-ring (23) on the cylinder gland (25) with clean oil. 16. Install the cylinder gland (25) into the cylinder tube (7). 17. Tighten the cylinder gland (25) to 325Nm (240 lb.ft).

E05–01–43

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–44

DIGGER SWING SYSTEM GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER LOWER EXTERNAL WEAR PADS Top and Bottom Bearing Pads Note: • Make sure the weight of the inner section is on the bottom bearing pad. 1. Fully extend the dipper arm and boom to a suitable working height. 2. Extend the extendable dipper approximately 300mm. 3. Remove the top bearing pad covers.

TV040735

4. Remove the top bearing pad and shim(s).

TV040736

Note: • Make sure the weight of the inner section is not on the bottom bearing pad. 5. Lower the dipper arm and boom to the ground. 6. Remove the bottom bearing pad cover.

TV040737

E05–01–45

BHE0501GB

DIGGER SWING SYSTEM 7. Remove the bottom bearing pad and shim(s).

TV040738

8. Install a new bottom bearing pad. 9. Install the bottom bearing pad cover and tighten to 140Nm (103 lb.ft).

TV040737

Note: • Make sure the weight of the inner section is on the bottom bearing pad. 10. Fully extend the dipper arm and boom to a suitable working height. 11. Install a new top bearing pad. 12. Install the top bearing pad covers and tighten to 140Nm (103 lb.ft).

TV040735

13. Using a suitable measuring device, measure the clearance between the extendable dipper inner section and the top bearing pad.

E05–01–46

DIGGER SWING SYSTEM Note: • Shims are available in 0.5mm, 1.0mm, 2.0mm and 4.0mm thicknesses.

•

Caution: Make sure the shims are installed between the bearing pad and the outer section of the dipper.

14. Install equal quantities of adjusting shims as required to the top and bottom bearing pads to achieve a total clearance of less than 1.0mm.

Side Wear Pads 1. Fully extend the dipper arm and boom to a suitable working height. 2. Remove the left-hand and right-hand side bearing pad covers (right-hand side shown).

TV040739

3. Remove the side bearing pads and shims from the covers.

TV040740

4. Install new bearing pads to the four bearing pad covers. 5. Install the left-hand and right-hand side bearing pad covers and tighten to 60Nm (right-hand side shown, left-hand side similar).

TV040739

E05–01–47

DIGGER SWING SYSTEM Note: • Make sure no clearance is present between the left-hand side of the extendable dipper inner section and the left-hand side bearing pad. 6. Apply pressure to right-hand side of the extendable dipper inner section. 7. Using a suitable measuring device, measure the clearance between the extendable dipper inner section and the right-hand side bearing pads. Note: • Shims are available in 1.0mm or 2.0mm thicknesses.

•

Caution: Make sure the shims are installed between the bearing pads and the covers.

8. Install equal quantities of adjusting shims as required to the left-hand and right-hand side bearing pads to achieve a total clearance of less than 1.0mm.

E05–01–48

DIGGER SWING SYSTEM GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER EXTERNAL WEAR PADS Extendable Dipper Upper External Wear Pads 1. Fully extend the dipper arm and boom. 2. Extend the extendable dipper approximately three quarters and position the bucket 50mm from the ground. 3. Using a suitable measuring device, measure the clearance between the upper external wear pad and the extendable dipper outer section.

TV040741

Note: • If the clearance is less than 1.0mm, replacement is not required. 4. If the clearance is greater than 1.0mm, remove the upper external wear pad cover.

TV040742

5. Remove the upper external wear pad (1), shims (2) and the spacers (3).

TV040743

E05–01–49

BHE0501GC

DIGGER SWING SYSTEM Note: • If the initial clearance was 2.0mm and the shims are 3.0mm, the replacement shims required would be 2.0mm to obtain the required clearance of 1.0mm. Shims are available in 1.0mm, 2.0mm and 3.0mm thicknesses. 6. Using a suitable measuring device, measure the shims and replace as required to reduce the clearance shown to below 1.0mm.

TV040741

7. Install the upper external wear pad replacement shims (2) and the spacers (3).

(1),

TV040743

8. Install the upper external wear pad cover and tighten to 920Nm +/- 120Nm (679 lb.ft +/- 89 lb.ft).

TV040742

E05–01–50

DIGGER SWING SYSTEM GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER UPPER INTERNAL WEAR PADS Extendable Dipper Upper Internal Wear Pads 1. Remove the backhoe bucket. For additional information, refer to STANDARD BACKHOE BUCKET, PAGE D04–01–1 or QUICK ATTACH BACKHOE BUCKET, PAGE C03–01–1 in this section. Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. Note: Make sure the weight of the inner section is on the bottom bearing pad.

•

2. Fully extend the dipper arm and boom to a suitable working height. 3. Extend the extendable dipper approximately 300mm. 4. Remove the top bearing pad covers.

TV040735

5. Remove the top bearing pad and shim(s).

TV040736

Note: • Make sure the weight of the inner section is not on the bottom bearing pad. 6. Lower the dipper arm and boom to the ground.

E05–01–51

BHE0501GD

DIGGER SWING SYSTEM 7. Remove the bottom bearing pad cover.

TV040737

8. Remove the bottom bearing pad and shim(s).

TV040738

9. Fully extend the dipper arm and boom until the dipper arm is in horizontal position. 10. Fully extend the extendable dipper. Note: • Using a suitable block (3), support the hydraulic cylinder. 11. Remove the extendable dipper hydraulic cylinder pivot pin circlip (1) and remove the pivot pin (2).

TV040744

E05–01–52

DIGGER SWING SYSTEM 12. Remove the upper external wear pad cover.

TV040742

13. Remove the upper external wear pad (1), shims (2) and the spacers (3).

TV040743

14. Disconnect the backhoe bucket hydraulic cylinder pipes.

TV040745

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

15. Using suitable lifting equipment, support the extendable dipper inner section.

E05–01–53

DIGGER SWING SYSTEM 16. Carefully slide out the extendable dipper inner section.

TV040746

17. Remove the internal upper wear pad (1). 18. Remove the internal side wear pads (2) and shims (3).

Note: • Do not install the shims at this time. 19. Install new side wear pads to the extendable dipper inner section. 20. Measure the distance across the wear pads (A). 21. Measure the internal diameter of the extendable dipper outer section (B). Note: Shims are available in 1.0mm and 2.0mm thicknesses.

•

22. The difference between dimensions A and B = X. Total clearance of 0.5mm to 1.0mm is required. Dimension X minus the clearance required is the total thickness of shims required.

TV040748

E05–01–54

DIGGER SWING SYSTEM

•

Caution: Make sure the shims are installed between the bearing pad and the extendable dipper inner section.

Note: Use a suitable grease to stop the pads becoming dislodged during installation.

•

23. Install equal amounts of shims behind the left and right wear pads to give the correct clearance required. 24. Install a new upper internal wear pad. 25. Install the extendable dipper inner section. 26. Connect the backhoe bucket hydraulic cylinder pipes. 27. Install the upper external wear pad, shims and the spacers. 28. Install the upper external wear pad cover and tighten to 920Nm +/- 120Nm (679 lb.ft +/- 89 lb.ft).

TV040742

Note: • Make sure the hydraulic cylinder is aligned with the pivot pin hole. 29. Install the extendable dipper hydraulic cylinder pivot pin and circlip. 30. Install the bottom bearing pad and shim(s). 31. Install the bottom bearing pad cover and tighten to 140Nm (103 lb.ft).

TV040737

32. Install the top bearing pad and shim(s).

E05–01–55

DIGGER SWING SYSTEM 33. Install the top bearing pad covers and tighten to 140Nm (103 lb.ft).

TV040735

34. If required, adjust the extendable dipper upper external wear pads. For additional information, refer to EXTENDABLE DIPPER UPPER EXTERNAL WEAR PADS, PAGE E05–01–49 in this section. 35. Install the backhoe bucket. For additional information, refer to STANDARD BACKHOE BUCKET, PAGE D04–01–1 or QUICK ATTACH BACKHOE BUCKET, PAGE C03–01–1 in this section.

E05–01–56

DIGGER SWING SYSTEM GENERAL PROCEDURE — STABILIZER LEG WEAR PADS (SIDESHIFT)

BHE0501GE

Stabilizer Leg Wear Pads (Sideshift) 1. Remove the stabilizer leg. For additional information, refer to STABILIZER LEG (SIDESHIFT), PAGE E05–01–13 in this section. 2. Remove the stabilizer leg lower wear pads.

TV040176

3. Remove the stabilizer leg upper wear pads (1). 4. Clean the stabilizer leg and housing. Note: • Do not install the wear pads. 5. Using suitable lifting equipment, stabilizer leg (2).

install the

TV040175

6. Position the stabilizer leg until the top is level with the upper part of the stabilizer leg housing inner face.

TV040750

7. Position the stabilizer leg (1) flush with the stabilizer leg housing (2) in the two positions indicated. 8. Measure the distance at positions (A) and (B).

E05–01–57

DIGGER SWING SYSTEM Note: • A maximum clearance of 1.0mm is required when new wear pads are installed. Wear pads are available in green 3.6mm, blue 4.0mm, yellow 4.5mm, black 5.0mm, grey 5.5mm, natural 6.0mm and red 6.5mm. 9. Calculate the upper wear pads required. Distance (A) minus 1.0mm will give the total wear pad thickness required. This value divided by two will indicate the thickness of the two wear pads required to give the correct clearance. 10. Calculate the upper wear pads required. Distance (B) minus 1.0mm will give the total wear pad thickness required. This value divided by two will indicate the thickness of the two wear pads required to give the correct clearance.

TV040751

11. Position the stabilizer leg until the bottom is level with the lower part of the stabilizer leg housing. 12. Position the stabilizer leg (1) flush with the stabilizer leg housing (2) in the two positions indicated. 13. Measure the distance at positions (A) and (B). Note: • A maximum clearance of 1.0mm is required when new wear pads are installed. Wear pads are available in green 3.6mm, blue 4.0mm, yellow 4.5mm, black 5.0mm, grey 5.5mm, natural 6.0mm and red 6.5mm. 14. Calculate the lower wear pads required. Distance (A) minus 1.0mm will give the total wear pad thickness required. This value divided by two will indicate the thickness of the two wear pads required to give the correct clearance.

E05–01–58

DIGGER SWING SYSTEM 15. Calculate the lower wear pads required. Distance (B) minus 1.0mm will give the total wear pad thickness required. This value divided by two will indicate the thickness of the two wear pads required to give the correct clearance.

TV040751

16. Remove the stabilizer leg from the housing. Note: • Use a suitable grease to stop pads becoming dislodged during installation. 17. Install the correct thickness upper and lower wear pads. 18. Install the stabilizer leg. For additional information, refer to STABILIZER LEG (SIDESHIFT), PAGE E05–01–13 in this section.

E05–01–59

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–60

DIGGER SWING SYSTEM GENERAL PROCEDURE — STABILIZER LEGS CONTROL LEVER ADJUSTMENT Adjustment Procedure 1. Park the machine on firm level ground. 2. Switch off the engine. 3. Make sure that both stabilizer control levers are vertical and that the knobs are in line. 4. Adjust the connecting rods located behind the left side trim panel to make the control levers vertical or to align the knobs. 5. Operate each stabilizer control lever over its full range of movement. Make sure that the relevant spool on the backhoe valve operates over its full stroke and the knobs are in line. 6. Tighten the lock nuts in position.

E05–01–61

BHE0501GF

DIGGER SWING SYSTEM GLAZED/R.O.P.S Cab

1

Lock nuts

2

Connecting rod

3

Lock nuts

4

Rod assembly

E05–01–62

DIGGER SWING SYSTEM R.O.P.S Cab

1

Lock nuts

2

Connecting rod

E05–01–63

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–64

DIGGER SWING SYSTEM GENERAL PROCEDURE — BOOM LATCH CABLE ADJUSTMENT

BHE0501GG

Adjustment Procedure 1. Make sure the boom latch cable is correctly fixed to the boom latch control lever (1). 2. Adjust the cable sheath stop (2) on the latch side of the boom, so that the cable is slightly slack. 3. Lower the boom latch control lever (1). If the boom latch (3) does not engage fully over the stops on the mast casting, slacken the cable by moving the cable sheath stop (2) towards the boom until full engagement is achieved. 4. Raise the boom latch control lever (1) and make sure the boom latch is fully disengaged from the stops on the mast casting, adjust as required.

3

1 2

TV040514

1

Boom latch control lever

2

Cable sheath stop

3

Boom latch

E05–01–65

DIGGER SWING SYSTEM

Note: This page intentionally left blank.

E05–01–66

DIGGER SWING SYSTEM SPECIFICATIONS — DIGGER SWING SYSTEM

BHE0501SA

Torque Values Description

Nm

Lb.ft

320 — 550

236 — 405

Dipper hydraulic cylinder lock screw

23

17

Backhoe bucket hydraulic cylinder piston locking screw

23

17

320 — 550

236 — 405

23

17

1075

793

Slew hydraulic cylinder piston locking screw

23

17

Slew hydraulic cylinder gland

395

291

Sideshift stabilizer hydraulic cylinder piston nut

825

608

320 — 350

236 — 258

Sideshift stabilizer hydraulic cylinder gland locking screw

23

17

Centremount stabilizer leg hydraulic cylinder piston

675

498

Centremount stabilizer leg hydraulic cylinder piston locking screw

23

17

Centremount stabilizer leg hydraulic cylinder gland

325

240

Extendable dipper lower external top/bottom bearing pad covers

140

103

Extendable dipper lower external side bearing pad covers

60

44

Extendable dipper upper external wear pad cover

920

679

Mast casting

1067

787

Dipper hydraulic cylinder gland

Backhoe bucket hydraulic cylinder gland Backhoe bucket hydraulic cylinder gland locking screw Slew hydraulic cylinder piston

Sideshift stabilizer hydraulic cylinder gland

Extendable Dipper Shim Sizes Wear Pad Description Lower external top/bottom Lower external side Upper external Side internal

Shim Sizes (mm)

Required Clearance (mm)

0.5, 1, 2 and 4

1

1 and 2

1

1, 2 and 3

1

1 and 2

1

Sideshift Stabilizer Leg Wear Pad Sizes Colour

Size (mm)

Green

3.6

Blue

4.0

Yellow

4.5

Black

5.0

Grey

5.5

Natural

6.0

Red

6.5

Required clearance = 1mm

E05–01–67

MAIN HYDRAULICS

F06 SECTION

HYDRAULIC SYSTEM DIAGRAM . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . F06–01–1 DIAGNOSING AND TESTING — HYDRAULICS/PRESSURE TESTING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . F06–01–5 DIAGNOSING AND TESTING — HYDRAULIC OIL CONTAMINATION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–19 REMOVAL AND INSTALLATION — HYDRAULIC OIL RESERVOIR . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–21 REMOVAL AND INSTALLATION — OIL COOLER.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–23 REMOVAL AND INSTALLATION — HYDRAULIC PUMP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–25 REMOVAL AND INSTALLATION — HYDRAULIC PUMP 2007.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–29 REMOVAL AND INSTALLATION — BACKHOE CONTROL VALVE BANK . .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–33 REMOVAL AND INSTALLATION — LOADER CONTROL VALVE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–39 REMOVAL AND INSTALLATION — CHANGEOVER VALVE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–43 REMOVAL AND INSTALLATION — STEERING PRIORITY/UNLOADER VALVE .. .. .. .. .. .. .. .. .. .. .. F06–01–45 REMOVAL AND INSTALLATION — RIDE CONTROL VALVE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–47 REMOVAL AND INSTALLATION — SERVO CONTROL VALVE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–49 REMOVAL AND INSTALLATION — SERVO CONTROL CONFIGURATION CHANGEOVER VALVE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–51 DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–55 DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP — 2007. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–59 DISASSEMBLY AND ASSEMBLY — BACKHOE CONTROL VALVE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–63 DISASSEMBLY AND ASSEMBLY — LOADER CONTROL VALVE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–75 DISASSEMBLY AND ASSEMBLY — CHANGEOVER VALVE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–81 DISASSEMBLY AND ASSEMBLY — RIDE CONTROL VALVE.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–83 DISASSEMBLY AND ASSEMBLY — SERVO CONTROL VALVE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–85 GENERAL PROCEDURE — HYDRAULIC CYLINDER INSPECTION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–87 GENERAL PROCEDURE — CLEANING THE HYDRAULIC SYSTEM . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–89 GENERAL PROCEDURE — FLUSHING WATER FROM THE HYDRAULIC SYSTEM. .. .. .. .. .. .. .. .. F06–01–91 GENERAL PROCEDURE — RELEASING THE HYDRAULIC SYSTEM PRESSURE .. .. .. .. .. .. .. .. .. F06–01–95 GENERAL PROCEDURE — HYDRAULIC CYLINDER RING LUG EXTRACTION . .. .. .. .. .. .. .. .. .. .. F06–01–97 SPECIFICATIONS — MAIN HYDRAULIC SYSTEM. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F06–01–99

MAIN HYDRAULICS HYDRAULIC SYSTEM DIAGRAM

BHF0601OA

F06–01–1

MAIN HYDRAULICS 1

Multi-Purpose Bucket

2

Loader Beam

3

Loader Bucket

4

Ride Control Valve

5

Orbitrol Steering Motor

6

Steering Hydraulic Cylinder

7

Tandem Gear Hydraulic Pumps

8

Steering Priority/Unloader Valve (SP/UV)

9

Oil Reservoir

10

Oil Cooler

11

Return Oil Filter

12

Back-Pressure Check Valve

13

Load Sense Drain

14

Backhoe Slew

15

Backhoe Boom

16

Backhoe Dipper

17

Backhoe Bucket

18

Backhoe Stabilizers

19

Backhoe Extendable Dipper

20

Mast Casting Clamps (Sideshift Only)

21

Backhoe Control Valve Bank

22

Backhoe Bucket Quick Attach Unit Control Valve

23

Backhoe Bucket Quick Attach Unit Hydraulic Cylinder

24

Change Over Valve

25

Auxiliary Services

26

Mast Casting Clamp Hydraulic Cylinders (Sideshift Only)

F06–01–2

MAIN HYDRAULICS Hydraulic System Diagram-Servo Controls

1

2

3

4

M

T1

B

B

B

B

A

A

A

A

1

2

3

4

5

A2 B2 C2 D2 A1 B1 C1 D1

Orange

1

Green

Blue

2

3

White

Yellow

Purple

4

1

2

Red

3

10 T

P

8 9

P

TV051518

1

Backhoe Slew

2

Backhoe Boom

3

Backhoe Dipper

4

Backhoe Bucket

5

Change Over Valve

6

Right Hand Joystick Control

7

Accumulator

8

Servo Control Valve

9

Oil Reservoir

10

Left Hand Joystick Control

P

T

F06–01–3

A M1 M2

7

Brown

4

6

MAIN HYDRAULICS

Note: This page intentionally left blank.

F06–01–4

MAIN HYDRAULICS DIAGNOSING AND TESTING — HYDRAULICS/PRESSURE TESTING

Classification

BHF0601TB

Check Item

Pump 1 Operation Time (± 15%)

Pump 1 and 2 Operation Time (± 15%)

Raise

9.5 Secs (± 1.4 Secs)

5.3 Secs (± 0.8 Secs)

Lower

3.2 Secs (± 0.5 Secs)

3.0 Secs (± 0.5 Secs)

Crowd

4.5 Secs (± 0.7 Secs)

2.7 Secs (± 0.4 Secs)

Dump

3.2 Secs (± 0.5 Secs)

2.0 Secs (± 0.3 Secs)

Open

1.8 Secs (± 0.3 Secs)

1.3 Secs (± 0.2 Secs)

Close

1.9 Secs (± 0.3 Secs)

1.3 Secs (± 0.2Secs)

Raise

5.8 Secs (± 0.9 Secs)

4.0 Secs (± 0.6 Secs)

Lower

4.0 Secs (± 0.6 Secs)

3.6 Secs (± 0.5 Secs)

Conditions

Positioning

Front Loader Beam

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Front Loader Bucket

• • Operational Speed

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Multi-Purpose Loader Bucket

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Backhoe Boom

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

F06–01–5

MAIN HYDRAULICS

Classification

Check Item

Pump 1 Operation Time (± 15%)

Pump 1 and 2 Operation Time (± 15%)

Raise

5.8 Secs (± 0.9 Secs)

3.6 Secs (± 0.5 Secs)

Lower

8.1 Secs (± 1.2 Secs)

4.8 Secs (± 0.7 Secs)

Crowd

4.7 Secs (± 0.7 Secs)

2.8 Secs (± 0.4 Secs)

Dump

3.1 Secs (± 0.5 Secs)

2.0 Secs (± 0.3 Secs)

Left

6.3 Secs (± 0.9 Secs)

5.8 Secs (± 0.9 Secs)

Right

6.3 Secs (± 0.9 Secs)

5.8 Secs (± 0.9 Secs)

Extend

4.9 Secs (± 0.7 Secs)

2.9 Secs (± 0.4 Secs)

Retract

3.7 Secs (± 0.6 Secs)

3.2 Secs (± 0.5 Secs)

Conditions

Positioning

Backhoe Dipper Arm

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Backhoe Bucket

• • Operational Speed

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Backhoe Boom Swing

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

Positioning

Extendable Dipper Arm

• •

Engine Speed 1800 rpm Oil Temp 50–60 °C (122–140 °F)

F06–01–6

MAIN HYDRAULICS Fault Finding General Problem

Possible Cause

• •

Low hydraulic oil level.

• Speed low at all hydraulic cylinders • •

Faulty hydraulic pump.

All circuits fail to operate.

Restricted hydraulic pump suction line. Fast mode is not selected. Unloader pressure relief valve set too low.

Action

• •

CHECK hydraulic oil level.

• • •

PRESSURE and FLOW TEST.

CHECK for restriction.

SELECT fast mode. ADJUST.

•

LS pressure relief valve set too low.

•

ADJUST.

• • Force low on one hydraulic cylinder •

Faulty LS pressure relief valve.

• • •

REPLACE.

Slow operation on one hydraulic cylinder

Erratic hydraulic cylinder operation

Lack of load hold

Increased force required to operate the controls

Faulty hydraulic pump. Secondary pressure relief valve set too low.

PRESSURE and FLOW TEST. ADJUST.

•

Faulty secondary pressure relief valve.

•

REPLACE.

•

Secondary pressure relief valve set too low.

•

ADJUST.

•

Control valve spool stroke incorrect.

•

ADJUST.

•

Individual pressure compensator piston blocked.

•

REPLACE.

•

Secondary pressure relief valve set too low.

•

ADJUST.

•

Hydraulic cylinder worn/damaged.

•

REPLACE.

• •

Hydraulic pump cavitation.

• •

CHECK for cavitation

•

Excessive clearance between the spool and the control valve housing.

•

REPLACE.

•

Hydraulic cylinder oil seal(s) worn/damaged.

•

REPLACE.

•

Tie-rod bolts too tight.

•

CHECK torque of tie-rod bolts. (Loosen and torque to 42Nm).

•

Control valve spool sticking.

•

CHECK torque of tie-rod bolts. (Loosen and torque to 42Nm). REPLACE control valve.

• •

Control linkage worn/damaged.

• •

REPLACE.

Load hold check valve worn/damaged.

Control valve spool oil seals damaged.

F06–01–7

REPLACE.

REPLACE spool oil seals.

MAIN HYDRAULICS Problem Sideshift clamps not operating

Hydraulic system overheating

Hydraulic pump cavitation

Action

Possible Cause

•

No voltage present at the solenoid coil.

•

CHECK for 12 Volts at the solenoid connector.

•

Solenoid coil faulty.

•

CHECK solenoid coil resistance (7.6 Ohms at 20 °C). REPLACE solenoid coil.

• • • •

Solenoid valve faulty.

• • • • •

REPLACE.

•

Hydraulic oil contaminated.

•

DRAIN and REFILL Hydraulic oil.

•

LS Pressure relief valve set incorrectly.

•

ADJUST.

•

LS Pressure relief valve worn/damaged.

•

REPLACE.

•

Control valve spool/housing worn/damaged.

•

REPLACE.

•

Secondary pressure relief valve set incorrectly.

•

ADJUST.

•

Secondary pressure relief valve worn/damaged.

•

REPLACE.

•

Control valve spool not centering.

•

CHECK spool stroke.

•

Hydraulic cylinder oil seals too tight causing partial flow through pressure relief valve.

•

REPLACE oil seals.

•

Hydraulic cylinder worn/damaged.

•

Replace.

• •

Hydraulic pump cavitation.

• •

CHECK for cavitation.

•

Air entering through hydraulic pump shaft oil seal.

•

CHECK for hydraulic pump inlet restriction. REPLACE hydraulic pump shaft oil seal.

•

Air entering at hydraulic pump inlet.

•

CHECK retaining bolt torques and oil seals.

• •

Suction screen blocked.

• •

CLEAN/REPLACE.

Shuttle valve faulty. Oil cooler blocked. Hydraulic oil supply low.

Vacuum in hydraulic oil reservoir.

Incorrect specification of oil.

Pressure Testing A pressure test kit is available, part number 6108395M91. This test kit contains adaptors specifically designed for access to test ports.

•

F06–01–8

REPLACE. CLEAN. CHECK hydraulic oil level. CHECK for supply line restriction.

CHECK/REPLACE filler cap.

REPLACE with correct specification of hydraulic oil.

Warning: Do not work on or around hydraulic systems without wearing safety glasses. Failure to follow this instruction, may result in personal injury.

MAIN HYDRAULICS

•

Caution: If serious hydraulic pump failure is suspected, do not run the hydraulic pump for longer than is absolutely necessary to determine its condition. If metal fragments are found in the hydraulic lines, oil reservoir, hydraulic pump outlet port, suction screen and/or return oil filter. DO NOT restart the hydraulic pump. Replace the hydraulic pump and clean the hydraulic system. For additional information, refer to CLEAN THE HYDRAULIC SYSTEM, PAGE F06–01–89 in this section. Failure to follow this instruction, may result in further damage to the hydraulic system.

Note: Hydraulic gauges will have a + or – 5% tolerance. Testing at 200 bar it is possible to have a 10 bar discrepancy in the readings. Allow for this if using two separate gauges. Use the same gauge for all tests if possible.

•

Inlet Compensating Valve Note: • Hydraulic gauge to be fitted to the Backhoe Hydraulic Control Valve. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the pressure test port plug and install a 9/16 UNF stor adapter and attach a 0-40 bar (0-580 PSI) pressure gauge to the Backhoe Hydraulic Control Valve.

TV041076

4. Connect the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 .

•

Warning: Do not operate any hydraulic service during this test.

5. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 6. Allow the system to warm up to approximately 50–60 °C (122–140 °F).

F06–01–9

MAIN HYDRAULICS 7. Set the engine speed to 1800 RPM.

F06–01–10

MAIN HYDRAULICS 8. Select slow mode. Make sure the indicator light (1) on the hydraulic pumps flow control switch is illuminated. By selecting slow mode, the hydraulic system is not influenced by the outer hydraulic pump or the unloader valve. If the indicator light is not illuminated, depress the switch (2).

1

TV041078

9. The Inlet Compensator Valve pressure should be 20–21 bar (290–305 PSI). 10. Stop the engine and release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 11. If the pressure reading is not to specification, add or remove shims from the Inlet Compensator as required.

Main Pressure Relief Valve Pressure Test 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the pressure test port plug and install a 9/16 UNF stor adapter. 4. Attach a 0–400 bar (0–5800 PSI) pressure gauge. 5. Connect the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 7. Allow the system to warm up to approximately 50–60 °C (122–140 °F).

F06–01–11

2

MAIN HYDRAULICS 8. Set the engine speed to 1800 RPM.

TV041076

9. Select slow mode. Make sure the indicator light (1) on the hydraulic pumps flow control switch is illuminated. By selecting slow mode, the hydraulic system is not influenced by the outer hydraulic pump or the unloader valve. If the indicator light is not illuminated, depress the switch (2).

1

TV041078

10. Fully raise the backhoe boom and record the pressure indicated. 11. The pressure reading should be 225 bar (3260 PSI). 12. If the pressure reading is not to specification, remove the protective cap and adjust the pressure relief valve. • To increase the pressure, turn the adjusting screw (2) clockwise. • To decrease the pressure, turn the adjusting screw (2) anti-clockwise.

TV041077

13. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section.

F06–01–12

2

MAIN HYDRAULICS 14. Remove the diagnostic equipment install/connect the removed items. 15. Start the engine and check for oil leaks.

and

Load Sense Pressure Test 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the load sense hydraulic hose from the Loader Control Valve.

4. Plug and seal the Loader Control Valve fitting using a 9/16 JIC cap. 5. In the open end of the hydraulic hose, install a 0–400 bar hydraulic pressure gauge. 6. Connect the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 7. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 8. Allow the system to warm up to approximately 50–60 °C (122–140 °F). 9. Set the engine speed to 1800 RPM. 10. Operate each service of the backhoe control valve, one at a time, note the readings on the hydraulic gauge, should be 205–212 bar (2973–3074) (Backhoe Pressure Relief). 11. If the pressure readings are not to specification, there is a fault in the backhoe control valve section of the Load Sense line. 12. Stop the engine and release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 13. Remove the plug and seal from the Loader Control Valve, install a hydraulic “Tee” fitting in its place. Remove the hydraulic gauge fitted to the backhoe load sense hose. Connect the load sense hydraulic hose to one end of the hydraulic “Tee” fitting, and the hydraulic gauge, to the other side of the hydraulic “Tee” fitting. 14. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 15. Allow the system to warm up to approximately 50–60 °C (122–140 °F). 16. Set the engine speed to 1800 RPM.

F06–01–13

MAIN HYDRAULICS 17. Operate each service of the Loader Valve, one at a time, the readings on the hydraulic pressure gauge should be around 205–212 bar (2973–3074) . 18. If the readings are not the same, there is a loss in the loader control valve Load Sense line. 19. Stop the engine and release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 20. Remove the diagnostic equipment and install/connect the removed items. 21. Start the engine and check for oil leaks.

Steering Pressure Relief Valve Pressure Test 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the pressure test port plug and install an M10 x 1.0 adaptor.

TV041079

4. Attach a 0–400 bar (0–5800 PSI) pressure gauge. 5. Connect the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 7. Allow the system to warm up to approximately 50–60 °C (122–140 °F). 8. Set the engine speed to 1800 RPM. 9. Turn the steering wheel to full left-hand lock and record the pressure indicated. 10. Turn the steering wheel to full right-hand lock and record the pressure indicated. 11. The pressure readings should be 170–175 bar (2465–2538 PSI). 12. If the pressure reading is not to specification, adjust the pressure relief valve in the Orbitrol steering motor. 13. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 14. Remove the diagnostic equipment and install/connect the removed items. 15. Start the engine and check for oil leaks.

F06–01–14

MAIN HYDRAULICS Unloader Pressure Relief Valve Pressure Test 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the pressure test port plug (1) and install an M10 x 1.0 adaptor. 4. Attach a 0–400 bar (0–5800 PSI) pressure gauge. 5. Connect the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Start the engine. Inspect the diagnostic equipment connectors for oil leaks. 7. Allow the system to warm up to approximately 50–60 °C (122–140 °F). 8. Set the engine speed to 1800 RPM.

1

2

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9. Select fast mode. Make sure the indicator light (1) on the hydraulic pumps flow control switch is not illuminated. This indicates that full flow from both hydraulic pumps is provided. If the indicator light is illuminated, depress the switch (2).

1

TV041078

10. Slowly raise the loader beam, the pressure will slowly increase until the pressure is released back to the oil reservoir by the pressure relief valve. The maximum pressure indicated on the pressure gauge before zero pressure is indicated is the unloader relief valve pressure. 11. The pressure reading should be 207–214 bar (3000–3100 PSI).

F06–01–15

2

MAIN HYDRAULICS 12. If the pressure reading is not to specification, adjust the pressure relief valve (2). • To increase the pressure, turn the adjusting screw (2) clockwise. • To decrease the pressure, turn the adjusting screw (2) anti-clockwise.

1

2

TV041075

13. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 14. Remove the diagnostic equipment and install/connect the removed items. 15. Start the engine and check for oil leaks.

F06–01–16

MAIN HYDRAULICS Cylinder Leak Down Test Procedure 1. Park the machine on firm, level ground. 2. Place the machine in the posture shown, and switch off the engine.

2

3 4

1

5

6

7 TV074063

3. Measure each of the hydraulic cylinders as shown leave the machine for 5 minutes then remeasure the hydraulic cylinders. Check with the table for the maximum permissible amount of leak down. Position Number

Hydraulic Service

Permissible Leak Down (mm) Low Specification

High Specification

1

Backhoe Bucket

17

2

Extendable Dipper Arm (if fitted)

33

3

Backhoe Dipper Arm

4

Backhoe Boom

5

Loader Beam

10

9

6

Loader Bucket

13

11

7 — Side Shift

Stabiliser Legs

17

7 — Centre Mount

Stabiliser Legs

29

Note: • The maximum amount of leak down in a 5 minute period with the hydraulic oil at an operating temperature of 50 — 60 °C (122–140 °F).

F06–01–17

11

10 14

MAIN HYDRAULICS Backhoe Bucket

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Extendable Dipper Arm

TV074070

Backhoe Dipper Arm

TV074068

Stabiliser Legs (side shift)

TV074067

Loader Beam

TV074065

Loader Bucket

TV074064

Backhoe Boom

TV074072

Stabiliser Legs (centre mount)

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F06–01–18

MAIN HYDRAULICS DIAGNOSING AND TESTING — HYDRAULIC OIL CONTAMINATION

BHN0601TA

Hydraulic Oil Contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When the oil is drained or any line disconnected. • When a component is disassembled. • From normal wear of the hydraulic components. • From damaged or worn seals. • From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems. • Cylinder rod seals leak. • Control valve spools do not return to neutral. • Movement of control valve spools is difficult. • Hydraulic oil becomes too hot. • Pump gears, housing, and other parts wear rapidly. • Relief valves or check valves held open by dirt. • Quick failure of components that have been repaired. • Cycle times are slow; machine does not have enough power. If any of the above problems are encountered, check the hydraulic oil for contamination. See Types of Contamination. If contamination is found, use the Portable Filter to clean the hydraulic system. For

additional information, refer to CLEANING THE HYDRAULIC SYSTEM, PAGE F06–01–89 in this section.

Types of Contamination There are two types of contamination: • Microscopic • Visible Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. Microscopic particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems are: • Cylinder rod seal leak. • Control valve spools do not return to NEUTRAL. • The hydraulic system has a high operating temperature. Visible contamination is foreign material that can be found by sight, touch, or odour. Visible contamination can cause a sudden failure of components. Examples of visible contamination: • Particles of metal or dirt in the oil. • Air in the oil. • The oil is dark and thick. • The oil has the odour of burnt oil. • Water in the oil. Note: If water is present in the oil, flush the water from the hydraulic system. For additional information, refer to FLUSHING WATER FROM THE HYDRAULIC SYSTEM, PAGE F06–01–91 in this section.

•

F06–01–19

MAIN HYDRAULICS

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F06–01–20

MAIN HYDRAULICS REMOVAL AND INSTALLATION — HYDRAULIC OIL RESERVOIR

BHF0601RA

Operation: Removing and Installing the Hydraulic Oil Reservoir Suitable trolley jack

Job Code: 06 09 13 xx Standard tools, Suitable container (90 Ltrs),

Removal All Vehicles Note: Make a note of the position of any hydraulic hoses prior to disconnection to aid installation.

•

Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Vehicles with Single Battery 2. Remove the battery. For additional information, refer to Section J09-01 BATTERY (SINGLE), PAGE J09–01–11 . Vehicles with Twin Batteries 3. Remove the batteries. For additional information, refer to Section J09-01 BATTERY (TWIN), PAGE J09–01–13 . All Vehicles 4. Drain the hydraulic oil into a suitable container. 5. Disconnect the hydraulic oil reservoir hoses and pipes.

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F06–01–21

MAIN HYDRAULICS 6. Detach the front loader hydraulic hoses from the top of the hydraulic oil reservoir.

TV040183

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

7. Using a suitable trolley jack, support the hydraulic oil reservoir. 8. Remove the hydraulic oil reservoir.

TV040184

9. Withdraw the battery wiring harness through the hydraulic oil reservoir.

Installation 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

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3. Check and adjust the hydraulic oil level as required.

F06–01–22

MAIN HYDRAULICS REMOVAL AND INSTALLATION — OIL COOLER

BHF0601RB

Operation: Removing and Installing the Oil Cooler None

Job Code: 06 07 13 xx Standard tools

Removal All Vehicles Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: Always install blanking plugs to any open ports to avoid contamination.

•

1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Disconnect the horn electrical connectors.

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3. Remove the radiator support bracket. (1)

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F06–01–23

MAIN HYDRAULICS Vehicles with Air Conditioning 4. Remove the A/C condenser upper retaining bolts (2).

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5. Remove the A/C condenser lower retaining bolts.

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6. Detach the A/C condenser and position it to one side. All Vehicles 7. Disconnect the oil cooler pipes from the oil cooler and remove the oil cooler.

TV040079

Installation 1. To install, reverse the removal procedure. 2. Check and adjust the hydraulic and transmission oil levels as required.

F06–01–24

MAIN HYDRAULICS REMOVAL AND INSTALLATION — HYDRAULIC PUMP

BHF0601RC

Operation: Removing and Installing the Hydraulic Pump Suitable container

Job Code: 06 11 13 xx Standard tools

Vehicles with Powershift transmission Vehicles with Synchroshuttle transmission

Removal All Vehicles Note: Make a note of the position of any hydraulic hoses prior to disconnection to aid installation.

•

Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Drain the hydraulic oil into a suitable container. Vehicles with Powershift Transmission 4. Remove the cabin heater ducting. For additional information, refer to section H08-01 CABIN HEATER DUCTING, PAGE H08–01–13 . All Vehicles 5. Disconnect the hydraulic pump hoses from the steering priority/unloader valve.

TV040157

F06–01–25

MAIN HYDRAULICS 6. Disconnect the suction hose from the tandem gear pump. Note: • Remove and discard the O-ring seal.

TV040158

•

Warning: This component is very heavy. Make sure it is supported adequately. Failure to follow this instruction may result in personal injury.

7. Remove the hydraulic pump.

Installation Note: • Install a new O-ring seal. 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

F06–01–26

MAIN HYDRAULICS 3. Tighten to 98Nm (72 lb.ft).

TV040158

4. Fully extend and retract all hydraulic services and check for correct operation.

F06–01–27

MAIN HYDRAULICS

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F06–01–28

MAIN HYDRAULICS REMOVAL AND INSTALLATION — HYDRAULIC PUMP 2007

BHF0601RK

Operation: Removing and Installing the Hydraulic Pump Suitable container

Job Code: xx xx xx xx Standard tools

Vehicles with Powershift transmission Vehicles with Synchroshuttle transmission

Removal All Vehicles Note: Make a note of the position of any hydraulic hoses prior to disconnection to aid installation.

•

Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE , PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Note: • Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner. 3. Drain the hydraulic oil into a suitable container. Vehicles with Powershift Transmission 4. Remove the cabin heater ducting. For additional information, refer to section H08-01 CABIN HEATER DUCTING, PAGE H08–01–13 . All Vehicles 5. Disconnect the hydraulic pump hoses from the pump.

F06–01–29

MAIN HYDRAULICS 6. Disconnect the suction hose from the tandem gear pump. Note: • Remove and discard the O-ring seal.

TV040158

•

Warning: This component is very heavy. Make sure it is supported adequately. Failure to follow this instruction may result in personal injury.

7. Remove the hydraulic pump.

Installation Note: • Install a new O-ring seal. 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

F06–01–30

MAIN HYDRAULICS 3. Tighten to 98Nm (72 lb.ft).

TV040158

4. Fully extend and retract all hydraulic services and check for correct operation.

F06–01–31

MAIN HYDRAULICS

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F06–01–32

MAIN HYDRAULICS REMOVAL AND INSTALLATION — BACKHOE CONTROL VALVE BANK

BHF0601RD

Operation: Removing and Installing the Backhoe Control Valve Bank Suitable lifting equipment

Job Code: 06 01 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. If the backhoe is equipped with an extendable dipper, install the extendable dipper locking pin. 3. Lower the stabilizers until the stabilizer pads just touch the floor. 4. Extend the backhoe straight behind the machine with the backhoe bucket resting on the floor and stop the engine. 5. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 in this section. 6. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 7. Remove the extendable dipper/auxiliary service changeover valve. For additional information, refer to EXTENDABLE DIPPER/AUXILIARY SERVICE CHANGEOVER VALVE, PAGE F06–01–43 in this section. 8. Remove the retaining bolts and detach the hydraulic hose bracket.

TV040141

9. Disconnect the load sensing line (1) from the valve bank. 10. Disconnect the load sensing drain line (2) from the valve bank. 11. Disconnect the supply line (3) from the valve bank.

F06–01–33

MAIN HYDRAULICS 12. Disconnect the return line (4) from the valve bank.

3

1 2

4

TV040142

13. Disconnect the slew supply and return hoses (1) from the valve bank. 14. Disconnect the boom supply and return hoses (2) from the valve bank.

2

1

TV040167

15. Disconnect the dipper arm supply and return hoses (1) from the valve bank. 16. Disconnect the bucket supply and return hoses (2) from the valve bank.

2

1

TV040144

17. Remove the retaining bolts and detach the hydraulic hose bracket.

TV040145

F06–01–34

MAIN HYDRAULICS 18. Disconnect the right-hand stabilizer leg supply and return hoses (1) from the valve bank. 19. Disconnect the left-hand stabilizer leg supply and return hoses (2) from the valve bank.

2

1

TV040146

20. Disconnect the auxiliary service supply and return lines (1). 21. Disconnect the side shift clamp hose (2).

1

2

TV040147

22. Disconnect the side shift clamp solenoid electrical connector.

TV040148

F06–01–35

MAIN HYDRAULICS Note: • Make a note of the position of the control linkage prior to disconnection to aid installation. 23. Disconnect the backhoe control linkage.

TV040149

24. Disconnect the auxiliary service/extendable dipper control linkage (1). Note: • Make a note of the position of the control linkage prior to disconnection to aid installation. 25. Disconnect the left-hand and right-hand stabilizer leg control linkages (2).

1 TV040150

26. Position the hydraulic hoses to one side.

F06–01–36

2

MAIN HYDRAULICS

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

27. Using suitable lifting equipment, support the backhoe control valve bank. Remove the retaining bolts and remove the backhoe control valve bank from the chassis.

TV040151

Installation Note: • Install new lock nuts. 1. To install, reverse the removal procedure. 2. Tighten to 58Nm (43 lb.ft).

TV040151

3. Check and adjust the hydraulic oil level as required. 4. Fully extend and retract all hydraulic services and check for correct operation.

F06–01–37

MAIN HYDRAULICS

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F06–01–38

MAIN HYDRAULICS REMOVAL AND INSTALLATION — LOADER CONTROL VALVE

BHF0601RE

Operation: Removing and Installing the Loader Control Valve None

Job Code: 06 13 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. Extend the backhoe straight behind the machine with the backhoe bucket resting on the floor. 3. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 in this section. 4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Note: • Make a note of the position of the control linkages prior to disconnection to aid installation. Note: Cab shown removed for clarity

•

5. Disconnect the loader control valve linkage (1). 6. Remove the loader control valve upper retaining bolt (2).

1

2 TV040152

F06–01–39

MAIN HYDRAULICS 7. Disconnect the loader control valve supply and return lines from the loader control valve.

TV040153

8. Disconnect the load sensing line from the loader control valve (1). 9. Disconnect the ride control hose from the loader control valve (2).

TV040154

10. Disconnect the loader auxiliary service supply and return pipes (1). 11. Disconnect the loader supply and return pipes (2). 12. Disconnect the bucket supply and return pipes (3).

TV040155

13. Disconnect the loader auxiliary service electrical connector (1).

F06–01–40

MAIN HYDRAULICS

•

Warning: This component is very heavy. Make sure it is supported adequately. Failure to follow this instruction may result in personal injury.

14. Support the loader control valve. Remove the retaining bolts and remove the loader control valve (2).

TV040156

Installation 1. To install, reverse the removal procedure. 2. Tighten (2) to 58Nm (43 lb.ft).

TV040156

3. Tighten (2) to 58Nm (43 lb.ft).

1

2 TV040152

4. Check and adjust the hydraulic oil level as required. 5. Fully extend and retract all hydraulic services and check for correct operation.

F06–01–41

MAIN HYDRAULICS

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F06–01–42

MAIN HYDRAULICS REMOVAL AND INSTALLATION — CHANGEOVER VALVE

BHF0601RF

Operation: Removing and Installing the Changeover Valve None

Job Code: 06 03 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Disconnect the changeover valve supply and return pipes from the changeover valve (1). 4. Disconnect the auxiliary service supply and return pipes from the changeover valve (2). 5. Disconnect the extendable dipper supply and return hoses from the changeover valve (3). 6. Disconnect the electrical connector from the changeover valve (4).

2

1

4 3 TV040130

7. Remove the changeover valve.

TV040131

F06–01–43

MAIN HYDRAULICS Installation 1. To install, reverse the removal procedure. 2. Tighten to 12Nm (9 lb.ft).

TV040131

3. Check and adjust the hydraulic oil level as required.

F06–01–44

MAIN HYDRAULICS REMOVAL AND INSTALLATION — STEERING PRIORITY/UNLOADER VALVE

BHF0601RG

Operation: Removing and Installing the Steering Priority/Unloader Valve None

Job Code: 06 20 13 xx Standard Tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-09 BATTERY ISOLATION, PAGE J09–01–33 . 3. Disconnect the hydraulic pump hoses from the steering priority/unloader valve (SP/UV).

TV040157

4. Disconnect the SP/UV solenoid electrical connector (1). 5. Disconnect the load sensing hose (2) from the SP/UV. 6. Disconnect the steering orbitrol valve hose (3) from the SP/UV. 7. Disconnect the backhoe/loader supply pipe (4) from the SP/UV.

F06–01–45

MAIN HYDRAULICS 8. Disconnect the steering priority return line (5) from the SP/UV.

TV040164

9. Remove the steering priority/unloader valve.

TV040165

Installation 1. To install, reverse the removal procedure. 2. Tighten to 30Nm (22 lb.ft).

TV040165

3. Check and adjust the hydraulic oil level as required.

F06–01–46

MAIN HYDRAULICS REMOVAL AND INSTALLATION — RIDE CONTROL VALVE

BHF0601RH

Operation: Removing and Installing the Ride Control Valve None

Job Code: 06 17 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure from the hydraulic system. For additional information, refer to RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 in this section. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Disconnect the ride control accumulator pipe (1). 4. Disconnect the loader valve hose from the ride control valve (2). 5. Disconnect the front loader pipes from the ride control valve (3).

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6. Disconnect the solenoid electrical connectors (1). 7. Remove the ride control retaining bolt, and remove the ride control valve (2).

TV040163

Installation 1. To install, reverse the removal procedure.

F06–01–47

MAIN HYDRAULICS 2. Tighten (2) to 56Nm (41 lb.ft).

TV040163

3. Check and adjust the hydraulic oil level as required.

F06–01–48

MAIN HYDRAULICS REMOVAL AND INSTALLATION — SERVO CONTROL VALVE

BHN1301DB

Operation: Removal and installation — Servo Control Valve None

Job Code: 06 21 13 xx Standard tools,

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure in the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE., PAGE F06–01–95 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Disconnect the joystick return hoses (1). 4. Disconnect the servo control valve return hose (2).

2

1

TV051483

5. Disconnect the servo control valve supply hose (1). 6. Disconnect the servo control joystick supply hoses (2).

2

2 1

TV051484

F06–01–49

MAIN HYDRAULICS 7. Disconnect the servo control solenoid electrical connector.

TV051485

8. Remove the retaining bolts and remove the servo control valve.

TV051485

Installation

•

Warning: Incorrect connection of the hoses will result in the incorrect function of the backhoe controls. Failure to follow this instruction may result in personal injury.

1. To install, reverse the removal procedure. 2. Tighten to 23Nm (17 lb.ft).

TV051485

F06–01–50

MAIN HYDRAULICS REMOVAL AND INSTALLATION — SERVO CONTROL CONFIGURATION CHANGEOVER VALVE. Operation: Removal and Installation— Servo Control Configuration Changeover Valve None

Job Code: 06 22 13 xx Standard tools,

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Release the pressure in the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE., PAGE F06–01–95 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION., PAGE J09–01–33 3. Remove the cover plate.

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4. Remove the retaining bolt and remove the selector lever.

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F06–01–51

BHN1301DB

MAIN HYDRAULICS Note: • Reposition the floor mat to gain access. 5. Remove the pedestal cover left hand lower retaining bolt.

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Note: • Reposition the floor mat to gain access. 6. Remove the pedestal cover right hand lower retaining bolt.

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7. Remove the pedestal cover upper retaining bolts and remove the front section of the pedestal cover.

TV051475

F06–01–52

MAIN HYDRAULICS 8. Cut the cable tie securing the servo control relay to the velcro pad. Position the relay to one side.

TV051476

9. Disconnect the upper hydraulic hoses from the changeover valve in the order indicated.

3 1

4 2

TV051477

10. Disconnect the lower hydraulic hoses from the changeover valve in the order indicated.

4 1

TV051478

11. Remove the retaining bolts and remove the changeover valve.

TV051479

F06–01–53

3

2

MAIN HYDRAULICS Installation

•

Warning: Incorrect connection of the hoses will result in the incorrect function of the backhoe controls. Failure to follow this instruction may result in personal injury.

1. To install, reverse the removal procedure. 2. Tighten to 23Nm (17 lb.ft).

TV051479

3. Tighten to 18Nm (13 lb.ft).

TV051505

F06–01–54

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP

BHF0601DA

Operation: Disassembling and Assembling the Hydraulic Pump

Job Code: 06 11 17 xx

None

Standard tools

21 20

2

3

5

4

8

7

6

9 14

1 13

19 10 16 11

12

15

TV040895

F06–01–55

17

18

21

20

MAIN HYDRAULICS 1

Mounting Flange

2

Sealing Bushing

3

Tandem Gears

4

Wear Bushing

5

Drive Shaft

6

Tandem Gear Locking Pin

7

Sealing Bushing

8

Housing

9

Driven Shaft

10

Housing

11

Connecting Shaft

12

Sealing Bushing

13

Drive Shaft

14

Tandem Gear Locking Pin

15

Driven Shaft

16

Wear Bushing

17

Tandem Gears

18

Sealing Bushing

19

End Housing

20

Back Up Seal

21

Sealing Ring

F06–01–56

MAIN HYDRAULICS Disassembly 1. Place the hydraulic pump on a suitable work surface. 2. Mark the hydraulic pump casing to aid installation.

TV040894

3. Remove the hydraulic pump clamping bolts.

TV040893

Assembly Note: • Lubricate the piston O-ring seals with a suitable light grease. Note: • Install new O-ring seals. 1. To assemble, reverse the disassembly procedure. 2. Tighten to between 90 and 100Nm (66 and 74 lb.ft).

TV040893

F06–01–57

MAIN HYDRAULICS

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F06–01–58

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP — 2007

BHF0601DH

Operation: Disassembling and Assembling the Hydraulic Pump

Job Code: 06 11 17 xx

None

Standard tools

21 20

2

3

5

4

8

7

6

9 14

1 13

19 10 16 11

12

15

TV040895

F06–01–59

17

18

21

20

MAIN HYDRAULICS 1

Mounting Flange

2

Sealing Bushing

3

Tandem Gears

4

Wear Bushing

5

Drive Shaft

6

Tandem Gear Locking Pin

7

Sealing Bushing

8

Housing

9

Driven Shaft

10

Housing

11

Connecting Shaft

12

Sealing Bushing

13

Drive Shaft

14

Tandem Gear Locking Pin

15

Driven Shaft

16

Wear Bushing

17

Tandem Gears

18

Sealing Bushing

19

End Housing

20

Back Up Seal

21

Sealing Ring

F06–01–60

MAIN HYDRAULICS Disassembly 1. Place the hydraulic pump on a suitable work surface. 2. Mark the hydraulic pump casing to aid installation.

TV040894

3. Remove the hydraulic pump clamping bolts.

TV040893

Assembly Note: • Lubricate the piston O-ring seals with a suitable light grease. Note: • Install new O-ring seals. 1. To assemble, reverse the disassembly procedure. 2. Tighten to between 90 and 100Nm (66 and 74 lb.ft).

TV040893

F06–01–61

MAIN HYDRAULICS

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F06–01–62

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — BACKHOE CONTROL VALVE

BHF0601DB

Operation: Disassembling and Assembling the Backhoe Control Valve None

Job Code: 06 01 17 xx Standard tools

1

Outlet Element

2

Auxiliary Service/Extendable Dipper Element

3

Right Stabiliser Element

4

Left Stabiliser Element

5

Bucket Element

6

Dipper Element

7

Boom Element

8

Slew Element

9

Inlet Element

Disassembly 1. Place the backhoe control valve on a suitable work surface. 2. Remove the backhoe control valve clamping nuts.

TV040609

F06–01–63

MAIN HYDRAULICS Outlet Element

1

9/16” UNF plug

2

Shuttle Throttle

3

11/16” UNF Plug

4

Valve Body

5

2 Way Valve

6

Solenoid

F06–01–64

MAIN HYDRAULICS Auxiliary Service/Extendable Dipper element

1

Plug

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–65

MAIN HYDRAULICS Right Stabiliser Element

1

Compensator Valve

2

Check Valves

3

Valve

4

Mechanical Actuator

5

Mechanical Return

6

Valve Body

F06–01–66

MAIN HYDRAULICS Left Stabiliser Element

1

Compensator Valve

2

Check Valves

3

Valve

4

Mechanical Actuator

5

Mechanical Return

6

Valve Body

F06–01–67

MAIN HYDRAULICS Bucket Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–68

MAIN HYDRAULICS Dipper Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–69

MAIN HYDRAULICS Boom Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–70

MAIN HYDRAULICS Slew Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–71

MAIN HYDRAULICS Inlet Element

1

11/16” UNF Plug

2

Inlet Compensator

3

Valve Body

4

Load sensing Pressure Relief Valve

5

Flow Regulator

6

Filter

7

5/16” UNF Plug

Assembly Note: • Install new O-ring Seals 1. To assemble, reverse the disassembly procedure.

F06–01–72

MAIN HYDRAULICS 2. Tighten to 42Nm (31 lb.ft).

TV040609

F06–01–73

MAIN HYDRAULICS

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F06–01–74

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — LOADER CONTROL VALVE

BHF0601DC

Operation: Disassembling and Assembling the Loader Control Valve None

Job Code: 06 13 17 xx Standard tools

1

Cover

2

Auxiliary Service Element

3

Loader Beam Cylinder Element

4

Bucket Hydraulic Cylinder Element

5

Inlet Element

Disassembly 1. Place the loader control valve on a suitable work surface. 2. Remove the loader control valve clamping nuts.

TV040610

F06–01–75

MAIN HYDRAULICS Auxiliary Service Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Plug

5

Valve

6

Mechanical Actuator

7

Mechanical Return

8

Valve Body

F06–01–76

MAIN HYDRAULICS Loader Beam Cylinder Element

1

Anti Cavitation Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Mechanical Detent

8

Valve Body

F06–01–77

MAIN HYDRAULICS Bucket Ram Cylinder Element

1

Pressure Relief Valve

2

Compensator Valve

3

Check Valves

4

Pressure Relief Valve

5

Valve

6

Mechanical Actuator

7

Electrical Detent

8

Valve Body

F06–01–78

MAIN HYDRAULICS Inlet Element

1

5/16” UNF Plug

2

Closed Centre Valve

3

Valve Body

4

11/16” UNF Plug

Assembly Note: • Install new O-ring seals. 1. To assemble, reverse the disassembly procedure. 2. Tighten to 42Nm +/-4Nm (31 lb.ft +/-3 lb.ft).

TV040610

F06–01–79

MAIN HYDRAULICS

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F06–01–80

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — CHANGEOVER VALVE

BHF0601DD

Operation: Disassembling and Assembling the Changeover Valve None

Job Code: 06 03 17 xx Standard tools

3 18 8 1 2 4 5

6 7 10

15 11

17 9 13 12 14 TV040899

F06–01–81

16

MAIN HYDRAULICS 1

Solenoid Retaining Cap

2

Solenoid Coil

3

O-ring

4

Retaining Bolts

5

Valve End Cap

6

Solenoid valve

7

O-ring

8

Valve Retainer

9

Changeover Valve

10

Spacer

11

Spring

12

Valve Retainer

13

O-ring

14

O-ring

15

End Cap

16

Retaining Bolt

17

Valve Body

18

O-ring

F06–01–82

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — RIDE CONTROL VALVE

BHF0601DF

Operation: Disassembling and Assembling the Ride Control Valve

Job Code: 06 17 17 xx

None

Standard Tools

1

2

3

10

9

8

4

TV040897

1

Solenoid Retaining Cap

2

Solenoid Coil

3

Solenoid Valve

4

Union

5

Valve Body

6

Unions

7

Union

8

Solenoid Valve

9

Solenoid Coil

10

Solenoid Retaining Cap

F06–01–83

6

5

7

6

MAIN HYDRAULICS

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F06–01–84

MAIN HYDRAULICS DISASSEMBLY AND ASSEMBLY — SERVO CONTROL VALVE

BHN1301DB

Operation: Disassembly and Assembly — Servo Control Valve

Job Code: 06 21 17 xx

None

Standard tools,

2

1

3

4 6 5

TV051502

1

Pressure Regulator Valve Assembly

2

Retaining Bolts

3

Activation Solenoid Valve Assembly

4

Accumulator

5

Union

6

Valve Assembly

F06–01–85

MAIN HYDRAULICS Disassembly 1. Remove the union (1) to gain access to the valve assembly (2). 2. Remove the valve assembly (2). Note: • Discard the O-ring seals. 3. Remove the accumulator (3).

3

2 1 TV051486

4. Remove the pressure regulator valve assembly. Note: • Discard the O-ring seals.

TV051511

5. Remove the retaining bolts and remove the activation solenoid valve assembly.

TV051512

Assembly Note: • Use new O-ring seals. 1. To assemble, reverse the disassembly procedure.

F06–01–86

MAIN HYDRAULICS GENERAL PROCEDURE — HYDRAULIC CYLINDER INSPECTION

BHF0601GA

Inspection 1. Clean the piston, gland, piston rod and tube in cleaning solvent. 2. Discard the parts that were removed from the piston and the gland. 3. Illuminate the inside of the tube. Inspect the inside of the tube for deep grooves and other damage. If there is damage to the tube, a new tube must be used. 4. Check to be sure that the piston rod is straight. If the piston rod is not straight, install a new piston rod. 5. Remove small scratches on the inside of the tube with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the gland for rust and clean and remove rust as required. 7. Inspect the gland end of the tube for sharp edges that will cut the gland O-ring. Remove as required. 8. Inspect the piston for damage and wear. If the piston is damaged or worn, a new piston must be used.

F06–01–87

MAIN HYDRAULICS

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F06–01–88

MAIN HYDRAULICS GENERAL PROCEDURE — CLEANING THE HYDRAULIC SYSTEM

BHF0601GB

Cleaning the Hydraulic System Note: • This procedure requires the special tools CAS-10162A-Portable Filter and the CAS-10508-Fitting kit . 1. Prepare the portable filter by carrying out the following steps: a. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. b. Remove the filter element from the portable filter. c. Remove all hydraulic oil from the portable filter. d. Clean the inside of the housing for the filter element. 2. Check if the contamination is microscopic or visible. For additional information, refer to HYDRAULIC OIL CONTAMINATION in this section. 3. If the contamination is microscopic: a. Check the maintenance schedule for the machine to see if the hydraulic oil is due to be changed. If required, change the hydraulic oil and hydraulic filter. b. Carry out Steps 6 through to 32. 4. If the contamination is visible: a. Change the hydraulic oil and hydraulic filter. b. Carry out Steps 5 through to 32. 5. Check the amount of contamination in the hydraulic system by carrying out the following steps: a. Disassemble one cylinder from two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. b. If the damage to the cylinders appears to be caused by severe contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Position a suitable clean container under the hydraulic reservoir drain plug. Note: • Make sure the valve in the fitting kit (CAS-10508) is in the closed position. Note: • Some oil will be lost during this operation, replace the drain plug with the valve as quickly as possible. 7. Remove the drain plug from the hydraulic reservoir and install a suitable valve from the fitting kit (CAS-10508) into the drain plug hole. 8. Fill with hydraulic oil as required. 9. Connect the inlet hose of the portable filter to the valve that is installed in the drain plug hole. 10. Remove the hydraulic reservoir filler cap. 11. Install the outlet hose of the portable filler through the filler cap into the hydraulic reservoir. 12. Open the valve installed in the drain plug hole.

F06–01–89

MAIN HYDRAULICS 13. Move the switch for the portable filter to the ON position. Start and run the engine at 1500 rpm. 14. Run the portable filter for 10 minutes. 15. Continue to run the portable filter and increase the engine speed to full throttle. Heat the oil to operating temperature by doing the following steps: a. Hold the bucket control lever in the ROLLBACK position for 15 seconds. b. Return the bucket control lever to NEUTRAL for 30 seconds. c. Repeat Steps 14a and 14b until the oil in the hydraulic system is at operating temperature. 16. Continue to run the engine at full throttle and continue to run the portable filter. 17. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit twice, one after the other, for 45 minutes. 18. Decrease the engine speed to low idle. 19. Continue to run the portable filter for 10 minutes. 20. Stop the portable filter. 21. Stop the engine. 22. Remove the outlet hose of the portable filter from the hydraulic reservoir. 23. Close the valve that is installed in the drain plug hole. 24. Disconnect the inlet hose of the portable filter from the valve in the drain plug hole. 25. Position a suitable clean container under the hydraulic reservoir drain plug.

•

Warning: The hydraulic oil can be extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to follow this instruction may result in personal injury.

Note: Some oil will be lost during this operation, replace the valve with the drain plug as quickly as possible.

•

26. Remove the valve from the drain plug hole and install the hydraulic reservoir drain plug. 27. Remove the hydraulic filter element from the machine. 28. Install a new hydraulic filter element on the machine. 29. Fill with hydraulic oil as required. 30. Install the hydraulic reservoir filler cap. 31. Start the engine and check for oil leakage around the new hydraulic filter. 32. Stop the engine.

F06–01–90

MAIN HYDRAULICS GENERAL PROCEDURE — FLUSHING WATER FROM THE HYDRAULIC SYSTEM Flushing Water from the Hydraulic System 1. Start and run the engine at 1500 rpm.

•

Warning: If retracting the hydraulic cylinder rods causes any part of an attachment to be in the raised position, secure the attachment in place using suitable hydraulic cylinder safety stops or lifting equipment. Failure to follow these instructions may result in personal injury.

2. Completely retract all of the hydraulic cylinders. 3. Remove the filler cap from the hydraulic oil reservoir. 4. Drain the hydraulic oil into a suitable container and discard. 5. Install the drain plug in the hydraulic oil reservoir. 6. Replace the hydraulic oil filter. 7. Fill with hydraulic oil as required. 8. Move each hydraulic cylinder attachment control lever in all directions to release the hydraulic system pressure. Note: • Note the position of the hydraulic lines to aid installation. 9. Disconnect the hydraulic lines from the rod end (1) and cylinder end (2) of one of the hydraulic cylinders.

TV040902

•

•

Caution: Make sure the hydraulic cylinder control levers are in the neutral position. Caution: Make sure the hydraulic oil level does not go below the minimum level or damage to the hydraulic system may occur.

10. Start the and run the engine at low idle speed. 11. Position a suitable container under the disconnected hydraulic cylinder lines.

F06–01–91

BHF0601GE

MAIN HYDRAULICS Note: • Hold the control lever in each position until clean hydraulic oil is visible from the line(s). 12. Slowly move the control lever for the disconnected hydraulic cylinder in each direction until clean oil begins to flow from the open line(s).

F06–01–92

MAIN HYDRAULICS 13. Switch off the engine. 14. Connect the line to the cylinder end (2) of the disconnected hydraulic cylinder. 15. Connect a suitable hose to the rod end of the hydraulic cylinder (1) and place the open end in a suitable container.

TV040902

•

•

Caution: Make sure the hydraulic cylinder control levers are in the neutral position. Caution: Make sure the hydraulic oil level does not go below the minimum level or damage to the hydraulic system may occur.

16. Start and run the engine at low idle speed.

•

•

Warning: Extending the hydraulic cylinder rod may cause a part of an attachment to move, support the attachment using suitable lifting equipment. Failure to follow this instruction may result in personal injury. Caution: Oil will be forced out of the hydraulic cylinder and into the suitable container.

17. Slowly and completely extend the disconnected hydraulic cylinder. 18. Switch off the engine. 19. Disconnect the suitable hose from the rod end of the hydraulic cylinder (1) and connect the disconnected hydraulic line. 20. Repeat steps 9 to 19 to clean the remaining hydraulic cylinders and lines. 21. Start and run the engine at 1500 rpm. 22. Fully operate all hydraulic cylinders in all directions. 23. Switch off the engine. 24. Check the hydraulic oil level and fill as required. 25. Install the hydraulic oil reservoir filler cap.

F06–01–93

MAIN HYDRAULICS

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F06–01–94

MAIN HYDRAULICS GENERAL PROCEDURE — RELEASING THE HYDRAULIC SYSTEM PRESSURE Inspection All Vehicles 1. Park the machine on firm level ground. 2. Position the loader and backhoe flat on the ground. 3. Lower the rear stabilizer legs to the ground. 4. Switch off the engine. 5. Remove the hydraulic reservoir cap. 6. Operate the stabilizer control levers in all directions several times until the pressure is fully released. 7. Operate all the backhoe and the loader control levers and pedals in all directions several times. 8. Operate the loader auxiliary service control switches until the pressure is fully released. Vehicles with Extendable Dipper 9. Turn the ignition switch to the ON position. 10. Operate the extendable dipper/auxiliary service changeover valve control switch. 11. Operate the extendable dipper/auxiliary service pedal until the pressure is fully released. 12. Switch off the ignition. All Vehicles 13. Refit the hydraulic reservoir cap.

F06–01–95

BHF0601GC

MAIN HYDRAULICS

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F06–01–96

MAIN HYDRAULICS GENERAL PROCEDURE — HYDRAULIC CYLINDER RING LUG EXTRACTION

BHF0601GD

Extraction A failed ring lug can be removed using the following process: 1. Through the insertion hole, centre punch the ring as near to the centre of the ring as possible.

TV040729

2. Refering to the diagram, use a size (B) drill, and drill through the ring and into the gland to the depth (C).

•

Caution: The drilled hole must not be drilled deeper than shown, or the drill may break through the gland, in which case the gland must be scrapped.

3. Cut off a section of ring or piano wire of diameter (A), to the length (D) and insert it into the blind hole. This will now take the place of the lug and drive the broken ring out in the normal way.

F06–01–97

MAIN HYDRAULICS 4. After complete withdrawal of the ring, pull the piston rod sharply out until it contacts the gland, this will normally remove it. Note: • In the event of failure to remove the gland in this way due to burrs around the ring grooves, it is suggested that either a hydraulic press or a hand operated pump be used to remove the gland.

•

Warning: If a hydraulic pump is used to dismantle the gland from the cylinder, extreme care must be taken to purge all air from the cylinder before pressurisation. COMPRESSED AIR INSIDE THE CYLINDER AT THIS STAGE IS EXTREMELY DANGEROUS. Robust restraints should be attached to both the piston rod-eye and the cylinder mounting, as a further precaution. Failure to follow this instruction may result in personal injury.

C =2xA

D = 1.5 x A

A B = A + 0.1mm TV040730

F06–01–98

MAIN HYDRAULICS SPECIFICATIONS — MAIN HYDRAULIC SYSTEM

BHF0601SA

Torque Values Cylinder Gland (Nm)

Lock screw (Nm)

Piston (Nm)

Stop screw (Nm)

Piston bolt (Nm)

Piston nut (Nm)

Dipper

320—550

23

—

—

1780–2180

—

Backhoe bucket

320–550

23

—

—

1780–2180

—

Loader bucket

320–55

23

2300–2500

23

—

—

Boom

320–550

23

2300–2500

23

—

—

Extendable dipper

—

—

—

—

—

790–810

Loader lift Models 820 and 760B

350–400

—

1000–1100

23

—

—

Loader lift Models 860(B) to 970

350–400

—

1170–1220

23

—

—

Slew

370–420

—

1050–1100

23

—

—

—

—

650–700

23

—

—

300–350

—

—

—

—

800–850

Cylinder

Stabiliser centremount Stabiliser side shift

General Information Hydraulics

820

860 – 970

Tandem Gear Pump Make

Commercial

Pump 1 Flow

80 l/min

80 l/min

Pump 2 Flow

62 l/min

80 l/min

Pump 1 Pressure

225bar (225min – 232max)

225bar (225min – 232max)

Pump 2 Pressure

207bar (207min – 214max)

207bar (207min – 214max)

Control Valves

Closed Center Type and Inlet Compensator

Make

Rexroth

Loader Control Valve Type

SX14 – 3 Spool

Backhoe Control Valve Type

SX14 – 7 Spool

Spool Leakage Oil Flow @ 100bar

11cc/min

Compensator Pressure (Engine @ 1800rpm)

20bar (20min – 21max) 16mm

Spool Stroke Tie Rod Nuts Tightening Torque

42Nm +/-4 Nitrogen

Ride Control System Gas

25bar

Gas Charge Pressure

Capacity System Hydraulics

Temperatures

Viscocity

Up to +30°C

ISO VG 46

Up to +50°C

ISO VG 68

Specification DIN 51524

F06–01–99

Capacity 143 (Total System)

Notes Tank Capacity = 85 Litre

MAIN HYDRAULICS Torque Values For JIC Hydraulic Hose Fittings

Hex. Size A/F

Thread Size UNF

Termination Dash Size

mm

inch

—

9/16

04

—

5/8

—

Machines Built With “Gates/Global” Hydraulic Hoses

Machines Built With “Manuli” Hydraulic Hoses

Nm

Lb.ft

Nm

Lb.ft

7/16”-20

14

10

15

11

05

1/2”-20

18

13

20

15

11/16

06

9/16”-18

22

16

35

26

—

7/8

08

3/4”-16

41

30

50

37

24

—

10

7/8”-14

60

44

80

59

—

1

10

7/8”-14

60

44

80

59

27

—

10

7/8”-14

60

44

80

59

—

1 1/4

12

1 1/16”-12

90

66

100

74

—

1 1/2

16

1 5/16”-12

130

96

150

111

Torque Values For O-Ring Face Seal (ORFS) Hydraulic Fittings Torque Value

Termination Dash Size

Inch Size

Thread Size UNF

Nm

Lb.ft

04

1/4

9/16–18

15

11

06

3/8

11/16–16

26

19

08

1/2

13/16–16

45

33

10

5/8

1–14

65

48

12

3/4

1 3/16–12

92

68

16

1

1 7/16–12

130

96

20

1 1/4

1 11/16–12

180

133

24

1 1/2

2–12

215

159

Torque Values For Split Flange Retaining Bolts Size

Torque Value Nm

Lb.ft

5/16–18

24

18

3/8–16

45

33

7/16–14

54

40

1/2–13

81

60

5/8–11

197

145

F06–01–100

MAIN HYDRAULICS Torque Values For Dryseal Pipe (NPTF or Equivalent) Steel Fittings Torque Value

Size Inch

Nm

Lb.ft

1/8

25

18

1/4

45

33

3/8

70

52

1/2

125

92

3/4

180

132

1

240

177

1 1/4

280

206

F06–01–101

LOADER

G07 SECTION

REMOVAL AND INSTALLATION — FRONT LOADER BEAM. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–1 REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDER .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–7 REMOVAL AND INSTALLATION — FRONT LOADER HYDRAULIC CROWD CYLINDER.. .. .. .. .. .. . G07–01–9 REMOVAL AND INSTALLATION — LOADER BUCKET POTENTIOMETER.. .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–13 DISASSEMBLY AND ASSEMBLY — LOADER BUCKET HYDRAULIC CYLINDER . .. .. .. .. .. .. .. .. . G07–01–15 GENERAL PROCEDURE — ANTI ROLLBACK ADJUSTMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–19 GENERAL PROCEDURE — RETURN TO DIG ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–21 SPECIFICATIONS — LOADER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . G07–01–23

LOADER REMOVAL AND INSTALLATION — FRONT LOADER BEAM

BHG0701RA

Operation: Removing and Installing the Front Loader Beam Suitable axle Stands Suitable lifting equipment

Job Code: 07 08 13 xx Standard tools, Suitable slide hammer

Removal All vehicles Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: Always install blanking plugs to any open ports to avoid contamination.

•

1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Release the pressure from the hydraulic system, for additional information refer to Section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Vehicles with Quick Attach Loader 5. Remove the quick attach loader unit. For additional information, refer to Section A01-01 QUICK ATTACH LOADER UNIT, PAGE A01–01–5 . Vehicles without Quick Attach Loader 6. Remove the standard loader bucket. For additional information, refer to Section B02-01 STANDARD LOADER BUCKET, PAGE B02–01–1 or B02-01 MULTI PURPOSE LOADER BUCKET, PAGE B02–01–3 . All Vehicles 7. Remove the front loader hydraulic crowd cylinder. For additional information, refer to FRONT LOADER HYDRAULIC CROWD CYLINDER, PAGE G07–01–9 in this section. 8. Using suitable axle stands, support the front loader beam.

TV040214

G07–01–1

LOADER

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Left-hand side shown, right-hand side similar.

•

9. Using suitable lifting equipment, support the front loader hydraulic cylinder. 10. Remove the hydraulic cylinder pivot pin retaining bolt (1). 11. Remove the hydraulic cylinder pivot pin and detach the front loader hydraulic cylinder from the front loader beam (2). 12. Remove the loader beam safety strut (3). 13. Repeat steps 9 to 11 to detach the right-hand side front loader hydraulic cylinder from the front loader beam.

TV040207

14. Disconnect the front loader hydraulic pipes (1). 15. Remove the hydraulic pipe retaining bracket (2). 16. Detach the feed back link strut from the feed back link bracket (3). 17. Remove the feed back link (4).

TV040215

G07–01–2

LOADER 18. Remove the right-hand outer pivot pin retaining bolt.

TV040216

19. Disconnect the front loader crowd cylinder hydraulic pipes (1). 20. Disconnect the load potentiometer electrical connector. (2). 21. Remove the left-hand outer pin retainer bolt (3). 22. Detach the front loader hydraulic pipes (4). Note: • Cut the cable ties.

TV040217

23. Remove the front loader and crowd cylinder hydraulic pipes.

TV040218

24. Remove the air cleaner assembly. For further information, refer to Section P14-01 AIR CLEANER, PAGE P14–01–33 .

G07–01–3

LOADER 25. Remove the front loader beam upper pivot pin retaining bolts.

TV040219

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Left-hand side shown, right-hand side similar.

•

26. Using suitable lifting equipment, support the front loader arm. 27. Using a suitable slide hammer, remove the front loader beam upper pivot pins and remove the front loader beam.

TV040695

Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (1) to 48Nm (35 lb.ft).

TV040207

G07–01–4

LOADER 3. Tighten to 67Nm (49 lb.ft).

TV040219

4. Tighten (3) to 230Nm (170 lb.ft).

TV040217

5. Tighten to 230Nm (170 lb.ft).

TV040216

G07–01–5

LOADER

Note: This page intentionally left blank.

G07–01–6

LOADER REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDER

BHG0701RB

Operation: Removing and Installing the Loader Beam Hydraulic Cylinder Suitable lifting equipment

Job Code: 07 07 13 xx Standard tools, Suitable slide hammer

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm level ground. 2. Position the loader bucket flat on the ground. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 4. Release the pressure from the hydraulic system . For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 5. Disconnect the loader arm cylinder hydraulic hoses.

TV040206

6. Remove the hydraulic cylinder pivot pin retaining bolt (1). 7. Remove the hydraulic cylinder pivot pin (2). 8. Remove the loader arm safety strut (3).

TV040207

G07–01–7

LOADER

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment support the front loader cylinder.

•

9. Remove the hydraulic cylinder outer retaining bolt (1). 10. Remove the hydraulic pivot pin inner retaining bolt (2).

TV040208

11. Using a suitable slide hammer, remove the cylinder pivot pin and remove the front loader cylinder.

TV040209

Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten to 230Nm (170 lb.ft).

TV040208

3. Check and adjust the hydraulic oil level as required.

G07–01–8

LOADER REMOVAL AND INSTALLATION — FRONT LOADER HYDRAULIC CROWD CYLINDER Operation: Removing and Installing the Front Loader Hydraulic Crowd Cylinder Suitable lifting equipment

BHG0701RC

Job Code: 07 01 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Park the machine on firm, level ground. 2. Position the loader bucket flat on the ground. 3. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–35 . 4. Release the pressure from the hydraulic system. For additional information, refer to section F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 5. Disconnect the front loader crowd cylinder hydraulic pipes.

G07–01–9

LOADER

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

6. Using suitable lifting equipment, support the front hydraulic crowd cylinder.

TV040693

7. Remove the hydraulic crowd cylinder pivot pin retaining bolt (1). 8. Detach the crowd cylinder from the front loader (2). 9. Remove the hydraulic crowd beam pivot pin retaining bolt (3). 10. Detach the hydraulic crowd beam from the front loader (4).

TV040211

11. Remove the circlip and detach the feed back link from the feed back link bracket (1). 12. Remove the feed back link bracket from the front loader crowd pin (2). 13. Remove the hydraulic crowd cylinder pivot pin retaining bolt (3).

3

1 2 TV040212

G07–01–10

LOADER 14. Detach the automatic return to dig switch and position it to one side.

TV040601

15. Disconnect and remove the hydraulic pipes from the crowd cylinder (1). 16. Remove the pivot pin circlip (2). 17. Remove the front loader hydraulic crowd beam (3) and hydraulic crowd cylinder (4).

1

4

3

2

TV040213

Installation Note: • Install new pivot pin lock nuts. 1. To install, reverse the removal procedure. 2. Tighten (2) and (3) to 10Nm (7 lb.ft).

3

1 2 TV040212

G07–01–11

LOADER 3. Tighten (1) and (3) 10Nm (7 lb.ft).

TV040211

G07–01–12

LOADER REMOVAL AND INSTALLATION — LOADER BUCKET POTENTIOMETER

BHG0701RD

Operation: Removing and Installing the Loader Bucket Potentiometer None

Job Code: 07 09 13 xx Standard tools

Removal 1. Position the loader bucket flat on the ground. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Disconnect the loader bucket switch electrical connector. • Cut the cable ties.

TV040631

Note: • Make a note of the position of the loader bucket switch prior to removal, to aid installation. 4. Remove the loader bucket switch.

TV040601

Installation 1. To install, reverse the removal procedure.

G07–01–13

LOADER

Note: This page intentionally left blank.

G07–01–14

LOADER DISASSEMBLY AND ASSEMBLY — LOADER BUCKET HYDRAULIC CYLINDER

BHE0701DA

Operation: Disassembling and Assembling the Loader Bucket Hydraulic Cylinder Suitable lifting equipment

Job Code: 07 01 17 xx Standard tools, Suitable piston ring compression tool

2 3

1

21

15

20 19 18

9

17 16 14 13 12 11 10 8

7 6 5 4 23

24

22 TV040503

G07–01–15

LOADER 1

Cylinder

2

Bush

3

Grease Nipple

4

Wiper Seal

5

Seal

6

Ring

7

Ring

8

Bush

9

Locking Screw

10

O-Ring

11

Back-up Ring

12

O-Ring

13

O-Ring

14

Piston

15

Locking Screw

16

Guide Ring

17

Ring

18

Seal

19

Guide Ring

20

Retaining Nut

21

Snap Ring

22

Bush

23

Grease Point

24

Piston Rod

Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (1) in a soft jawed vice. 3. Remove the locking screw (9) from the bush (8) and cylinder (1). 4. Remove the bush (8) from the cylinder (1). 5. Pull the piston rod (24) straight out of the cylinder (1). 6. Fasten the piston rod eye (24) in a vice and put a support below the piston rod (24) near the piston. 7. Remove the snap ring (21) and the retaining nut (20) from the piston rod (24). 8. Remove the locking screw (15), and unscrew the piston (14) from the piston rod (24). 9. Remove the bush (8) from the piston rod (24).

G07–01–16

LOADER 10. Remove the guide ring (19), seal (18), ring (17), guide ring (16) and the O-ring (13) from the piston (14). 11. Remove the ring (12), O-ring (11), back-up ring (10), O-ring (9), ring (8), ring (6), seal (5) and wiper seal (4) from the bush (8).

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (4), seal (5), ring (6), ring (7), back-up ring (10), O-ring (11) and ring (12) to the bush (8). 2. Install the O-ring (13), guide ring (16), ring (17), seal (18) and guide ring (19) to the piston (14). Note: • To aid installation of the bush, lubricate the bore of the bush with clean oil. 3. Install the bush (8) onto the piston rod (24).

•

Caution: Do not apply Loctite to the first 7mm of the piston rod threads. Failure to follow this instruction may result in damage to the piston.

4. Clean the threads on the end of the piston rod. Apply Loctite 242 to the piston rod threads from the open end of the piston rod. 5. Install the piston (14) onto the piston rod (24) and install the locking screw (15) and tighten to 23Nm (17 lb.ft). 6. Install the retaining nut (20) and the snap ring (21) onto the piston rod. 7. Lubricate the inside of the cylinder (1) and the piston (14) with clean oil. Use a piston ring compression tool to hold the new sealing rings in place. 8. Start the cylinder (1) onto the piston rod assembly. Push the tube onto the piston rod assembly until the compression tool is pushed off the piston rod assembly. Be careful not to damage the carrier rings and seals. 9. When the piston (14) is in the smooth part of the cylinder (1), start the bush (8) into the cylinder (1). 10. Tighten the bush (8) to a torque between 320 and 550Nm. When the locking screw holes become aligned in this torque range, install the lock screw. Tighten the lock screw to 23Nm (17 lb.ft).

G07–01–17

LOADER

Note: This page intentionally left blank.

G07–01–18

LOADER GENERAL PROCEDURE — ANTI ROLLBACK ADJUSTMENT

BHG0701GA

Adjustment Procedure 1. Park the machine on firm level ground and engage the parking brake. 2. Raise the lift arm until the bucket commences to self level (roll forward). 3. Check the height of the bucket (lift arm pivot should be 1200 to 1400 mm above ground). 4. If the height is above or below the recommended measurement, carry out the following procedure. 5. Make sure the loader controls are set correctly. 6. Position the bucket/lift arm pivot pin 675 mm above the ground. 7. Roll back the bucket until contact stops on the lift arm (fully crowded). 8. Make sure the link assembly (3) is in contact with the bucket link.

9. Adjust the strut (1) until the lever (4) just makes contact with the disc (5) on the bucket control rod (6) in neutral position.

6

4 TV040516

G07–01–19

LOADER 10. If excessive adjustment of the strut (1) is required, position the lever (7) as required. 11. Lower the lift arm to the ground. 12. Raise the lift arm until the bucket commences to self level (roll forward). 13. Check the height of the bucket (lift arm pivot should be 1200 to 1400 mm above ground). 14. Check that the lever (7) does not contact the cab cross member when the loader is fully raised and lowered. Note: • Rod assembly (2) standard length should be 723 mm.

Note: • Gas strut (1) standard length should be 610 mm.

G07–01–20

LOADER GENERAL PROCEDURE — RETURN TO DIG ADJUSTMENT

BHG0701GB

Adjustment Procedure 1. Park the machine on firm level ground and engage the parking brake. 2. Lower the loader bucket to the ground and make sure that the bottom of the bucket is at the required digging angle. 3. Stop the engine and remove the starter switch key. 4. Disconnect the return to dig electrical connector and place a multimeter across the switch side of the connector. 5. Unscrew the return to dig switch lock bolt and slide the switch in the groove until the multimeter reads open circuit, then tighten the bolt.

TV074019

6. Remove the multimeter and re-connect the electrical connector. 7. Start the engine, raise the loader attachment completely and place the bucket in the dump position. 8. Press the return to dig override switch to illuminate the light.

9. Place the control lever in the return to dig position to enable the bucket to reset. 10. Lower the arms to the ground and check the digging angle. Adjust if necessary. Note: • If a multimeter is not available, set the return to dig switch to the middle position and test the system, adjusting as necessary.

G07–01–21

LOADER

Note: This page intentionally left blank.

G07–01–22

LOADER SPECIFICATIONS — LOADER

BHG0701SA

Torque Values Description

Nm

Lb.ft

Lock Screw

23

17

320–550

236–405

Left-hand Outer Pin Retainer Bolt

230

170

Right-hand Outer Pin Retainer Bolt

230

170

Upper Pivot Pin Retaining Bolt

67

49

Pivot Pin Lock Nuts

48

35

Hydraulic Ram Cylinder Outer Retaining Bolt

230

170

Bush

G07–01–23

OPERATORS ENVIRONMENT

H08 SECTION

REMOVAL AND INSTALLATION — CAB .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . H08–01–1 REMOVAL AND INSTALLATION — CAB HEATER AIR DUCTING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–13 REMOVAL AND INSTALLATION — CAB HEATER MOTOR .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–17 REMOVAL AND INSTALLATION — CAB HEATER MATRIX .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–19 REMOVAL AND INSTALLATION — DRIVER SEAT (ALL MODELS) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–23 REMOVAL AND INSTALLATION — CAB DOOR GLAZING PANEL.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–25 REMOVAL AND INSTALLATION — AIR CONDITIONING EVAPORATOR .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–27 REMOVAL AND INSTALLATION — REAR WINDOW OPEN POSITION LATCH . .. .. .. .. .. .. .. .. .. .. ..H08–01–31 REMOVAL AND INSTALLATION — SERVO CONTROL JOYSYICK . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–33 REMOVAL AND INSTALLATION — CONTROLS TILT PEDAL . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–37 REMOVAL AND INSTALLATION — HOSE REMOVAL AND INSTALLATION. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–41 GENERAL PROCEDURE — AIR CONDITIONING RECOVERY AND CHARGING . .. .. .. .. .. .. .. .. .. ..H08–01–45 SPECIFICATIONS — OPERATORS ENVIRONMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..H08–01–49

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB

BHH0801RA

Operation: Removing and Installing the Cab Suitable lifting equipment, Suitable wheel chocks

Job Code: 08 08 13 xx Standard tools

Vehicles with Air Conditioning Vehicles without Air Conditioning

Removal Note: • Make a note of the position of any pipes / hoses prior to disconnection to aid installation. Note: Always install blanking plugs to any open ports to avoid contamination.

•

•

Warning: Place suitable wheel chocks against the wheels to prevent vehicle movement. Failure to follow this instruction may result in personal injury.

All Vehicles 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Evacuate the air conditioning system (where fitted). For additional information, refer to AIR CONDITIONING RECOVERY AND CHARGING, PAGE H08–01–45 in this section. 3. Remove the cab floor mat. 4. Remove the cab floor access panel(s).

TV040007

Note: • Make a note of the position of the auxiliary service control linkage prior to disconnection, to aid installation. 5. Disconnect the auxiliary service control linkage (2).

H08–01–1

OPERATORS ENVIRONMENT 6. Disconnect the stabilizer legs control linkage (1).

TV040008

Note: • Make a note of the position of the backhoe control linkage prior to disconnection, to aid installation. 7. Disconnect the backhoe control linkages.

TV040009

8. Remove the parking brake cable retaining clip (1). 9. Remove the parking brake return spring retainer (2). 10. Remove the parking brake return spring (3).

TV040010

11. Remove the parking brake cable adjustment nut (1).

H08–01–2

OPERATORS ENVIRONMENT 12. Detach the parking brake cable (2).

TV040011

13. Turn the heater control fully to the COLD position. 14. Remove the heater control cable retaining clip (1). Note: Make sure the heater control valve is still in the COLD position.

•

15. Detach the heater control cable (2). 16. Clamp the heater return hose (3).

2 TV040012

17. Disconnect the heater inlet hose (1). 18. Disconnect the heater return hose (2).

1 2

TV040013

H08–01–3

OPERATORS ENVIRONMENT Note: • Make a note of the position of the loader control linkages prior to disconnection, to aid installation. 19. Disconnect the loader control valve linkage (cab shown removed for clarity).

TV040904

20. Remove the retaining nut and remove the auxiliary service pedal.

TV040014

21. Remove the rear cab floor mat. 22. Detach the backhoe control trim cover.

TV040015

23. Remove the backhoe control levers.

TV040016

H08–01–4

OPERATORS ENVIRONMENT 24. Remove the backhoe lock lever retaining bolts (1). 25. Remove the backhoe lock cable retaining pin (2). 26. Remove the lever.

TV040017

27. Remove the backhoe lock cable retaining clip (1) and push the cable through the floor (2).

TV040018

28. Detach the instrument cluster and the switch panel.

29. Disconnect the instrument cluster connector (1). 30. Disconnect the ignition switch connectors (2) and (3).

electrical electrical

H08–01–5

OPERATORS ENVIRONMENT 31. Remove the fuse panel cover.

TV040140

Note: • Make a note of the position of the electrical connectors to aid installation. 32. Disconnect the fuse box electrical connectors and push the wiring harness through the bottom of the cab.

TV040022

33. Disconnect the earth strap.

TV040023

H08–01–6

OPERATORS ENVIRONMENT 34. Detach the front loader control lever trim. 35. Disconnect the front loader lever electrical connector.

TV040024

36. Remove the retaining clip (1). 37. Loosen the throttle cable adjustment nut (2) and detach the throttle cable from the fuel pump.

2

1

TV041141

38. Remove the steering motor retaining bolts.

TV040028

Vehicles with Powershift Transmission 39. Disconnect the powershift electrical connector.

TV040088

H08–01–7

OPERATORS ENVIRONMENT Vehicles with Synchro-shuttle Transmission 40. Remove the gearshift lever boot trim cover.

TV040143

41. 42. 43. 44.

Remove the gearshift lever return spring (1). Remove the gearshift lever retaining bolt (2). Remove the gearshift selector lever (3). Disconnect the dump button electrical connector (4).

TV040135

All Vehicles 45. Remove the rear fenders. For additional information, refer to Section K10-01 REAR FENDER, PAGE K10–01–1 . 46. Remove the front loader levers and linkage.

TV040029

H08–01–8

OPERATORS ENVIRONMENT 47. Disconnect the window washer tubes (1).

TV040030

48. Remove the air cleaner. For additional information, refer to Section P14-01 AIR CLEANER, PAGE P14–01–33 . Note: Install blanking contamination.

•

plugs

to

avoid

49. Disconnect the master cylinder supply and return hoses from the master cylinder (1). 50. Disconnect the left-hand and right-hand brake supply hose (2).

TV040039

51. Disconnect the air conditioning low pressure pipe. Note: • Remove and discard the O-ring seals.

TV040040

52. Disconnect the air conditioning high pressure pipe (1). Note: Remove and discard the O-ring seals.

•

H08–01–9

OPERATORS ENVIRONMENT 53. Disconnect the glow plug electrical connector (2).

TV040041

54. Disconnect the air conditioning filter/drier pipe. Note: Remove and discard the O-ring seals.

•

TV040042

55. Detach the auxiliary service hoses and position to one side.

TV040043

56. Remove the front cab mounting bolts (left-hand side shown, right-hand side similar).

TV040044

H08–01–10

OPERATORS ENVIRONMENT 57. Remove the rear cab mounting bolts (left-hand side shown, right-hand side similar).

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

58. Using suitable lifting equipment, remove the cab.

TV040905

Installation 1. To install, reverse the removal procedure. 2. Tighten to 395Nm (291 lb.ft).

TV040044

3. Tighten to 395Nm (291 lb.ft).

TV040905

H08–01–11

OPERATORS ENVIRONMENT 4. Tighten to 24Nm (18 lb.ft).

TV040028

5. Bleed the brake system. For additional information, refer to section N13-03 BRAKE BLEEDING, PAGE N13–03–19 . 6. Adjust the parking brake cable. For additional information, refer to the Operator’s Manual. For 7. Recharge the air conditioning system. additional information, refer to Section AIR CONDITIONING RECOVERY AND CHARGING, PAGE H08–01–45 in this section.

H08–01–12

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB HEATER AIR DUCTING

BHH0801RB

Operation: Removing and Installing the Cab Heater Air Ducting Suitable transmission jack

Job Code: 08 38 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the cab front mat. 3. Detach the cab rear mat and position it to one side. 4. Remove the cab floor front access panel(s).

TV040007

5. Remove the cab floor rear access panel.

TV040160

6. Remove the front console lower retaining bolts (1). 7. Remove the pedal box floor plate (2).

TV040096

H08–01–13

OPERATORS ENVIRONMENT 8. Remove the seat box front retaining bolts.

TV040099

9. Remove the seat box rear retaining bolts. 10. Pull the seat away from the back of the cab, away from the ducting.

TV040100

11. Remove the front console upper air vents.

TV040097

12. Remove the front console.

TV040098

13. Open the hood. 14. Remove the exhaust stack. For additional information, refer to Section P14-01 EXHAUST PIPE, PAGE P14–01–35 .

H08–01–14

OPERATORS ENVIRONMENT 15. Using a suitable transmission jack, support the transmission.

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

16. Loosen the transmission mount to chassis retaining bolts (1), both sides. (Right-hand shown, left-hand similar). 17. Remove the transmission mount retaining bolts (2), both sides. (Right-hand shown, left-hand similar).

TV040069

•

Caution: Make sure excessive force is not applied to any pipes, hoses or wiring harnesses.

Note: • Remove and discard the cabin heater air ducting seal. 18. Carefully lower the transmission to enable the removal of the cabin heater air ducting. 19. Remove the cab heater air ducting.

TV040101

Installation Note: • Install a new cabin heater air ducting seal. 1. To install, reverse the removal procedure.

H08–01–15

OPERATORS ENVIRONMENT 2. Tighten (2) to 98Nm (72 lb.ft).

TV040069

H08–01–16

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB HEATER MOTOR

BHH0801RG

Operation: Removing and Installing the Cab Heater Motor None

Job Code: 08 39 13 xx Standard tools

Removal 1. Isolate the battery. For additional information, J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the driver seat. For additional information, refer to DRIVER SEAT, PAGE H08–01–23 in this section. 3. Remove the floor front mat. 4. Detach the cab floor rear mat and position it to one side. 5. Detach the backhoe lock lever.

TV040643

6. Remove the blower vent.

TV040644

7. Remove the cab heater cover.

TV040645

H08–01–17

OPERATORS ENVIRONMENT 8. Remove the cab heater top cover.

TV040646

9. Disconnect the cab blower motor electrical connectors.

TV040647

10. Remove the cab blower motor.

TV040648

Installation 1. To install, reverse the removal procedure.

H08–01–18

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB HEATER MATRIX

BHH0801RC

Operation: Removing and Installing the Cab Heater Matrix None

Job Code: 08 40 13 xx Standard tools

Removal 1. Isolate the battery. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the driver seat. For additional information, refer to Section DRIVER SEAT, PAGE H08–01–23 in this section. 3. Remove the floor front mat. 4. Detach the cab floor rear mat and position it to one side. 5. Detach the backhoe lock lever.

TV040643

6. Remove the blower vent.

TV040644

7. Remove the cab heater cover.

TV040645

H08–01–19

OPERATORS ENVIRONMENT 8. Remove the cab heater top cover.

TV040646

•

•

Warning: Do not release the cooling system pressure when the system is hot. Failure to follow this instruction may result in personal injury. Warning: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.

9. Loosen the radiator cap. 10. Turn the heater control fully to the COLD position. 11. Clamp the heater return hose (2). 12. Disconnect the heater inlet hose (1). 13. Disconnect the heater return hose (2).

1 2

TV040013

14. Remove the cab heater matrix. Note: Lubricate all grommets to aid installation.

•

TV040749

H08–01–20

OPERATORS ENVIRONMENT Installation 1. To install, reverse the removal procedure. 2. Make sure the correct grade, and quality of antifreeze is added to the water. Recommended content mixture is 50% water, with 50% antifreeze. 3. Refill the cooling system through the radiator cap until completely full. Re-install the radiator cap and refill the coolant expansion tank to the full mark. 4. Start the engine and run until the normal engine operating temperature is achieved. Check for leaks, allow to cool then recheck the coolant level.

H08–01–21

OPERATORS ENVIRONMENT

Note: This page intentionally left blank.

H08–01–22

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — DRIVER SEAT (ALL MODELS)

BHH0801RD

Operation: Removing and Installing the Driver Seat (All Models) None

Job Code: 08 41 13 xx Standard tools

Removal 1. Isolate the battery. For additional information, refer to Section J09-01 BATTERY ISOLATION . 2. Disconnect the air seat electrical connector (if equipped).

TV040637

3. Remove the bellows retaining clips. (Left-hand side shown, right-hand side similar). 4. Detach the belows from the drivers seat.

TV040638

5. Remove the driver’s seat retaining bolts (left-hand side shown, right-hand side similar) and remove the driver’s seat.

TV040639

H08–01–23

OPERATORS ENVIRONMENT Installation 1. To install, reverse the removal procedure. • Tighten to 29Nm (21 lb.ft).

TV040639

H08–01–24

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CAB DOOR GLAZING PANEL

BHH0801RE

Operation: Removing and Installing the Cab Door Glazing Panel

Job Code: 08 20 13 xx

None

Standard tools

Removal 1. Open the cab door. 2. Remove the cab glazing panel bump stop (1). Note: • Remove the bolt caps. 3. Remove the cab glazing panel grab handle (2).

2 1

TV040809

•

Caution: Support the cab glazing panel. Failure to follow this instruction may result in damage to the machine.

Note: • Remove the bolt caps. 4. Remove the cab glazing panel upper and lower retaining nuts, rubbers and washers.

TV040840

5. Remove the cab glazing panel. 6. Remove and discard the cab glazing panel seal.

Installation Note: • Install a new cab glazing panel seal. 1. To install, reverse the removal procedure. 2. Using a suitable cleaning solution, clean the cab glazing panel.

H08–01–25

OPERATORS ENVIRONMENT

Note: This page intentionally left blank.

H08–01–26

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — AIR CONDITIONING EVAPORATOR

BHH0801RH

Operation: Removing and Installing the Air Conditioning Evaporator None

Job Code: 08 01 13 xx Standard tools

Removal Note: • Make a note of the position of any pipes / hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Isolate the battery. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the driver’s seat. For additional information, refer to DRIVERS SEAT, PAGE H08–01–23 in this section. 3. Evacuate the air conditioning system. For additional information, refer to AIR CONDITIONING RECOVERY AND CHARGING, PAGE H08–01–31 in this section. 4. Remove the floor front mat. 5. Detach the cab floor rear mat and position to one side. 6. Remove the two retaining bolts and detach the backhoe lock lever.

TV040643

7. Remove the blower vent.

TV040644

H08–01–27

OPERATORS ENVIRONMENT 8. Remove the cab heater cover.

TV040645

9. Remove the cab heater top cover.

TV040646

10. Disconnect the air conditioning filter/drier.

TV040042

11. Remove the cab heater box retaining bolts. 12. Position the cab heater box to one side.

13. Remove the air conditioning evaporator pipe clamp (1) and detach the pipes.

H08–01–28

OPERATORS ENVIRONMENT 14. Remove the cab heater box plate (2).

15. Remove the evaporator protective foam.

16. Remove the air conditioning temperature control switch electrical connectors (1). 17. Remove the air conditioning temperature control switch (2).

18. Remove the air conditioning evaporator.

Installation 1. To install, reverse the removal procedure.

H08–01–29

OPERATORS ENVIRONMENT

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H08–01–30

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — REAR WINDOW OPEN POSITION LATCH

BHH0801RI

Operation: Removing and Installing the Rear Window Open Position Latch None

Job Code: 08 42 13 xx Standard tools

Removal 1. Remove the rear window open position latch plate.

TV040067

2. Remove the rear window open position latch.

TV040068

Installation 1. To install, reverse the removal procedure. 2. Tighten to 28Nm (21 lb.ft).

TV040068

H08–01–31

OPERATORS ENVIRONMENT

Note: This page intentionally left blank.

H08–01–32

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — SERVO CONTROL JOYSYICK

BHN1301DB

Operation: Removal and Installation — Servo Control Joystick

Job Code: 08 43 13 xx

None

Standard tools,

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. Note: Right-hand shown, left-hand similar.

•

1. Release the pressure in the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the position adjustment knob.

TV051506

4. Remove the joystick control valve inner cover.

TV051506

H08–01–33

OPERATORS ENVIRONMENT 5. Remove the three retaining screws and remove the joystick control valve outer cover.

TV051509

6. Reposition the joystick gaiter.

TV051435

7. Disconnect the override button electrical connector.

TV051436

8. Remove the retaining bolts and detach the servo control joystick assembly.

TV051437

H08–01–34

OPERATORS ENVIRONMENT 9. Disconnect the six hydraulic hoses in the order indicated.

1

2

6

5 4 TV041438

10. Remove the servo control joystick.

TV051439

Installation 1. To install, reverse the removal procedure. 2. Tighten to 18Nm (13 lb.ft).

TV051437

H08–01–35

3

OPERATORS ENVIRONMENT

Note: This page intentionally left blank.

H08–01–36

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — CONTROLS TILT PEDAL

BHN1301DB

Operation: Removal and Installation — Controls Tilt Pedal. None

Job Code: 08 44 13 xx Standard tools,

Removal

1. Release the pressure in the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the cover plate.

TV051472

4. Remove the retaining bolt and remove the selector lever.

TV051473

H08–01–37

OPERATORS ENVIRONMENT Note: • Reposition the floor mat to gain access. 5. Remove the pedestal cover left hand lower retaining bolts.

TV051513

Note: • Reposition the floor mat to gain access. 6. Remove the pedestal cover right hand lower retaining bolts.

TV051514

7. Remove the pedestal cover upper retaining bolts and remove the pedestal cover.

TV051475

H08–01–38

OPERATORS ENVIRONMENT Note: • Right side shown, left hand similar. 8. Remove the four retaining screws and remove the servo control arm covers.

TV051441

Note: • Position the servo control arms in the up position. 9. Remove the foot pedal return spring (1). 10. Remove the pivot bolt (2). 11. Remove the foot pedal (3).

1 3

2 TV051516

Installation Note: • Position the servo control arms in the up position. 1. To install, reverse the removal procedure. 2. Position the controls in the working position, making sure the locating pin (1) on the foot pedal is fully engaged in the cam (2).

2 1

TV051517

H08–01–39

OPERATORS ENVIRONMENT 3. Loosen the locknut (1) and adjust the bolt (2) until it is clear of the microswitch plunger (3).

3

2 1

TV051519

4. Adjust the bolt height until the microswitch plunger (1) is compressed by 5mm. Tighten the locknut (2).

1 2

TV051520

Note: • Ensure that the microswitch breaks the circuit as soon as the pedal is depressed and before the pin is released from the cam. 5. Tighten to 18Nm (13 lb.ft).

TV051505

H08–01–40

OPERATORS ENVIRONMENT REMOVAL AND INSTALLATION — HOSE REMOVAL AND INSTALLATION

BHN1301DB

Operation: Removal and Installation — Hose removal and install

Job Code: 08 45 13 xx

None

Standard tools,

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. Note: This procedure describes the removal and installation of a joystick hydraulic return hose. Use this procedure when removing any joystick hydraulic hose.

•

Note: • Right-hand shown, left-hand similar. 1. Release the pressure in the hydraulic system. For additional information, refer to F06-01 RELEASING THE HYDRAULIC SYSTEM PRESSURE, PAGE F06–01–95 . 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the position adjustment knob.

TV051506

4. Remove the joystick control valve inner cover.

TV051506

H08–01–41

OPERATORS ENVIRONMENT 5. Remove the three retaining screws and remove the joystick control valve outer cover.

TV051509

6. Remove the cover plate.

TV051472

7. Remove the retaining bolt and remove the selector lever.

TV051473

Note: • Reposition the floor mat to gain access. 8. Remove the pedestal cover left hand lower retaining bolts.

TV051440

H08–01–42

OPERATORS ENVIRONMENT Note: • Reposition the floor mat to gain access. 9. Remove the pedestal cover right hand lower retaining bolts.

TV051474

10. Remove the pedestal cover upper retaining bolts and remove the pedestal cover.

TV051475

11. Remove the four retaining screws and remove the servo control arm covers.

TV051441

12. Cut the cable ties and recover the three hydraulic hose retaining brackets.

TV051442

H08–01–43

OPERATORS ENVIRONMENT 13. Remove the hydraulic hose retaining bracket. 14. Cut any remaining cable ties.

TV051443

15. Disconnect the joystick hydraulic return hose from the joystick.

TV041444

16. Disconnect the joystick hydraulic return hose from the servo control valve.

TV051445

17. Remove the hose.

Installation 1. To install, reverse the removal procedure. 2. Tighten to 18Nm (13 lb.ft).

TV051505

H08–01–44

OPERATORS ENVIRONMENT GENERAL PROCEDURE — AIR CONDITIONING RECOVERY AND CHARGING Operation: Recovery and Recharging the Air Conditioning System None

BHH0801GA

Job Code: 08 02 09 xx Refrigerant management station

Recovery

• •

• • • • • • •

Warning: Before overhauling an air conditioning system observe the following Safety Precautions. When servicing air conditioning units a certified refrigerant management station operated by a certified technician must be used. Always refer to and follow the refrigerant management station’s operating instructions. Do not allow refrigerant to escape into the atmosphere. Refrigerant must be handled with care in order to avoid hazards. Direct contact with liquid refrigerant may cause freezing of the skin or eyes. Keep the refrigerant container and air conditioning system away from naked flames and sources of heat. Recover the refrigerant in the system in a well ventilated area. Always wear suitable safety glasses and gloves to protect against accidental spillage of the refrigerant. Never disconnect fittings or lines until the refrigerant has been properly discharged.

1. Make sure the valves on the refrigerant management station are closed. 2. Connect the low pressure (blue) hose of the refrigerant management station to the machine.

TV040951

H08–01–45

OPERATORS ENVIRONMENT 3. Connect the high pressure (red) hose of the refrigerant management station to the machine.

TV040950

•

Warning: Follow and observe the refrigerant management station operating instructions. Failure to follow this instruction may result in personal injury.

4. Recover the refrigerant. For additional information, refer to the refrigerant management station operating instructions. 5. Disconnect the low pressure (blue) and high pressure (red) hoses of the refrigerant management station from the machine.

Charging 1. Make sure the valves on the refrigerant management station are closed. 2. Connect the low pressure (blue) hose of the refrigerant management station to the machine.

TV040951

3. Connect the high pressure (red) hose of the refrigerant management station to the machine.

TV040950

H08–01–46

OPERATORS ENVIRONMENT

•

Warning: Follow and observe the refrigerant management station operating instructions. Failure to follow this instruction may result in personal injury.

4. Vacuum down the air conditioning system. For additional information, refer to the refrigerant management station operating instructions. Quantity (g) Standard Recharge

900–1000

Total System Capacity

1200

5. Charge the system with the correct specified quantity of R-134A refrigerant. For additional information, refer to the refrigerant management station operating instructions. 6. Disconnect the low pressure (blue) and high pressure (red) hoses of the refrigerant management station from the machine. Note: Make sure the air conditioning is switched off.

•

7. Start the engine and allow to idle. 8. Switch the air conditioning on and allow the system to operate for at least one minute before increasing the engine speed.

•

Warning: Use a suitable certified R-134A gas detector to check the system for possible leaks.

H08–01–47

OPERATORS ENVIRONMENT

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H08–01–48

OPERATORS ENVIRONMENT SPECIFICATIONS — OPERATORS ENVIRONMENT

BHH0801SA

Torque Values Description

Nm

Lb.ft

Cab Mounts

395

291

Steering Motor Retaining Bolts

24

18

Cab Earth Strap

98

72

Backhoe Control Lever Bracket

28

21

Cab Floor Access Panel Retaining Bolts

28

21

Front Loader Linkage Retaining Bolts

28

21

Auxiliary Service Hoses Retaining Bracket

28

21

Cab Heater Cover

28

21

Cab Heater Box

28

21

Rear Window Open Position Latch

28

21

Refrigerant Type

Quantity (g)

Standard Recharge

R–134A

900–1000

Total System Capacity

R–134A

1200

Air Conditioning Specifications

H08–01–49

ELECTRICS

J09 SECTION

DIAGNOSING AND TESTING — STARTING SYSTEM. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–01–1 DIAGNOSING AND TESTING — CHARGING SYSTEM.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–01–5 DIAGNOSING AND TESTING — BATTERY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–01–7 REMOVAL AND INSTALLATION — BATTERY (SINGLE).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–11 REMOVAL AND INSTALLATION — BATTERY (TWIN). .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–13 REMOVAL AND INSTALLATION — STARTER MOTOR . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–15 REMOVAL AND INSTALLATION — STARTER MOTOR SOLENOID. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–17 REMOVAL AND INSTALLATION — ALTERNATOR .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–19 REMOVAL AND INSTALLATION — FRONT WIPER MOTOR . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–21 REMOVAL AND INSTALLATION — REAR WIPER MOTOR. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–25 REMOVAL AND INSTALLATION — INDICATOR SWITCH. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–27 REMOVAL AND INSTALLATION — FORWARD/REVERSE SWITCH .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–29 GENERAL PROCEDURE — BATTERY ISOLATION.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–33 GENERAL PROCEDURE — BATTERY CHARGING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–35 SPECIFICATIONS — ELECTRICS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–01–43 GENERAL ELECTRICAL INFORMATION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–02–1 FUSE AND RELAY INFORMATION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–02–5 CONNECTOR INFORMATION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..J09–02–9 COMPONENT LOCATIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–33 WIRING DIAGRAMS — POWER SUPPLY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–47 WIRING DIAGRAMS — ENGINE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–51 WIRING DIAGRAMS — TRANSMISSION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–53 WIRING DIAGRAMS — DIFFERENTIAL LOCK . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–57 WIRING DIAGRAMS — STEERING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–61 WIRING DIAGRAMS — CONSOLE PANELS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–63 WIRING DIAGRAMS — LIGHTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–69 WIRING DIAGRAMS — WARNING FUNCTIONS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–83 WIRING DIAGRAMS — OPERATORS ENVIRONMENT.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–87 WIRING DIAGRAMS — HYDRAULIC SYSTEMS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. J09–02–93 WIRING DIAGRAMS — SERVO LEVER CONTROL .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .J09–02–103 CONNECTOR LOCATIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .J09–02–105

ELECTRICS DIAGNOSING AND TESTING — STARTING SYSTEM

4

BHJ0901TD

1

2

3

TV040942

1

Solenoid Positive (+) Terminal (From Battery)

2

Solenoid Terminal (From Ignition Switch)

3

Negative Terminal (-) (Ground)

4

Solenoid Positive (+) After Contact Terminal (To Motor)

J09–01–1

ELECTRICS General Information Power which is available during starting varies according to the temperature and condition of the battery. The following table shows the voltages that are expected from a battery at the various temperature ranges. Typical Voltages Expected During Starting At Various Ambient Temperatures Temperature ºC (ºF)

Expected Voltage (Volts)

−23 to −7 (−10 to 20)

6 to 8

−7 to 10 (20 to 50)

7 to 9

10 to 27 (50 to 80)

8 to 10

The following table shows the maximum acceptable loss of voltage in the battery circuit. The battery circuit supplies high current to the starter motor. Voltage drops that are greater than the values in the table below are normally caused by the following conditions. • Loose connections • Corroded connections • Faulty switch contacts Note: The values in the table are for batteries that have been in service for more than 2000 hours.

•

Maximum Acceptable Voltage Drop In The Starter Motor Circuit During Starting Circuit

Maximum Voltage Drop (Volts)

Battery negative terminal (-) to starter motor negative terminal (-) (3)

0.7

Drop across the disconnect switch

0.5

Battery positive terminal (+) to starter motor solenoid positive terminal (+) (1)

0.5

Starter motor solenoid terminal (1) to the solenoid terminal (4)

0.4

Test A — Testing The Battery Voltage Under Load 1. Disconnect the fuel injection pump stop solenoid electrical connector to prevent the engine from starting. 2. Using a suitable multimeter connected between the battery positive (+) terminal and the battery negative (-) terminal, measure the voltage. 3. Operate the starter motor. The voltage indicated should be 8 to 10 Volts at an ambient temperature of 10 to 27ºC (50 to 80ºF). A low voltage reading indicates excessive current flow in the circuit due to low resistance. 4. Connect the fuel injection pump stop solenoid electrical connector, if no further tests are required.

Test B — Testing The Starter Motor Terminal Voltage Under Load 1. Disconnect the fuel injection pump stop solenoid electrical connector (if connected) to prevent the engine from starting.

J09–01–2

ELECTRICS 2. Using a suitable multimeter connected between the solenoid positive (+) terminal (1) and the negative (-) terminal (3), measure the voltage. 3. Operate the starter motor. The voltage indicated should not be more than 0.5 Volts less than the battery voltage indicated in “Test A — Testing the battery voltage under load”. 4. A low voltage (more than 0.5 Volts difference between tests A and B), indicates high resistance in cables or contacts. 5. A high voltage indicates high resistance in the starter motor. 6. Connect the fuel injection pump stop solenoid electrical connector.

Test C — Testing The Voltage Drop In The Positive Circuit 1. Using a suitable multimeter connected between the solenoid positive (+) after contact terminal (4) and the battery positive (+) terminal, measure the voltage. 2. The voltage indicated should be: Battery voltage with the key start switch OFF. Approximately zero voltage with the starter motor engaged. 3. A high voltage indicates a high resistance in the positive circuit. Check all positive connections. Continue to “Test D”.

Test D — Testing The Voltage Drop Across The Solenoid Terminals 1. Using a suitable multimeter connected between the solenoid positive (+) terminal (1) and the solenoid positive (+) after contact terminal (4), measure the voltage. 2. The voltage indicated should be: Battery voltage with the key start switch OFF. Less than 0.4 Volts with the starter motor engaged. 3. A voltage less than 0.4 Volts indicates the high resistance in the starter circuit is due to either a high resistance in the starter cable or soldered connections. Clean and tighten all positive cable connections. Test the system. If a high resistance is still indicated, install a new battery positive cable. 4. A voltage greater than 0.4 Volts indicates a faulty starter solenoid or connection.

Test E — Testing The Voltage Drop In The Ground Circuit 1. Using a suitable multimeter connected between the starter motor negative (-) terminal (3) and the battery negative (-) terminal, measure the voltage. 2. The voltage indicated should be less than 0.7 Volts with the starter motor engaged. 3. A voltage greater than 0.7 Volts indicates a high resistance in the ground circuit. Clean and tighten all battery ground cable connections, starter motor mounting and body to ground straps. Test the system. If a high resistance is still indicated, install a new battery ground cable.

J09–01–3

ELECTRICS

Note: This page intentionally left blank.

J09–01–4

ELECTRICS DIAGNOSING AND TESTING — CHARGING SYSTEM

BHJ0901TB

W

D+

B+

TV040941

Testing Cable Continuity 1. Check the charge warning lamp illuminates with the ignition switch ON. 2. Using a suitable multimeter, check for battery voltage between the alternator terminal (B+) and ground. If the voltage indicated is less than battery voltage, check the electrical connectors and the wiring harness, repair or replace as required. 3. Using a suitable multimeter, check for battery voltage between the alternator terminal (D+) and ground. If the voltage indicated is less than battery voltage, check the electrical connectors and the wiring harness, repair or replace as required.

Testing The Voltage Drop 1. Using a suitable multimeter connected between the battery positive terminal and the alternator terminal (B+), measure the voltage. 2. Start and run the engine at maximum engine RPM. 3. Switch ON all vehicle electrical loads i.e. headlamps, worklamps etc. 4. Check the voltage indicated is less than 0.5V. If the voltage indicated is more than 0.5V, this indicates a high resistance in the wiring harness between the battery positive terminal and the alternator terminal (B+). 5. Turn the ignition key to the OFF position. 6. Connect the multimeter between the battery ground terminal and the alternator housing. 7. Start and run the engine at maximum engine RPM. 8. Switch ON all vehicle electrical loads i.e. headlamps, worklamps etc.

J09–01–5

ELECTRICS 9. Check the voltage indicated is less than 0.25V. If the voltage indicated is more than 0.25V, this indicates a high resistance in ground circuit.

Warning Lamp Does Not Illuminate Note: • The warning lamp for the charging system should illuminate when the ignition switch is in the ON position. 1. Check the charge warning indicator warning lamp. Replace the lamp if the element is blown. 2. Using a suitable multimeter, check the battery voltage. Check the battery voltage with the ignition switch OFF. 3. Check the voltage between the alternator terminal (B+) and ground. The voltage indicated should equal the battery voltage. 4. Turn the ignition switch to the ON position. Check the voltage between the alternator terminal (D+) and ground. If the voltage indicated is more than approximately 2 volts, replace the alternator.

Warning Lamp Is On When the Engine is Running 1. Start the engine and run the engine at fast idle. 2. Measure the voltage between the alternator terminal (B+) and ground. 3. Measure the voltage between the alternator terminal (D+) and ground. 4. The voltages indicated at the alternator terminals (B+) and ground and (D+) and ground should indicate between approximately 13 and 15 Volts. 5. If the voltages indicated are not correct, replace the alternator. 6. Increase the engine to high idle and operate an electrical load. 7. Measure the voltage between the alternator terminal (B+) and ground. 8. Measure the voltage between the alternator terminal (D+) and ground. 9. The voltages indicated at the alternator terminals (B+) and ground and (D+) and ground should indicate between approximately 13 and 15 Volts. 10. If the voltages indicated are not correct, replace the alternator.

J09–01–6

ELECTRICS DIAGNOSING AND TESTING — BATTERY

BHJ0901TC

Quiescent Current Drain The machines, ex-factory, have no permanently live circuits and should have zero quiescent current drain, when the key-switch is off and all lights are switched off. It should be noted that permanently live accessories fitted by the dealer, such as a clock or theft alarm system, will place a quiescent drain on the battery. Typically the quiescent drain will be in the range of 10–20 mA. If the quiescent drain measures 40 mA or more, there is a problem with the wiring insulation or the accessories, which must be cured.

•

Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, a beaten egg or vegetable oil. Do not give fluids that induce vomiting. Call a doctor immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

Battery Safety

•

•

•

• • • • • •

Warning: Battery acid causes severe burns. The battery contains sulphuric acid. Avoid contact with skin, eyes or clothing.

Warning: NEVER add electrolyte to an already charged battery.

•

Warning: Sparks can fly from electrical system or the engine. Before you operate this machine in an area which may contain inflammable vapour, completely ventilate the area. Warning: A spark or naked flame can cause the hydrogen in a battery to explode. To avoid all risk of explosion, follow these instructions: Turn the battery isolator to the “OFF” position (circuit disconnected). When disconnecting the battery cables, always disconnect the negative (-) cable first. To reconnect the battery cables, always connect the negative (-) cables last. Never use metal parts to short circuit the terminals of a battery. Do not weld, grind or smoke near a battery. Warning: A battery produces explosive gases. Keep all flames, sparks and cigarettes away. Provide adequate ventilation when charging the battery or when using it in an enclosed space. Always wear eye protection and protective clothing when working on or near a battery.

•

•

Warning: When the battery electrolyte is frozen, the battery can explode if you try to charge the battery or try to jump start and run the engine using another battery. To prevent battery electrolyte from freezing, keep the battery at full charge. Caution: Always connect/disconnect leads to/from the battery while the charger is switched off. Caution: If the battery temperature rises to 60°C (140°F) stop the charging process and allow the battery to cool.

•

Caution: Always measure battery temperature in the centre cell.

•

Caution: Always place a damp cloth over the vent covers when charging a battery.

•

J09–01–7

Caution: Use hot water to remove all evidence of corrosion from battery terminal post and connections, then smear with petroleum jelly or other non-acid grease.

ELECTRICS Battery inspection before test or charge Reject the battery if: 1. The electrolyte is excessively low. 2. Electrolyte levels vary by more than 20 mm (0.8 in) between cells. 3. Battery case, lid or mountings are cracked or damaged. 4. Terminals are damaged or loose in the case.

Test the open circuit voltage Do the open circuit voltage test as follows: 1. The engine must be stopped and all electrical circuits switched off during this test. 2. Measure the open circuit voltage of the battery only if it has not been charged or discharged in the past 16 hours. If the machine has recently been started, switch on the headlights for 15 seconds then wait one minute before testing. 3. Connect the voltmeter directly across both battery terminals and note the voltage. 12.5V or above — no action required. Below 12.5V, recharge the battery. For additional information, refer to BATTERY CHARGING, PAGE J09–01–35 in this section.

Load testing of the battery

•

Caution: Use a current controlled, high rate discharge tester with at least 500A capacity.

Load test the battery as follows: 1. Remove the battery from the machine. For additional information, refer to BATTERY (SINGLE), PAGE J09–01–11 or BATTERY (TWIN), PAGE J09–01–13 in this section. 2. Set the appropriate current on the discharge tester: CURRENT FOR SINGLE BATTERY

295A

CURRENT FOR TWIN BATTERY

410A

3. Connect a voltmeter across the battery terminals. 4. Apply the load tester across the battery terminals for 15 seconds and note the voltage during the test. Above 10V and steady

Battery is serviceable

Above 10V but falling rapidly

Replace battery

Below 10V

Replace battery

Poor Battery Performance Diagnostic Test with the Battery Still on the Machine 1. Test the open circuit voltage of the battery. For additional information, refer to TEST THE OPEN CIRCUIT, in this section. Is the voltage indicated greater than 12.5 Volts? a. YES – Continue to step 4. b. NO – Recharge the battery. For additional information, refer to BATTERY CHARGING, PAGE J09–01–35 in this section. Continue to step 2.

J09–01–8

ELECTRICS 2. Test the open circuit voltage of the battery. For additional information, refer to TEST THE OPEN CIRCUIT, in this section. Is the voltage indicated greater than 12.5 Volts? a. YES – Continue to step 4. b. NO – Continue to step 3. 3. Carry out a Load test on the battery. For additional information, refer to LOAD TEST THE BATTERY, in this section. Is the voltage indicated greater than 10 Volts? a. YES – Continue to step 4. b. NO – Replace the battery. 4. Check the charging system voltage. For additional information, refer to CHARGING SYSTEM, PAGE J09–01–5 in this section. Is the voltage indicated between 14.0 and 14.4 Volts? a. YES – Continue to step 5. b. NO – Test the alternator output. For additional information, refer to DIAGNOSING AND TESTING – CHARGING SYSTEM, PAGE J09–01–5 in this section. 5. Check the quiescent current drain. Is the current drain indicated zero with all electrical systems switched off? a. YES – Continue to step 7. b. NO – Continue to step 6. 6. Check if the quiescent current drain is caused by dealer/customer accessories. Check if there are dealer/customer accessories fitted such as a clock or theft alarm. If any of these are fitted, is the current drain indicated less than 20mA with all electrical systems switched off? a. YES – Continue to step 7. b. NO – Additional leakage is occurring in the circuit. Ensure the top of the battery is clean and dry. Check the wiring insulation for damage between the battery and key switch. 7. Check the battery voltage during cranking. Connect a voltmeter across the battery terminals and disconnect the fuel injection pump cut-off solenoid electrical connector. Crank the engine in the normal way. Is the voltage indicated greater than approximately 10 Volts? a. YES – Battery is okay. Possible fault in the charging or starting system. For additional information, refer to DIAGNOSING AND TESTING – CHARGING SYSTEM, PAGE J09–01–5 or DIAGNOSING AND TESTING – STARTING SYSTEM in this section. b. NO – Continue to step 8.

J09–01–9

ELECTRICS 8. Carry out a Load test on the battery. For additional information, refer to LOAD TEST THE BATTERY, in this section. Is the voltage indicated greater than 10 Volts? a. YES – Battery is okay. Possible fault in the charging or starting system. For additional information, refer to DIAGNOSING AND TESTING – CHARGING SYSTEM, PAGE J09–01–5 or DIAGNOSING AND TESTING – STARTING SYSTEM in this section. b. NO – Replace the battery.

J09–01–10

ELECTRICS REMOVAL AND INSTALLATION — BATTERY (SINGLE)

BHJ0901RA

Operation: Removing and Installing the Battery (Single) None

Job Code: 09 03 13 xx Standard tools

Removal

1. Isolate the battery ground cable. For additional information, refer to BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Disconnect the battery ground cable (1). 3. Disconnect the battery positive cable (2). 4. Loosen the battery clamp retaining nuts (3) and remove the clamp assembly.

TV040003

5. Detach the wiring harness (1) and position to one side. 6. Detach the fuse box (2). 7. Remove the battery.

TV040004

J09–01–11

ELECTRICS Installation

•

•

Warning: A spark or naked flame can cause the hydrogen in a battery to explode. To avoid all risk of explosion, follow these instructions: Turn the battery master switch key to the “OFF” position (circuit disconnected). When disconnecting the battery cable(s), always disconnect the negative (-) cable first. To reconnect the battery cables, always connect the positive (+) cable(s) first. Never use metal parts to short circuit the terminals of a battery. Do not weld, grind or smoke near a battery. Caution: Use hot water to remove all evidence of corrosion from battery terminal post and connections, then smear with petroleum jelly or other non acid grease.

1. To install, reverse the removal procedure.

J09–01–12

ELECTRICS REMOVAL AND INSTALLATION — BATTERY (TWIN)

BHJ0901RB

Operation: Removing and Installing the Battery (Twin) None

Job Code: 09 03 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Disconnect the battery positive and negative cables.

TV040431

3. Loosen the battery clamp retaining nuts and remove the clamp assembly.

TV040432

4. Remove the batteries.

TV040433

J09–01–13

ELECTRICS Installation

•

•

Warning: A spark or naked flame can cause the hydrogen in a battery to explode. To avoid all risk of explosion, follow these instructions: Turn the battery master switch key to the “OFF” position (circuit disconnected). When disconnecting the battery cables, always disconnect the negative (-) cable(s) first. To reconnect the battery cables, always connect the positive (+) cable(s) first. Never use metal parts to short circuit the terminals of a battery. Do not weld, grind or smoke near a battery. Caution: Use hot water to remove all evidence of corrosion from battery terminal post and connections, then smear with petroleum jelly or other non acid grease.

1. To install, reverse the removal procedure. 2. Tighten to 6Nm (4 lb.ft).

TV040431

J09–01–14

ELECTRICS REMOVAL AND INSTALLATION — STARTER MOTOR

BHJ0901RC

Operation: Removing and Installing the Starter Motor None

Job Code: 09 27 13 xx Standard tools

Removal

1. Isolate the battery ground cable. For additional information, refer to Section BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Open the hood. Note: • Make a note of the position of the electrical connectors to aid installation.

3. Disconnect the starter motor electrical connectors (1). 4. Remove the starter motor upper retaining bolt (2).

TV040005

5. Remove the two lower retaining bolts and remove the starter motor.

TV040006

Installation 1. To install, reverse the removal procedure.

J09–01–15

ELECTRICS 2. Tighten to 44Nm (32 lb.ft).

TV040006

3. Tighten (2) to 44Nm (32 lb.ft).

TV040005

J09–01–16

ELECTRICS REMOVAL AND INSTALLATION — STARTER MOTOR SOLENOID

BHJ0901RD

Operation: Removing and Installing the Starter Motor Solenoid None

Job Code: 09 26 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Remove the starter motor. For additional information, refer to STARTER MOTOR in this section. 3. Disconnect the starter motor feed wire (1) from the starter motor solenoid. 4. Remove the starter motor solenoid (2).

TV040019

Installation 1. To install, reverse the removal procedure. 2. Tighten (1) to 12Nm (9 lb.ft). 3. Tighten (2) to 6Nm (4 lb.ft).

TV040019

J09–01–17

ELECTRICS

Note: This page intentionally left blank.

J09–01–18

ELECTRICS REMOVAL AND INSTALLATION — ALTERNATOR

BHJ0901RE

Operation: Removing and Installing the Alternator None

Job Code: 09 02 13 xx Suitable belt tension tool, Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Remove the alternator shield (1). 3. Loosen the alternator drive belt adjustment bracket retaining bolt (2). 4. Remove the alternator drive belt adjustment bolt (3) and detach the alternator drive belts.

1 2 3

TV040031

Note: • Make a note of the electrical connector locations to aid installation. 5. Disconnect the alternator electrical connectors (1). 6. Remove the alternator (2).

2

1

TV040032

Installation 1. To install, reverse the removal procedure. 2. Using a suitable belt tension tool, adjust the belt tension. Note: • The belt tension should be checked at the centre of the longest part of the belt.

• •

New belt tension 535N (120 lb.ft). Used belt tension 355N (80 lb.ft).

J09–01–19

ELECTRICS 3. Tighten (2) to 78Nm (55 lb.ft).

1 2 3

TV040031

4. Tighten (2) to 22Nm (16 lb.ft).

2

1

TV040032

J09–01–20

ELECTRICS REMOVAL AND INSTALLATION — FRONT WIPER MOTOR

BHJ0901RF

Operation: Removing and Installing the Front Wiper Motor

Job Code: 09 32 13 xx

None

Standard tools

Removal

1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Note: • Note the position of the wiper arm.

2. Open the front wiper arm retaining nut cap (1). 3. Remove the front wiper arm retaining nut (2). 4. Remove the front wiper arm (3).

3

1

2

TV040045

5. Remove the front wiper motor spindle cover (1). 6. Remove the front wiper motor spindle retaining nut (2). 7. Remove the front wiper motor spindle seal (3).

3

1

TV040046

J09–01–21

2

ELECTRICS 8. Remove the rear window open position latch cover and headlining rear side clips.

TV040047

9. Detach the B pillar trim panel and position to one side.

TV040048

10. Remove the interior light (1). 11. Remove the sun visor retaining screw cover (2).

2

1 TV040049

12. Remove the sun visor retaining clips.

TV040050

J09–01–22

ELECTRICS Note: • Make sure excessive force is not applied to the headlining when lowering. 13. Remove the headlining front retaining clips and lower the front of the headlining.

TV040051

14. Disconnect the wiper motor electrical connector (1). 15. Remove the wiper motor retaining nut (2) and remove the front wiper motor.

2

1

TV040052

Installation

•

Caution: Do not operate the windscreen wiper on a dry windscreen. Failure to follow this instruction may result in damage to the wiper.

1. To install, reverse the removal procedure. 2. Check the range of movement and operation of the wiper.

J09–01–23

ELECTRICS

Note: This page intentionally left blank.

J09–01–24

ELECTRICS REMOVAL AND INSTALLATION — REAR WIPER MOTOR

BHJ0901RG

Operation: Removing and Installing the Rear Wiper Motor

Job Code: 09 32 13 xx

None

Standard tools

Removal

1. Isolate the battery ground cable. For additional information, refer to Section BATTERY ISOLATION, PAGE J09–01–33 in this section. Note: • Note the position of the rear wiper arm.

2. 3. 4. 5.

Open the wiper arm cap. Remove the rear wiper retaining nut (1). Remove the rear wiper arm and spindle cover (2). Remove the rear wiper arm spindle retaining nut and seal (3). 6. Remove the rear wiper motor retaining nut and seal (4).

1

3 TV040036

7. Remove the rear wiper motor cover.

TV040037

J09–01–25

2

4

ELECTRICS 8. Disconnect the rear wiper motor electrical connector and remove the rear wiper motor.

TV040038

Installation Do not operate the windscreen wiper on a dry windscreen. Failure to follow this instruction may result in damage to the wiper. 1. To install, reverse the removal procedure. 2. Check the range of the movement and operation of the wiper.

J09–01–26

ELECTRICS REMOVAL AND INSTALLATION — INDICATOR SWITCH

BHJ0901RH

Operation: Removing and Installing the Indicator Switch None

Job Code: 09 38 13 xx Suitable steering wheel puller, Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to BATTERY ISOLATION, PAGE J09–01–33 in this section. 2. Remove the steering wheel centre cap.

TV040190

3. Remove the steering wheel retaining nut.

TV040191

4. Using a suitable steering wheel puller, remove the steering wheel.

TV040649

J09–01–27

ELECTRICS 5. Detach the front instrument panel trim covers.

TV040193

6. Detach the turn signal stalk.

TV040618

7. Disconnect the turn signal stalk electrical connectors and remove the turn signal stalk.

TV040617

Installation 1. To install, reverse the removal procedure. 2. Tighten to 58Nm (43 lb.ft).

TV040191

J09–01–28

ELECTRICS REMOVAL AND INSTALLATION — FORWARD/REVERSE SWITCH

BHJ0901RJ

Operation: Removing and Installing the Forward/Reverse Switch None

Job Code: 09 30 13 xx Suitable steering wheel puller, Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to BATTERY ISOLATION, PAGE J09–01–29 in this section. 2. Remove the steering wheel centre cap.

TV040190

3. Remove the steering wheel retaining nut.

TV040191

4. Using a suitable steering wheel puller, remove the steering wheel.

TV040649

J09–01–29

ELECTRICS 5. Detach the front instrument panel trim covers.

TV040193

6. Remove the shuttle lever bracket retaining bolts.

TV040640

7. Disconnect the shuttle lever electrical connector (1). 8. Detach the shuttle lever and bracket (2) from the instrument shroud.

2

2 1 TV040641

9. Remove the shuttle lever.

TV040642

J09–01–30

ELECTRICS Installation 1. To install, reverse the removal procedure. 2. Tighten to 28Nm (21 lb.ft).

TV040640

3. Tighten (2) to 28Nm (21 lb.ft).

2

2 1 TV040641

4. Tighten to 58Nm (43 lb.ft).

TV040191

J09–01–31

ELECTRICS

Note: This page intentionally left blank.

J09–01–32

ELECTRICS GENERAL PROCEDURE — BATTERY ISOLATION

BHJ0901GA

Isolation

•

•

•

Warning: Batteries normally produce explosive gases which may cause personal injury, therefore do not allow flames, sparks or lighted substances to come near the battery. When charging or working near the battery always shield your face and protect your eyes. Always provide adequate ventilation. Failure to follow these instructions may result in personal injury. Warning: Batteries contain sulphuric acid, avoid contact with skin eyes or clothing. Shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with the skin or eyes, flush immediately for a minimum of 15 minutes and seek prompt medical attention. If swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury. Caution: Make sure the engine is not running before isolating the battery ground cable in order to avoid damage to the vehicle electrical system.

1. Open the battery cover.

TV040001

J09–01–33

ELECTRICS 2. Rotate the battery isolator key counterclockwise and remove.

TV040002

J09–01–34

ELECTRICS GENERAL PROCEDURE — BATTERY CHARGING

BHJ0901GB

Special Tools Battery charger — For slow and standard charging it is necessary to use a constant current type, with an output of at least 14 amps and an upper voltage limit of 50 volts per battery. (A constant voltage charger limited to 16 volts will not recover a battery with an open circuit voltage below 11 volts). For fast charging, an output of 35 amps is required. Digital voltmeter — with a precision of 0.2% or better and reading to two decimal places, over the range 0 to 19 volts. High-rate discharge tester — with a capacity of at least 500 amps. Thermometer — covering the range of −10°C to 110°C (14°F to 230°F).

General Description The machines are equipped with a single or twin batteries. In temperate climates no maintenance will be needed throughout the life of the battery, unless a charging system fault develops, which may cause some water loss. In hot climates there will be some water loss. It is therefore good practice to check the electrolyte level every 250 hours. Twin

Single

Cold Cranking Performance (CCA) (amps) — SAE

590

825

Cold Starting Performance (CCA) (amps) — IEC

420

590

Reserve Capacity (Rc) (minutes)

130

200

Ampere Hour Capacity

72

115

Standard Charge Rate (amps)

9

14

Pre-delivery Inspection

Stock Machines

—

Due to the frequent starts, but with little work, the batteries on stock machines will become discharged more quickly. Therefore, check the open circuit voltage every 2 weeks. For additional information, refer to DIAGNOSING AND TESTING – BATTERY, PAGE J09–01–7 in this section. If the voltage measures 12.3 volts or less, recharge the battery. For additional information, refer to STANDARD CHARGING OF THE BATTERY in this section.

—

Test the open circuit voltage, For additional information, refer to DIAGNOSING AND TESTING – BATTERY in this section. This precaution is very important when there is a long shipment/port handling time. If the voltage is above 12.5 volts the battery is good. If the voltage is below 12.5 volts, recharge the battery, according to the state of the battery. For additional information, refer to STANDARD CHARGING OF THE BATTERY in this section

Quiescent Current Drain The machines, ex-factory, have no permanently live circuits and should have zero quiescent current drain,

J09–01–35

ELECTRICS when the key-switch is off and all lights are switched off. It should be noted that permanently live accessories fitted by the dealer, such as a clock or theft alarm system, will place a quiescent drain on the battery.

Typically the quiescent drain will be in the range of 10–20 mA. If the quiescent drain measures 40 mA or more, there is a problem with the wiring insulation or the accessories, which must be cured.

J09–01–36

ELECTRICS Battery Safety

•

•

•

• • • • • •

Warning: NEVER add electrolyte to an already charged battery.

•

Antidote:

Warning: Sparks can fly from electrical system or the engine. Before you operate this machine in an area which may contain inflammable vapour, completely ventilate the area. Warning: A spark or naked flame can cause the hydrogen in a battery to explode. To avoid all risk of explosion, follow these instructions: Turn the isolator to the “OFF” position (circuit disconnected). When disconnecting the battery cables, always disconnect the negative (-) cable first. To reconnect the battery cables, always connect the negative (-) cables last. Never use metal parts to short circuit the terminals of a battery. Do not weld, grind or smoke near a battery. Warning: A battery produces explosive gases. Keep all flames, sparks and cigarettes away. Provide adequate ventilation when charging the battery or when using it in an enclosed space. Always wear eye protection and protective clothing when working on or near a battery.

Warning: Battery acid causes severe burns. The battery contains sulphuric acid. Avoid contact with skin, eyes or clothing. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, a beaten egg or vegetable oil. Do not give fluids that induce vomiting. Call a doctor immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

•

•

•

Warning: When the battery electrolyte is frozen, the battery can explode if you try to charge the battery or try to jump start and run the engine using another battery. To prevent battery electrolyte from freezing, keep the battery at full charge. Caution: Always connect/disconnect leads to/from the battery while the charger is switched off. Caution: If the battery temperature rises to 60°C (140°F) stop the charging process and allow the battery to cool.

•

Caution: Always measure battery temperature in the centre cell.

•

Caution: Always place a damp cloth over the vent covers when charging a battery.

•

J09–01–37

Caution: Use hot water to remove all evidence of corrosion from battery terminal post and connections, then smear with petroleum jelly or other non-acid grease.

ELECTRICS Battery inspection before test or charge Reject the battery if: 1. The electrolyte is excessively low. 2. Electrolyte levels vary by more than 20 mm (0.8 in) between cells. 3. Battery case, lid or mountings are cracked or damaged. 4. Terminals are damaged or loose in the case.

Slow charging of the battery

•

•

Caution: Use a battery charger of constant current type with an output of at least 14A and an upper voltage limit of 50V per battery. Caution: Parallel charging is not recommended, therefore on machines fitted with twin batteries, charge each one individually.

1. Remove the battery from the machine. For additional information, refer to BATTERY (SINGLE), PAGE J09–01–11 or BATTERY (TWIN), PAGE J09–01–13 in this section. 2. If a battery has been neglected and produces an open circuit voltage of 11V or less, it will be completely discharged and the plates will have suffered sulphation. Initially the battery will draw higher than normal voltage but lower than specified current. CURRENT FOR SINGLE BATTERY

9A

CURRENT FOR TWIN BATTERY

14A

3. Connect the battery charger to the battery. Make sure the polarity of the connections is correct and connect the (+) positive connection first. 4. After 30 minutes, check the charging voltage (the charging current may still be lower than specified). Below 12V reject the battery. Above 16V reject the battery. Between 12V and 16V, continue with charging process for 15 hours.

•

Warning: Check the battery temperature regularly and if it reaches 60°C (140°F) stop the charging process.

5. Set the battery charger to OFF. Disconnect the cables from the battery. Make sure you disconnect the (-) negative cable first. 6. Allow the battery to stand for 24 hours. 7. Load test the battery. For additional information, refer to DIAGNOSING AND TESTING – BATTERY, PAGE J09–01–7 in this section.

J09–01–38

ELECTRICS Standard charging of the battery

•

•

Caution: Use a battery charger of constant current type with an output of at least 14A. Caution: Parallel charging is not recommended, therefore on machines fitted with twin batteries, charge each one individually.

1. Remove the battery from the machine. For additional information, refer to BATTERY (SINGLE), PAGE J09–01–11 or BATTERY (TWIN), PAGE J09–01–13 in this section.

•

Caution: Do not use the standard charge process on a battery producing an open circuit voltage of 11V or less.

2. Connect the battery charger to the battery. Make sure the polarity of the connections is correct and connect the (+) positive cable first. 3. Set the battery charger to ON. 4. Set the appropriate charger current: CURRENT FOR SINGLE BATTERY

9A

CURRENT FOR TWIN BATTERY

14A

5. Charge the battery for the time indicated in the table below: MINIMUM charging period Open circuit volts

Charge period (hours)

Above 12.5

0

12.4

3

12.3

4

12.2

5

12.1

6

12.0

7

11.9

8

11.8

9

11.7

10

11.6

11

11.0 to 11.6

12

Below 11.0

Use slow charge

•

Warning: Check the battery temperature regularly and if it reaches 60°C (140°F), stop the charging process.

6. Set the battery charger to OFF. Disconnect the cables from the battery. Make sure you disconnect the (-) negative cable first.

J09–01–39

ELECTRICS 7. Load test the battery. For additional information, refer to DIAGNOSING AND TESTING – BATTERY, PAGE J09–01–7 in this section.

Fast charging of the battery

•

•

•

Caution: Use a battery charger of constant current type with an output of at least 35A. Caution: Parallel charging is not recommended, therefore on machines fitted with twin batteries, charge each one individually. Caution: The standard charge should always be used in preference to the fast charge procedure.

1. Remove the battery from the machine. For additional information, refer to BATTERY (SINGLE), PAGE J09–01–11 or BATTERY (TWIN), PAGE J09–01–13 in this section.

•

Caution: Never use the fast charge procedure for batteries producing an open circuit voltage of 11V or less.

2. Connect the battery charger to the battery. Make sure the polarity of the connections is correct and connect the (+) positive cable first. 3. Set the battery charger to ON. 4. Set the appropriate charger current: CURRENT FOR SINGLE BATTERY

9A

CURRENT FOR TWIN BATTERY

14A

5. Charge the battery for the time indicated in the table below:

J09–01–40

ELECTRICS MAXIMUM charging period Open circuit volts

Charge period (hours)

Above 12.5

0

12.4

0.25

12.3

0.5

12.2

0.75

12.1

1.0

12.0

1.25

11.9

1.5

11.8

1.75

11.7

2.0

11.6

2,25

11.0 to 11.6

2.5

Below 11.0

Use slow charge

•

•

Warning: Check the battery temperature frequently as the high charging current can cause a rapid rise in temperature. Stop the charging process if the temperature reaches 60°C (140°F). Caution: To avoid deterioration of the battery, do not exceed the charging time specified in the table.

6. Set the battery charger to OFF. Disconnect the cables from the battery. Make sure you disconnect the (-) negative cable first. 7. Load test the battery. For additional information, refer to DIAGNOSING AND TESTING – BATTERY, PAGE J09–01–7 in this section. Voltage above 10V — Install the battery. Voltage below 10V — charge battery using the standard charge procedure.

Boost charging of the battery

•

•

•

Caution: Use a battery charger with an output of 60A. Caution: Boost charging is not recommended. Boost charging may be carried out but the current must be limited to 60A. Caution: Parallel charging is not recommended, therefore on machines fitted with twin batteries, charge each one individually.

1. Remove the battery from the machine. For additional information, refer to BATTERY (SINGLE), PAGE J09–01–11 or BATTERY (TWIN), PAGE J09–01–13 in this section. 2. Remove the vent manifolds from the battery.

J09–01–41

ELECTRICS 3. Connect the battery charger to the battery. Make sure the polarity of the connections is correct and connect the (+) positive cable first. 4. Set the battery charger to ON. 5. Limit the battery charge to the minimum period required for the battery to start the engine.

•

Warning: Check the battery temperature frequently as the high charging current can cause a rapid rise in temperature. Stop the charging process if the temperature reaches 60°C (140°F).

6. Set the battery charger to OFF. Disconnect the cables from the battery. Make sure you disconnect the (-) negative cable first. 7. Install the vent manifolds on the battery.

J09–01–42

ELECTRICS SPECIFICATIONS — ELECTRICS

BHJ0901SA

General Information System Voltage

12V Negative Ground

Battery Capacity (Single)

105Ah

Battery Capacity (Double)

70Ah

Alternator

14V

Make

Denso

Type

A115i 75A

Capacity (Without Air Con)

2871A302

Perkins P/N

100A

Capacity (With Air Con)

2871A304

Perkins (P/N) Starter Motor Make

Denso

Type

P95RL

Power

3kW Hydraulic Control Valve

Clamp Solenoid Resistance

7.6Ω at 20°C

J09–01–43

ELECTRICS Torque Values Description

Nm

Lb.ft

Battery Terminals

6

4

Battery Isolation Switch Retaining Bolts

6

4

Battery Clamp

6

4

Alternator Retaining Bolt

22

16

Starter Motor Retaining Bolts

44

32

Solenoid Main ’BAT’ Terminal M8 Stud

6

4

Cable Fixing Nut M10 Stud

12

9

Solenoid Terminal M10 Stud

12

9

Solenoid Terminal M8 Nut

6

4

Starter Terminal 1/4 BSF Nut

4

3

Solenoid End-Cover Screws

2

1

Solenoid Unit Screws

6

4

Brush-Plate Screws

7

5

Starter Earth Nuts

8

6

Poles Shoes Fixing Screws

41

30

Through Bolts

11

8

Eccentric Pivot Pin Lock-Nut

20

15

Steering Wheel Retaining Bolt

58

43

Shuttle Lever Bracket Retaining Bolts

28

21

Shuttle Lever Bracket Retaining Bolts

28

21

Alternator Terminal ’W’

2

1

Alternator Terminal ’D+’

4

3

Alternator Terminal ’B+’

4

3

Alternator Pulley Nut

80

59

J09–01–44

ELECTRICS GENERAL ELECTRICAL INFORMATION

BHJ0902TA

PAGE

TITLE

4

Schematic symbols

4

Harness numbering

4

Wire Colour table

5

Codes and keys

5

Abbreviations

6

Fuse (F) identification numbers

7

Relay (K) identification numbers

8

Fuse and relay board layout

9

Fuse board connector J1

10

Fuse board connector J1 (Powershift)

11

Fuse board connector J2

12

Fuse board connector J3

13

Fuse board connector J4

14

Fuse board connector J4 (ROPS)

16

Fuse board connector J5A

17

Fuse board connector J5B

18

Fuse board connector J6A

19

Fuse board connector J6A (ROPS)

20

Fuse board connector J6B

21

Fuse board connector J6B (ROPS)

22

Fuse board connector J7

23

Fuse board connector J8

24

Fuse board connector J8 (Powershift)

25

Fuse board connector J9

26

Fuse board connector J9 (Powershift)

27

Fuse board Connector J10

28

Fuse board Connector J11

29

Fuse board connector J16

30

Transmission controller connector 213

31

Transmission controller connector 214

33

Component locations — front console instrument panel and controls

36

Component locations — side console instruments and controls

41

Component locations – ROPS side console instruments and controls

44

Wiring diagram — power supply Synchroshuttle

46

Wiring diagram – power supply Powershift

48

Wiring diagram — engine

50

Wiring diagram — transmission Synchroshuttle

52

Wiring diagram – transmission Powershift

J09–02–1

ELECTRICS PAGE

TITLE

54

Wiring diagram — 4WD differential lock Synchroshuttle

56

Wiring diagram — 4WD differential lock Powershift

58

Wiring diagram — steer mode (4WS)

60

Wiring diagram — front console panel Synchroshuttle

62

Wiring diagram — front console panel Powershift

64

Wiring diagram — side console panel

66

Wiring diagram — illumination front

68

Wiring diagram — illumination rear

70

Wiring diagram — direction indicators with cabin

72

Wiring diagrams — direction indicators without cabin (ROPS)

74

Wiring diagram — optional roof rear lights (ROPS)

76

Wiring diagram — worklights with cabin

78

Wiring diagram — worklights without cabin (ROPS)

80

Wiring diagram — warning functions with cabin

82

Wiring diagrams — warning functions without cabin (ROPS)

84

Wiring diagram — wiper washer

86

Wiring diagram — interior illumination switch pack

88

Wiring diagram — heating and air conditioning

90

Wiring diagram — ride control and hose burst

92

Wiring diagram — loader, return to dig with cabin

94

Wiring diagram — loader, return to dig without cabin (ROPS)

96

Wiring diagram — quick attach and change over with cabin

98

Wiring diagram — quick attach and change over without cabin (ROPS)

100

Connector locations — chassis harness Synchroshuttle

106

Connector locations — chassis harness Powershift and four wheel steer

112

Connector locations — engine harness

116

Connector locations — front console cabin lower harness

118

Connector locations — side console ignition harness

120

Connector locations — ROPS side console ignition harness

122

Connector locations — cabin upper harness

124

Connector locations — ROPS cabin upper harness

126

Connector locations — Battery harness

128

Component lists

J09–02–2

ELECTRICS SCHEMATICS SYMBOLS A (n)

Fuse and Relay board / Radio / Transmission controller

B (n)

Pressure switches / Sensors / Proximity switches

E (n)

Lighting components

F (n)

Fuses

G (n)

Electrical supply generators

H (n)

Warning devices

J (n)

Connectors

K (n)

Relays

M (n)

Motors

P (n)

Instruments

R (n)

Heating elements/heater plugs

S (n)

Switches/master switch

V (n)

Diodes

X (n)

Supply line connections

Y (n)

Solenoid valves/solenoids/lift pump

Note: • (n) Indicates the component number. Example: K2 stands for relay No. 2 HARNESS NUMBERING UC

Cabin upper harness

Connector No. C100 — C199

LC

Cabin lower harness

Connector No. C200 — C299

IG

Ignition harness

Connector No. C300 — C399

CH

Chassis harness

Connector No. C400 — C499

EN

Engine harness

Connector No. C500 — C599

4WS

Four wheel steer

Connector No. C600 — C699

WIRE COLOUR TABLE Symbol

B

W

N

K

G

O

R

Colour

Black

White

Brown

Pink

Green

Orange

Red

Symbol

Y

U

LG

P

S

Colour

Yellow

Blue

Light green

Purple

Slate

Note: • B/W indicates that the wire is black, striped by white

•

J09–02–3

Caution: Ensure that the ignition key is “Off” when disconnecting and re-connecting connectors.

ELECTRICS CODES AND KEYS The terms, Left hand, Right hand, Rear and Front used in this electrical section are sides of the machine as seen from the Operator’s seat in the position below.

1. 2. 3. 4.

Front Right hand Rear Left hand

*

Indicates other model variation

**

Indicates model specific

(Optional)

Indicates optional fit

ABBREVIATIONS ROPS

Roll Over Protection System

4WS

Four Wheel Steer

4WB

Four Wheel Braking

TC

Transmission Controller

Diff

Differential

FWD

Forward

REV

Reverse

Synchroshuttle

Synchronizer Mechanical Shift

Powershift

Automatic

J09–02–4

ELECTRICS FUSE AND RELAY INFORMATION

BHJ0902TB

FUSE (F) IDENTIFICATION NUMBERS Make sure when replacing a fuse the correct approved standard is used (DIN. 7.2581) F1

7.5A

Left hand main headlight

F2

7.5A

Right hand main headlight

F3

7.5A

Left hand dip headlight

F4

7.5A

Right hand dip headlight

F5

3A

Left hand side light / Number Plate light

F6

3A

Right hand side light

F7

5A

Indicator light

F8

10A

Hazard light

F9

15A

Front worklight

F10

15A

Front worklight

F11

15A

Rear worklight

F12

15A

Rear worklight

F13

15A

Rotating beacons

F14

3A

Left hand brake light

F15

3A

Right hand brake light

F16

3A

Instrument pack illumination

F17

7.5A

Differential lock / 4WD

F18

7.5A

Clamp / Quick attach / Quick attach loader

F19

5A

Return to dig / Un-loader valve

F20

15A

Front wiper / Rear wiper / Front washer / Rear washer

F21

7.5A

Interior light / Radio

F22

10A

Front / Rear horn

F23

10A

Ride control solenoid

F24

5A

Forward / Reverse solenoid (Synchroshuttle)

F25

7.5A

Fuel solenoid / Enrichment solenoid

F26

10A

Four wheel steer / Crab solenoid

F27

7.5A

Air conditioning switch

F28

15A

Cigar lighter / Fuel lift pump

F29

25A

Heater

F30

10A

Switch pack & illumination pack — Ignition

F31

3A

Switch pack & illumination pack — Battery

F32

5A

Battery relay coils

F33

5A

Ignition relay coils

F34

7.5A

Powershift supply

F35

10A

Spare battery supply

F36

10A

Spare ignition supply

F40

80A

Ignition cabin

F41

20A

Ignition switch

F42

40A

Starter relay

J09–02–5

ELECTRICS F43

80A

Fuse and relay board

N/A

80A

Mega fuse

RELAY (K) OR (RL)IDENTIFICATION NUMBERS K1

RL1

Main headlight relay

K2

RL2

Dip headlight relay

K3

RL3

Side lights / Number plate / Illumination pack relay

K4

RL4

Brake light relay

K5

RL5

Hazard relay

K6

RL6

Hazard enable relay

K7

RL7

Front wiper relay

K8

RL8

Rear wiper relay

K9

RL9

Front washer relay

K10

RL10

Rear washer relay

K11

RL11

Front / Rear horn relay

K12

RL12

Indicators flasher unit

K13

RL13

Front worklight relay

K14

RL14

Rear worklight relay

K15

RL15

Rotating beacon relay

K16

RL16

Float enable relay

K17

RL17

Clamp relay

K18

RL18

Digger quick attach relay

K19

RL19

Return to dig relay

K20

RL20

Un-loader relay

K21

RL21

Loader quick attach relay

K22

RL22

Ride control solenoid relay

K23

RL23

Forward relay (Synchroshuttle)

K24

RL24

Reverse relay (Synchroshuttle)

K25

RL25

Four wheel drive (4WD) relay (Synchroshuttle)

K26

RL26

Hose burst relay

K27

RL27

Neutral start relay (Synchroshuttle)

K28

RL28

Ignition relay

K29

RL29

Start relay

K30

RL30

Glow plug relay

K31

RL31

Fuel pump relay

K32

RL32

Auxiliary relay

K33

RL33

4WS relay board

J09–02–6

ELECTRICS FUSE AND RELAY BOARD LAYOUT

TV041129

J09–02–7

ELECTRICS

Note: This page intentionally left blank.

J09–02–8

ELECTRICS CONNECTOR INFORMATION

BHJ0902TC

FUSE BOARD CONNECTOR J1 (SYNCHROSHUTTLE) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

R/O

0.35

Side light switch

C209 — pin 4

2

G/R

0.5

Left hand indicator switch

C208 — pin 2

3

G/W

0.5

Right hand indicator switch

C208 — pin 3

4

P/Y

0.35

Horn switch

C208 — pin 5

5

LG

0.5

Indicator common (+)

C208 — pin 15

6

N/W

0.5

Neutral switch

C211 — pin 2

7

U

0.5

Forward (FWD) switch

C211 — pin 1

8

Y/W

0.5

Reverse (REV) switch

C211 — pin 3

9

B

0.5

FWD/REV switch common ground

C211 — pin 4

10

B

0.35 0.35 0.5

Ground

C208 — pin 4 C209 — pin 3 C212 — pin 3

11

LG/B

0.35

Front washer switch

C205 — pin 2

12

O/B

0.35

Front wiper switch

C205 — pin 4

13

R/G

0.35

Front drive axle switch (4WD)

C205 — pin 6

14

Y/O

0.35

Ride control switch

C205 — pin 8

15

O/N

0.35

Quick Attach switch

C205 — pin 9

16

U/K

0.35

Dipped beam switch

C209 — pin 2

17

G

0.5

Ignition (+)

C205 — pin 1

18

LG

0.35

Illumination (+)

C205 — pin 7

19

U/W

0.35

Main beam switch

C209 — pin 1

20

B

0.5

Ground

C205 — pin 5

J09–02–9

ELECTRICS FUSE BOARD CONNECTOR J1 (POWERSHIFT) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

R/O

0.35

Side light switch

C209 — pin 4

2

G/R

0.5

Left hand indicator switch

C208 — pin 2

3

G/W

0.5

Right hand indicator switch

C208 — pin 3

4

P/Y

0.35

Horn switch

C208 — pin 5

5

LG

0.5

Indicator common (+)

C208 — pin 1

6

N/W

0.35

Neutral switch

C211 — pin 6

7

—

—

Not used

—

8

Y/W

0.35

Reverse (REV) switch

C216 — pin 5

9

B

0.35

FWD/REV switch common ground

C216 — pin 8

10

B

0.35 0.35 0.5

Ground

C208 — pin 4 C209 — pin 3 C212 — pin 3

11

LG/B

0.35

Front washer switch

C205 — pin 2

12

O/B

0.35

Front wiper switch

C205 — pin 4

13

R/G

0.35

Front drive axle switch (4WD)

C205 — pin 6 C214 — pin 16 C212 — pin 3

14

Y/O

0.35

Ride control switch

C205 — pin 8

15

O/N

0.35

Quick Attach switch

C205 — pin 9

16

U/K

0.35

Dipped beam switch

C209 — pin 2

17

G

0.5

Ignition (+)

C205 — pin 1

18

LG

0.35

Illumination (+)

C205 — pin 7

19

U/W

0.35

Main beam switch

C209 — pin 1

20

B

0.5

Auxiliary relay ground

C205 — pin 5

J09–02–10

ELECTRICS FUSE BOARD CONNECTOR J2 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

G/R

0.5

Left hand indicator light

C206 — pin 3

2

U/W

1.0

Left hand main beam light

C206 — pin 6

3

U/W

1.0

Right hand main beam light

C207 — pin 6

4

U/K

1.0

Right hand dipped beam light

C207 — pin 1

5

U/K

1.0

Left hand dipped beam light

C206 — pin 1

6

R/W

0.5

Right hand side light

C207 — pin 2

7

R/B

0.5

Left hand side light

C206 — pin 2

8

G/W

0.5

Right hand indicator light

C207 — pin 3

9

B

2.0

Right hand common ground

C207 — pin 4

10

B

2.0

Left hand common ground

C206 — pin 4

11

—

—

Not used

—

12

—

—

Not used

—

J09–02–11

ELECTRICS FUSE BOARD CONNECTOR J3 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

W/B

0.5

Differential lock switch (+)

C203 — pin 1

2

K/U

0.35

Engine fault

C210 — pin 14

3

K/R

0.35

Bucket float indicator lamp

C210 — pin 12

4

N/K

0.35

Battery (+)

C210 — pin 4

5

G/P

0.5

Brake switch (+)

C204 — pin b C212 — pin 2

6

B

0.5

Differential lock switch (-)

C203 — pin 1

7

B/Y

0.5

Speedo (+)

C210 — pin 2

8

B

0.5

Ground

C210 — pin 20

9

B/O

0.35

Brake pressure warning lamp

C210 — pin 6

10

G

0.5

Ignition supply

C210 — pin 1

11

LG/K

0.35

Indicator / Hazard warning lamp

C210 — pin 10

12

B/W

0.35

Speedo (-)

C210 — pin 3

13

S/B

0.35

Neutral position indicator lamp

C210 — pin 13

14

LG

0.35

Side light indicator lamp

C210 — pin 18

15

U/W

0.35

Main beam warning lamp

C210 — pin 11

16

B

0.5

Brake switch (-)

C204 — pin a

J09–02–12

ELECTRICS FUSE BOARD CONNECTOR J4 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

P/LG

0.5

Return to dig switch

C310 — pin 4

2

O/U

0.5

Backhoe quick attach switch

C310 — pin 5

3

—

—

Not used

—

4

O/P

0.5

Unloader switch

C319 — pin 2

5

P/Y

0.5

Horn switch

C310 — pin 15

6

—

—

Not used

—

7

—

—

Not used

—

8

—

—

Not used

—

9

R

0.5

Battery (+)

C310 — pin 6

10

—

—

Not used

—

11

G

0.5

Ignition supply

C310 — pin 8

12

LG/Y

0.5

Rear washer switch

C310 — pin 12

13

LG

0.5

Side console illumination

C310 — pin 16

14

U/G

0.5

Front worklight switch

C310 — pin 1

15

P/K

0.5

Beacon switch

C310 — pin 9

16

G/N

0.5

Rear worklight switch

C310 — pin 10

17

O/B

0.5

Rear wiper switch

C310 — pin 11

18

LG/K

0.5

Hazard switch

C310 — pin 2

19

K/B

0.5

Sideshift clamp switch

C310 — pin 3

20

B

0.5

Ground

C310 — pin 7

J09–02–13

ELECTRICS FUSE BOARD CONNECTOR J4 ROPS Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

P/LG

0.5

Return to dig switch

C317 — pin 2

2

O/U

0.5

Backhoe quick attach switch

C326 — pin 2

3

LG/K

0.5

Hazard switch illumination

C316 — pin 1

4

O/P

0.5

Unloader switch

C310 — pin 14

5

P/Y

0.5

Horn switch

C325 — pin a

6

—

—

Not used

—

7

—

—

Not used

—

8

—

—

Not used

—

9

—

—

Not used

—

10

B

0.5

Ground

C312 C314 C322 C324 C318 C320 C315 C327

— — — — — — — —

pin pin pin pin pin pin pin pin

2 2 2 2 2 2 6 2

C312 C314 C322 C324 C318 C320 C327

— — — — — — —

pin pin pin pin pin pin pin

1 1 1 1 1 1 1

11

G

0.5

Switch illumination supply

12

—

—

Not used

—

13

—

—

Not used

—

14

U/G

0.5

Front worklight switch

C311 — pin 2

15

P/K

0.5

Beacon switch

C313 — pin 2

16

G/N

0.5

Rear worklight switch

C323 — pin 2

17

—

—

Not used

—

18

LG/K

0.5

Hazard switch

C315 — pin 1

19

K/B

0.5

Centermount / Sideshift switch

C321 — pin 2

20

B

0.5

Ground

J09–02–14

C311 C313 C321 C323 C317 C319 C315 C325 C326

— — — — — — — — —

pin pin pin pin pin pin pin pin pin

6 6 6 6 6 6 5 b 6

ELECTRICS

J09–02–15

ELECTRICS FUSE BOARD CONNECTOR J5A Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

G

1.0

Ignition relay

K28 — pin 6

2

Y/P

1.0

Reverse alarm (optional)

C409 — pin 1

3

G/W

1.0

Right hand rear indicators

C412 — pin 3

4

G/R

1.0

Left hand rear indicators

C415 — pin 3

5

K/B

1.0

Sideshift clamp

C411 — pin 1

6

P/Y

1.0

Rear horn (optional)

C410 — pin a

7

O/U

1.0

Bucket rear quick attach

C408 — pin 1

8

G/P

1.0

Left hand brake lamp (+)

C415 — pin 2

9

B

1.0

Right hand rear lamps common ground

C412 — pin 4

10

B

1.0

Rear horn (optional)

C410 — pin b

11

B

1.0

Reverse alarm (optional)

C409 — pin 2

12

R/W

1.0

Registration plate lights (+)

C413 — pin 1 C414 — pin 1

13

R/G

1.0

Right hand side rear light (-)

C412 — pin 1

14

B

1.0

Number plate lights (-)

C413 — pin 2

15

G/P

1.0

Right hand brake light (+)

C412 — pin 2

16

B

1.0

Registration plate lights (-)

C414 — pin 2

17

R/B

1.0

Left hand side light (+)

C415 — pin 1

18

B

1.0

Left hand rear lamps common ground

C415 — pin 4

J09–02–16

ELECTRICS FUSE BOARD CONNECTOR J5B Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

P/O

1.0

Return to dig solenoid (+)

C407 — pin 1

2

W/P

1.0

Differential lock solenoid (+)

C426 — pin 1

3

—

—

Not used

—

4

P/W

1.0

Return to dig switch

C431 — pin 2

5

B

1.0

Return to dig switch

C431 — pin 1

6

B

1.0

Return to dig solenoid (-)

C407 — pin 2

7

B

1.0

Sideshift clamp

C411 — pin 2

8

B

1.0

Bucket rear quick attach (optional)

C408 — pin 2

9

B

1.0

Ignition relay

K28 — pin 4

10

B

1.0

Differential lock solenoid (-)

C426 — pin 2

11

—

—

Not used

—

12

—

—

Not used

—

J09–02–17

ELECTRICS FUSE BOARD CONNECTOR J6A (CABIN) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

P/K

1.0

Front beacon

C112 — pin 1

2

B

1.0

Right hand rear worklight (outer)

C115 — pin 2

3

B

1.0

Right hand rear worklight (inner)

C116 — pin 2

4

O/LG

1.0

Rear wiper motor (park switch)

C108 — pin 3

5

O/Y

1.0

Rear wiper motor

C108— pin 2

6

O/G

1.0

Front wiper motor

C110 — pin 3

7

U/Y

1.0

Left hand front worklight

C117 — pin 3

8

U/Y

1.0

Right hand front worklight

C113 — pin 3

9

P/K

1.0

Rear beacon

C118 — pin 1

10

P/S

1.0

Left hand rear worklight (inner)

C120 — pin 1

11

P/S

1.0

Right hand rear worklight (inner)

C116 — pin 1

12

G/N

1.0

Left hand rear worklight (outer)

C121 — pin 1

13

G/N

1.0

Right hand rear worklight (outer)

C115 — pin 1

14

O/U

1.0

Rear wiper motor (park switch)

C108 — pin 1

15

O/R

1.0

Front wiper motor (park switch)

C110 — pin 2

16

O/B

1.0

Front wiper motor (park switch)

C110 — pin 1

17

U/G

1.0

Left hand front worklight

C117 — pin 1

18

U/G

1.0

Right hand front worklight

C113 — pin 1

J09–02–18

ELECTRICS FUSE BOARD CONNECTOR J6A (ROPS) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

P/K

1.0

Front beacon

C112 — pin 1

2

B

1.0

Right hand rear worklight (outer)

C115 — pin 2

3

B

1.0

Right hand rear worklight (inner)

C116 — pin 2

4

—

—

Not used

—

5

—

—

Not used

—

6

—

—

Not used

—

7

U/Y

1.0

Left hand front worklight

C117 — pin 3

8

U/Y

1.0

Right hand front worklight

C113 — pin 3

9

P/K

1.0

Rear beacon

C118 — pin 1

10

P/S

1.0

Right hand rear worklight (inner)

C116 — pin 1

11

P/S

1.0

Left hand rear worklight (inner)

C120 — pin 1

12

G/N

1.0

Right hand rear worklight (outer)

C115 — pin 1

13

G/N

1.0

Left hand rear worklight (outer)

C121 — pin 1

14

—

—

Not used

—

15

—

—

Not used

—

16

—

—

Not used

—

17

U/G

1.0

Left hand front worklight

C117 — pin 1

18

U/G

1.0

Right hand front worklight

C113 — pin 1

J09–02–19

ELECTRICS FUSE BOARD CONNECTOR J6B (CABIN) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

B

1.0

Rear beacon

C118 — pin 2

2

B

1.0

Front beacon

C112 — pin 2

3

B

1.0

Left hand rear worklight (outer)

C121 — pin 2

4

B

1.0

Left hand rear worklight (inner)

C120 — pin 2

5

B

2.0

Left hand front worklight

C117 — pin 2

6

B

2.0

Right hand front worklight

C113 — pin 2

7

B

1.0

Rear wiper motor (-)

C108 — pin 4

8

B

1.0

Front wiper motor (-)

C110 — pin 5

9

B

1.0

Radio (-)

C109 — pin b

10

B

1.0

Interior light (-)

C111 — pin b

11

R/K

1.0

Interior light (+)

C111 — pin a

12

R/P

1.0

Radio (+)

C109 — pin a

J09–02–20

ELECTRICS FUSE BOARD CONNECTOR J6B (ROPS) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

B

1.0

Rear beacon (-)

C118 — pin 2

2

B

1.0

Front beacon (-)

C112 — pin 2

3

B

1.0

Left hand rear worklight (outer)

C121 — pin 2

4

B

1.0

Left hand rear worklight (inner)

C120 — pin 2

5

B

2.0

Left hand front worklight

C117 — pin 2

6

B

2.0

Right hand front worklight

C113 — pin 2

7

—

—

Not used

—

8

—

—

Not used

—

9

—

—

Not used

—

10

—

—

Not used

—

11

—

—

Not used

—

12

—

—

Not used

—

J09–02–21

ELECTRICS FUSE BOARD CONNECTOR J7 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

G

0.5

Ignition

C308 — pin 1

2

N/K

0.5

Battery (+)

C308 — pin 4

3

R/U

0.5

Illumination

C308 — pin 18

4

B

0.5

Ground

C308 — pin 20

5

—

—

Not used

—

6

S

0.5

Engine fault lamp (link)

C308 — pin 17

7

—

—

Not used

—

8

—

—

Not used

—

J09–02–22

ELECTRICS FUSE BOARD CONNECTOR J8 (SYNCHROSHUTTLE) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

Y/O

1.0

Ride control solenoid (+) (optional)

C418 — pin 1

2

Y/O

1.0

Ride control solenoid (+) (optional)

C417 — pin 1

3

B

1.0

Ride control solenoid (-) (optional)

C418 — pin 2

4

U/S

1.0

Forward solenoid (+)

C425 — pin 2

5

B

1.0

Ride control solenoid (-) (optional)

C417 — pin 2

6

Y/P

1.0

Reverse solenoid (+)

C427 — pin 1

7

B

1.0

Forward solenoid (-)

C425 — pin 2

8

R/Y

1.0

Four wheel drive solenoid (+)

C428 — pin 1

9

B

1.0

Unloader valve solenoid (-)

C435 — pin 2

10

O/W

1.0

Unloader valve solenoid (+)

C435 — pin 1

11

B

1.0

Front horn (-)

C424 — b

12

P/Y

1.0

Front horn (+)

C424 — a

13

B

1.0

Loader quick attach (-) (optional)

C430 — pin 2

14

O/P

1.0

Loader quick attach (+) (optional)

C430 — pin 1

15

B

1.0

Front washer motor (-)

C422 — pin 2

16

LG/Y

1.0

Front washer motor (+)

C422 — pin 1

17

B

1.0

Rear washer motor (-)

C423 — pin 2

18

LG/B

1.0

Rear washer motor (+)

C423 — pin 1

19

B

1.0

Reverse solenoid (-)

C427 — pin 2

20

B

1.0

Four wheel drive solenoid (-)

C428 — pin 2

J09–02–23

ELECTRICS FUSE BOARD CONNECTOR J8 (POWERSHIFT) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

Y/O

1.0

Ride control solenoid (+) (optional)

C418 — pin 1

2

Y/O

1.0

Ride control solenoid (+) (optional)

C417 — pin 1

3

B

1.0

Ride control solenoid (-) (optional)

C418 — pin 2

4

—

—

Not used

—

5

B

1.0

Ride control solenoid (-) (optional)

C417 — pin 2

6

—

—

Not used

—

7

—

—

Not used

—

8

—

—

Not used

—

9

B

1.0

Unloader valve solenoid (-)

C435 — pin 2

10

O/W

1.0

Unloader valve solenoid (+)

C435 — pin 1

11

B

1.0

Front horn (-)

C424 — pin b

12

P/Y

1.0

Front horn (+)

C424 — pin a

13

B

1.0

Loader quick attach (-) (optional)

C430 — pin 2

14

O/P

1.0

Loader quick attach (+) (optional)

C430 — pin 1

15

B

1.0

Front washer motor (-)

C422 — pin 2

16

LG/Y

1.0

Front washer motor (+)

C422 — pin 1

17

B

1.0

Rear washer motor (-)

C423 — pin 2

18

LG/B

1.0

Rear washer motor (+)

C423 — pin 1

19

—

—

Not used

—

20

—

—

Not used

—

J09–02–24

ELECTRICS FUSE BOARD CONNECTOR J9 (SYNCHROSHUTTLE) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

Y/G

1.0

Transmission de-clutch switch gearlever (+)

C442 — pin 2

2

O/R

1.0

Unloader switch (+)

C416 — pin 1

3

Y/G

1.0

Transmission de-clutch switch loader lever (+)

C416 — pin 4

4

W/G

1.0

Starter relay

K29 — pin 2

5

B

1.0

Transmission de-clutch switch gearlever (-)

C442 — pin 1

6

B

1.0

Transmission de-clutch switch loader lever (-)

C416 — pin 3

7

B

1.0

Un-loader switch (-)

C416 — pin 2

8

—

—

Not used

—

9

B

1.0

Fuel shut-off (-)

C506 — pin 2

10

B/W

1.0

Speed sensor (optional)

C429 — pin 1

11

B/Y

1.0

Speed sensor (optional)

C429 — pin 2

12

N/O

1.0

Fuel shut-off (+)

C506 — pin 1

13

W/B

1.0

Hose burst float switch

C420 — pin 3

14

B/S

1.0

Fuel enrichment sensor

C508 — pin 1

15

Y/B

1.0

Hose burst harness

C420 — pin 2

16

R

1.0

Four wheel steer / Crab supply (+)

C405 — pin 1

17

P/B

1.0

Air conditioning switch (optional)

C210 — pin 11

18

B

1.0

Fuel lift pump (-)

C503 — pin 2

19

B

1.0

Hose burst harness (-)

C420 — pin 1

20

B

1.0

Four wheel steer / Crab ground (-)

C405 — pin 2

J09–02–25

ELECTRICS FUSE BOARD CONNECTOR J9 (POWERSHIFT) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

—

—

Not used

—

2

O/R

1.0

Unloader switch (+)

C416 — pin 1

3

Y/G

1.0

Transmission de-clutch switch wader lever (+)

C416 — pin 4

4

W/G

1.0

Starter relay

K29 — pin 2

5

—

—

Not used

—

6

B

1.0

Transmission de-clutch switch wader lever (-)

C416 — pin 3

7

B

1.0

Un-loader switch (-)

C416 — pin 2

8

—

—

Not used

—

9

B

1.0

Fuel shut-off (-)

C506 — pin 2

10

—

—

Not used

—

11

—

—

Not used

—

12

N/O

1.0

Fuel shut-off (+)

C506 — pin 1

13

W/B

1.0

Hose burst float switch

C420 — pin 3

14

B/S

1.0

Fuel enrichment sensor

508 — pin 1

15

Y/B

1.0

Hose burst harness

C420 — pin 2

16

R

1.0

Four wheel steer / Crab supply (+)

C405 — pin 1

17

P/B

1.0

Air conditioning switch (optional)

C210 — pin 11

18

B

1.0

Fuel lift pump (-)

C503 — pin 2

19

B

1.0

Hose burst harness

C420 — pin 1

20

B

1.0

Four wheel steer / Crab ground (-)

C405 — pin 2

J09–02–26

ELECTRICS FUSE BOARD CONNECTOR J10 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

—

—

Not used

—

2

K/O

1.0

Cigar lighter (+)

C305 — pin 1

3

R

1.0

Fuel lift pump relay (+)

K31 — pin 8

4

W

2.0

Ignition switch

C306 — pin 2

5

R

1.0

Change over valve (optional)

C304 — pin 1

6

B

1.0

Change over valve (optional) (-)

C304 — pin 2

7

B

1.0

Glow plug relay

K30 — pin 6

8

B

1.0

Auxiliary relay

K32 — pin 2

9

B

1.0

Fuel lift pump relay (-)

K31 — pin 4

10

B

2.0

Cigar lighter (-)

C305 — pin 2

11

—

—

Not used

—

12

—

—

Not used

—

J09–02–27

ELECTRICS FUSE BOARD CONNECTOR J11 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

G/U

2.5

Heater control switch

C105

2

—

—

Not used

—

3

P/R

1.0

Air conditioning thermostat

C106

4

P/G

1.0

Air conditioning thermostat

C101 — pin 3

5

B

2.5

Heater motor

C101 — pin 4

6

—

—

Not used

—

7

—

—

Not used

—

J09–02–28

ELECTRICS FUSE BOARD CONNECTOR J16 (POWERSHIFT) Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

1

R

1.0

Air seat pump supply

C217 — pin 2

2

—

—

Not used

—

3

G/R

0.5

Handbrake switch supply

C202 — pin b

4

G

1.0

Transmission control unit supply (+)

C214 — pin 1

5

B

1.0

Ground

C214 — pin 2

6

B

1.0

Ground

C213 — pin H

7

—

—

Not used

—

8

Y/G

1.0

Transmission de-clutch request

C214 — pin 17

J09–02–29

ELECTRICS TRANSMISSION CONTROLLER CONNECTOR 213 Pin No.

Colour

Wire Size

Function

To Connector / Pin No.

A

R/O xx

0.5

Speed sensor input

C214 — pin 21

B

G/Y

1.0

Forward Hi / Low selection solenoid

C214 — pin 5

C

U/S

1.0

Forward / Neutral selection solenoid

C214 — pin 6

D

O

1.0

1/2 selection solenoid

C214 — pin 4

E

R/Y

1.0

12v = All wheel drive / 0v = Rear wheel drive

c214 — pin 9

F

Y/P

1.0

Reverse / neutral selection solenoid

C214 — pin 7

G

B x

1.0

Direction modulation solenoid (-)

C214 — pin 3

H

B

1.0

Ground

J16 — pin 6

J

B xx

0.5

Sensor ground

C214 — pin 11

K

LG/S

1.0

Range modulation solenoid

C214 — pin 13

L

G/W xx

0.5

0 — 5K ohm temperature sensor

C214 — pin 18

M

R/S x

1.0

Supply range modulation / Direction modulation solenoid (+)

C214 — pin 22

xx = twisted together x = twisted pair

J09–02–30

ELECTRICS TRANSMISSION CONTROLLER CONNECTOR 214 Pin No.

Color

Wire Size

Function

To Connector / Pin No.

1

G xxx

1.0

12 volt supply

J16 — pin 4

2

B xxx

1.0

Ground

J16 — pin 5

3

B x

1.0

Direction modulation solenoid (-)

C213 — pin G

4

O

1.0

1/2 Selection solenoid

C213 — pin D

5

G/Y

1.0

Forward Hi / Low selection solenoid

C213 — pin B

6

U/S

1.0

Forward / Neutral selection solenoid

C213 — pin C

7

Y/P

1.0

Reverse / Neutral selection solenoid

C213 — pin F

8

S/W

0.5

Test probe RS232 receive input

C215 — pin 2

9

R/Y

1.0

12v = All wheel drive / 0V = Rear wheel drive

C213 — pin E

10

—

—

Not used

—

11

B xx

0.5

Sensor ground

C213 — pin J

12

U

0.5

Shift lever forward selection

C216 — pin 7

13

LG/S

1.0

Range modulation solenoid

C213 — pin K

14

O

0.5

Shift lever — forward hi / low switch

C216 — pin 3

15

G/Y

0.5

Shift lever 2 / 1 selection

C216 — pin 2

16

R/G

0.5

All wheel drive / Rear wheel drive selection

C212 — pin 3 C205 — pin 6 J1 — pin 13

17

Y/G

0.5

Transmission de-clutch request

J16 — pin 8

18

G/W xx

0.5

0 — 5 K ohm temperature sensor

C213 — pin L

19

Y/W

0.5

Shift lever reverse selection

J1 — pin 8

20

—

—

Not used

—

21

R/O xx

0.5

Speed sensor input

C213 — pin A

22

R/S x

1.0

Supply range modulation / Direction modulation solenoid (+)

C213 — pin M

23

—

—

Not used

—

24

—

—

Not used

—

25

B/Y

0.5

Speedometer signal

C210 — pin 2

26

B

0.5

Shift lever kick-down selection

C216 — pin 4

27

—

—

Not used

—

28

S/Y

0.5

Test probe RS232 transmit output

C215 — pin 3

xxx = twisted pair xx = twisted together x = twisted pair

J09–02–31

ELECTRICS

J09–02–32

ELECTRICS COMPONENT LOCATIONS

BHJ0902TD

COMPONENT LOCATIONS — FRONT CONSOLE INSTRUMENTS AND CONTROLS INSTRUMENTS P2

Instrument Panel

CONTROLS 1

Differential lock pedal

2

Left hand brake pedal

3

Right hand brake pedal

4

Engine accelerator pedal

5

Gear change level (Synchroshuttle)

SWITCHES S7

Indicator / Front horn switch

S8

Direction lever (forward / reverse) * Transmission control lever (Powershift)

S22

Transmission de-clutch switch (Synchroshuttle)

S24

Front right console switch pack

S52

2WD/4WD position switch

J09–02–33

ELECTRICS

J09–02–34

ELECTRICS COMPONENT LOCATIONS — FRONT CONSOLE INSTRUMENTS AND CONTROLS FRONT CONSOLE SWITCH PACK INSTRUMENTS H41

Low pressure brake warning lamp

H42

Parking brake warning lamp

H43

Main beam indicator lamp

H44

Neutral position indicator lamp

H45

Glow plug indicator lamp

H46

Not used

H47

Direction indicator lamp

H48

Loader bucket on float mode indicator lamp

H49

Engine fault indicator lamp

H50

Side light indicator lamp

P10

Speedometer (optional)

P14

Hour-meter

SWITCHES S7

Direction indicator switch / Front horn

S8

Forward / Reverse switch (Synchroshuttle) Transmission control lever (Powershift)

S52

2WD/4WD — 2 Wheel braking / 4 Wheel braking switch

S9

Front screen washer switch

including ON/OFF Indicator lamp

S10

Front wiper switch

including ON/OFF Indicator lamp

S12

Not used

—

S14

Ride control switch

including ON/OFF Indicator lamp

S15

Loader quick attach

including ON/OFF Indicator lamp

J09–02–35

ELECTRICS

(4) (4) (2)

J09–02–36

ELECTRICS COMPONENT LOCATIONS — SIDE CONSOLE INSTRUMENTS AND CONTROLS CONTROLS 1

Loader lever

INSTRUMENTS A2

Relay / Fuse board (cover)

P3

Side console panel

SWITCHES S2

Unloader valve switch

S3

Transmission de-clutch switch

S4

Handbrake switch

S19

Ignition switch

S20

Side console switch pack

S40

Heater switches

S45

Air conditioning switch (optional)

C416

Intermediate connector (De-clutch / Unloader valve switches)

J09–02–37

ELECTRICS

J09–02–38

ELECTRICS COMPONENT LOCATIONS — SIDE CONSOLE INSTRUMENTS AND CONTROLS INSTRUMENTS H19

Engine coolant warning lamp

H20

Alternator charge warning lamp

H21

Engine air filter pressure warning lamp

H24

Hydraulic oil temperature warning lamp

H35

Not used

H36

Engine oil pressure warning lamp

H37

Transmission oil temperature warning light

H38

Hydraulic oil filter pressure warning lamp

H39

Not used

H40

Not used

P11

Engine tachometer

P12

Fuel level gauge

P13

Engine coolant temperature gauge

SWITCHES S37

** Four wheel steer (4WS) switch

S50

** 4WS re-alignment switch

S51

Backhoe auxiliary hydraulics switch (optional)

S19

Ignition switch

E9

Cigar lighter

J09–02–39

ELECTRICS

J09–02–40

ELECTRICS COMPONENT LOCATIONS — SIDE CONSOLE INSTRUMENTS AND CONTROLS SWITCHES S11

Hazard warning switch

Including ON/OFF Indicator lamp

S25

Front worklight switch

Including ON/OFF Indicator lamp

S26

Rotating beacon switch

Including ON/OFF Indicator lamp

S27

Rear worklight switch

Including ON/OFF Indicator lamp

S28

Rear wiper switch

Including ON/OFF Indicator lamp

S29

Rear washer switch

Including ON/OFF Indicator lamp

S30

Backhoe boom unlocking switch *Sideshift unlocking switch

Including ON/OFF Indicator lamp

S31

Backhoe quick attach switch

Including ON/OFF Indicator lamp

S32

** Hydraulic enable switch

Including ON/OFF Indicator lamp

S33

Unloader valve

Including ON/OFF Indicator lamp

S34

Rear horn switch

Including ON/OFF Indicator lamp

S35

** Return to dig switch

Including ON/OFF Indicator lamp

S19

Ignition switch

0 R H HS

J09–02–41

= = = =

“OFF” Ignition “ON” Pre-Heat Start

ELECTRICS

J09–02–42

ELECTRICS COMPONENT LOCATIONS — ROPS SIDE CONSOLE INSTRUMENTS AND CONTROLS CONTROLS 1

Loader lever

2

Engine hand throttle

INSTRUMENTS P23

Side console instrument panel

A2

Fuse board cover

SWITCHES S2

Unloader valve switch

S3

Transmission de-clutch switch

S4

Handbrake switch

S19

Ignition switch

J09–02–43

0 = “OFF” R = Ignition “ON” H = Pre-Heat HS = Start

ELECTRICS

J09–02–44

ELECTRICS COMPONENT LOCATIONS — ROPS SIDE CONSOLE INSTRUMENTS AND CONTROLS INSTRUMENTS p11

Engine tachometer

P12

Fuel level gauge

P13

Engine coolant temperature gauge

SWITCHES S11

Hazard warning switch

Including ON/OFF Indicator lamp

S25

Front worklight switch

Including ON/OFF Indicator lamp

S26

Rotating beacon switch

Including ON/OFF Indicator lamp

S27

Rear worklight switch

Including ON/OFF Indicator lamp

S30

Backhoe boom unlocking switch * Sideshift unlocking switch

Including ON/OFF Indicator lamp

S33

Hydraulic pump flow switch

Including ON/OFF Indicator lamp

S34

Rear horn switch

Including ON/OFF Indicator lamp

S35

** Return to dig switch

Including ON/OFF Indicator lamp

S19

Ignition switch

0 = “OFF” R = Ignition “ON” H = Pre-Heat HS = Start

E9

Cigar lighter

J09–02–45

ELECTRICS

J09–02–46

ELECTRICS WIRING DIAGRAMS — POWER SUPPLY WIRING DIAGRAM — POWER SUPPLY SYNCHROSHUTTLE Components A2

Fuse and relay board

G1

Battery

G2

Alternator

H20

Alternator charge warning lamp

M1

Starter motor

P3

Side console instrument display

P11

Engine tachometer

S1

Battery isolation switch

S8

Forward / Reverse switch

S19

Ignition key switch

Relays K28

Ignition relay

K29

Starter relay

Connectors C211

Direction lever forward / Reverse selector switch connector

C306

Ignition switch connector (pin 2)

C307

Ignition switch connector (pin 3)

C308

Side console instruments / Warning lamp indicator

C309

Intermediate connector (to 403)

C401

Ignition switch connector (pin 1)

C402

Ignition switch connector (pin 4)

C436

Battery positive eyelet connection

C437

Battery negative eyelet connection

C501

Intermediate connector (to 433)

C502

Intermediate connector (to 432)

C510

Alternator eyelet (phase terminal)

C511

Alternator eyelet (warning light)

C512

Starter motor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–47

BHJ0902TG

TV040696

R

C437

G1

C436

R

S1

Battery Isolation Switch

W/LG

N/K

J09–02–48

W/G C502 C432 4

W/R

C512

4

2

C401

M1

J9

C402

3

1

K29

6

4

W

W

FWD

N/W

C307

C211

S8

C211

5A

F33

1

G

S19

IGN(15)

REV

J10

C306

20A

F41

40A

.

F42

R

Ignition Switch FORWARD/REVERSE Switch

.

Start Relay Starter Motor

Power Supply Syncroshuttle

9

9 B

J1

GND(31)

GND(31)

J5B

IGN(15) F33

J5A

B

1 G 1

N/Y B1

9 B1

N/S

Ignition Relay Side Control Panel

R

C511

H20

C308

J7

B/L B5

2 B5

10A

F30

.

P11

C433 C501 C510

C308 C309 C403

IGN(15) RLY

J14

K28

80A

F40

.

R

P3

BAT+(30) F32

5A

F32

.

BAT+(30)

J12

80A

F43

.

J13

J15

GND(31) GND(31)

Alternator

A2

N

G2

125A

Megafuse

.

ELECTRICS

ELECTRICS WIRING DIAGRAM — POWER SUPPLY POWERSHIFT Components A2

Fuse and relay board

G1

Battery

G2

Alternator

H20

Alternator charge warning lamp

M1

Starter motor

P3

Side console panel

P11

Engine tachometer

S1

Battery isolation switch

S8

Transmission control lever

S19

Ignition key switch

Relays K28

Ignition relay

K29

Starter relay

Connectors C216

Transmission control lever switch connector

C306

Ignition switch connector (pin 2)

C307

Ignition switch connector (pin 3)

C308

Side console instruments / Warning lamp indicator

C309

Intermediate connector (to 403)

C401

Ignition switch connector (pin 1)

C402

Ignition switch connector (pin 4)

C436

Battery positive eyelet connection

C437

Battery negative eyelet connection

C501

Intermediate connector (to 433)

C502

Intermediate connector (to 432)

C510

Alternator eyelet (phase terminal)

C511

Alternator eyelet (warning light)

C512

Starter motor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–49

TV040697

R

C437

G1

C436

R

S1

Battery Isolation Switch

J09–02–50

W/G C502 C432 4

C512

4

2

C401

M1

J9

C402

N/W

6

C307

K29

3

1

J10

C216

S8

5A

F33

.

1

G

S19

IGN(15)

C306

C216

4

W

W

20A

F41

40A

.

F42

R

Ignition Switch FORWARD/REVERSE Switch

.

W/R

Start Relay Starter Motor

W/LG

N/K

Power Supply Powershift

9

B

9 J1

GND(31)

GND(31)

J5B

IGN(15) F33

J5A

B

1

C511

B/U B5

10A

F30

.

N/Y B1

H20

C308

J7

C501 C433 C510

C308 C309 C403

P11

K28

80A

F40

.

IGN(15) RLY

J14

2 B5

1

G

R

9 B1

N/S

Ignition Relay Side Control Panel

5A

F32

.

BAT+(30)

J12

P3

BAT+(30) F32

R

80A

F43

.

J13

J15

GND(31) GND(31)

Alternator

A2

B/R

G2

125A

Megafuse

.

ELECTRICS

ELECTRICS WIRING DIAGRAMS — ENGINE

BHJ0902TH

WIRING DIAGRAM — ENGINE Components A2

Fuse and relay board

Y1

Fuel shut off solenoid

Y2

Fuel enrichment solenoid

Y25

Fuel lift pump

R1

Engine glow plugs

S19

Ignition key switch

Relays K30

Glow plug relay

K31

Fuel pump relay

Connectors C301

Engine glow plug connector

C306

Ignition switch connector (pin 2)

C307

Ignition switch connector (pin 3)

C401

Ignition switch connector (pin 1)

C402

Ignition switch connector (pin 4)

C501

Intermediate connector (to 433)

C503

Fuel lift pump connector

C506

Engine stop solenoid connector

C508

Fuel enrichment sensor connector

C512

Starter motor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–51

TV040698

C2

A5

Y2

N/O

C508

9

J09–02–52 C4

B

C506

J9

9

4

3

2

C401

1

S19

Y/P

3

Y1

B

C402

W/R

C307

C306

B2

R

C406

J10

K31

15A

12

F28

7.5A

BAT+ (30)

Fuel Lift Pump

.

GND (31)

Ignition Switch

F25

GND (31)

Engine Stop Solenoid

Fuel Lift Pump Relay

.

B/S

14

JGN (15)

Enrichment Solenoid

Engine

B4

B

18

C503

C501

C433

J9

7

J10

W/LG

GND (31)

Y25

B/S

GND (31)

R

R

Glow Plug

C301

J12

A2

K30

R1

BAT+ (30)

Glow Plug Relay

ELECTRICS

ELECTRICS WIRING DIAGRAMS — TRANSMISSION WIRING DIAGRAM — SYNCHROSHUTTLE Components A2

Fuse and relay board

Y7

Forward solenoid

Y8

Reverse solenoid

S22

De-clutch switch (Gear lever)

S3

De-clutch switch (Loader lever)

S8

Direction lever (Forward / Reverse)

Relays K23

Forward solenoid relay

K24

Reverse solenoid relay

K27

Neutral relay

Connectors C211

Direction lever connector (Forward / Reverse)

C416

De-clutch switch connector (Loader lever)

C427

Reverse solenoid

C425

Forward solenoid connector

C442

De-clutch switch connector (Gear lever)

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–53

BHJ0902TJ

J09–02–54

TV040699

C425

B

U/S

B

Y7

19

4

C425

K23

5A

F24

.

IGN (15) RLY

GND (31)

7

9

7

GND (31)

B

U

Forward Solenoid

Transmission Syncroshuttle

GND (31)

F

N

Y/K

6

R

C427

C427

J8

Reverse Solenoid

Forward/Reverse Switch

Y8

K24

Y/G

B

J1

1

GND (31)

8

Y/W

5

K27

IGN (15) F33

6

N/W

S8

C442

C211

Declutch Transmission Switch (Transmission Lever)

S22

B

6

3 Y/G

GND (31)

C416

J9

S3

A2

Declutch Transmission Switch (Loader Lever)

ELECTRICS

ELECTRICS WIRING DIAGRAM — POWERSHIFT Components A2

Fuse and relay board

Y40

Control valve transmission

APC71

Transmission controller

S3

De-clutch (loader lever)

S8

Transmission control lever

Connectors C213

Transmission connector

C214

Transmission controller connector

C215

Transmission controller test socket

C216

Transmission control lever connector

C416

De-clutch switch connector (Loader lever)

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–55

3

6

J09–02–56

5

G/Y

21

R/O

A

B

H

TV040700

1

17

B

G

Y/G

B

4

8

J9

6

GND (31)

GND (31)

Y/G

B

C416

S3

C

U/S

6

2

B

5 J16 2

D

O

4

8

S/W

GND (31)

7.5A

F34

.

IGN (15) RLY

Declutch Transmission Switch (Loader Lever)

Transmission Powershift

E

R/Y

9

28

S/Y

3

Test Socket

6

N/W

6

F

Y/P

7

B

5

F

R

C215

8

Y/W

N

G

B

3

B

9 J1

GND (31)

86 < K24

J1

J

B

11

A2

F

B

8

N

13

K

LG/S

R

19

Y/W

5

Transmission and Transmission Control Unit

L

LG/W

18

1

12

U

7

2

Forward/Reverse Switch

M

R/S

22

3

2

1

C213

C214

15

G/Y

4

Y40

2

3

4

14

O

3

26

B/S

4

C214

C216

APC 71

S8

ELECTRICS

ELECTRICS WIRING DIAGRAMS — DIFFERENTIAL LOCK WIRING DIAGRAM — 4WD DIFFERENTIAL LOCK SYNCHROSHUTTLE Components A2

Fuse and relay board

Y14

Differential lock solenoid

Y9

4WD solenoid

S5

Brake light switch

S12

4WD switch (optional)

S21

Differential lock switch

S24

Front console switch pack

S52

2WD/4WD and 2WB/4WB switch

Relays K25

4WD Relay

Connectors C203

Transmission connector

C204

Brake light switch connector

C205

Transmission control lever connector

C212

2WD/4WD position switch connector

C426

Differential lock solenoid connector

C428

4WD solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–57

BHJ0902TK

J09–02–58

TV040701

2

W/P

B

6

B

10

GND (31)

Differential Lock Solenoid

C426

C426

J5B

Y14

1

W/B

B

20

C203

Differential Lock Switch

4WD Differential Lock Syncroshuttle

B

8

G/P

C428

C428

J8

Y9

7.5A

F17

.

IGN (15) RLY

S5

R/Y

GND (31)

J3

C204a

C204b

GND (31)

16

S21

Brake Light Switch 4 WD Solenoid

13

R/G

GND (31)

K25

IGN (15) F33

10

B

C212

4 WD/4 WB Selector Switch

S52

R/G

6

S12

17

G

1

BAT+ (30)

20

B

5

Right Front Console Switch Pack

BAT+ (30)

GND (31)

J1

C205

10A

F30

.

S24

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — 4WD DIFFENTIAL LOCK POWERSHIFT Components A2

Fuse and relay board

Y9

4WD solenoid

S5

Brake light switch

S12

4WD switch (not used)

S21

Differential lock switch

S24

Front console switch pack

S52

2WD/4WD position switch

APC71

Transmission controller

Connectors C203

Transmission connector

C204

Brake light switch connector

C205

Transmission control lever connector

C212

2WD/4WD position switch connector

C214

Transmission controller connector

C426

Differential lock solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–59

J09–02–60

TV040702

2

W/P

B

6

B

10

GND (31)

Differential Lock Solenoid

C426

C426

J5B

C203

Y14

1

W/B

Differential Lock Switch

4WD Differential Lock Powershift

S21

7.5A

F17

.

S5

10

B

K25 not used

IGN (15) F33

GND (31)

J3

IGN (15) RLY

16

B

C204a

C204b

G/P

Brake Light Switch

GND (31)

13

R/G

C212

S52

4 WD/4WB Selector Switch

6 R/G

S12

20

B

5

GND (31)

J1

C205

Right Front Console Switch Pack

S24

A2

16

R/G

C214

APC 71

Transmission Controller

ELECTRICS

ELECTRICS WIRING DIAGRAMS — STEERING

BHJ0902TL

WIRING DIAGRAM — STEER MODE (4WS) Components A2

Fuse and relay board

B20

Front axle proximity switch

B21

Rear axle proximity switch

H30

4WS reset LED (front)

H31

4WS reset LED (rear)

Y27

4WS solenoid

Y28

Crab solenoid

S37

4WS selection switch

S50

4WS re-alignment indicator switch

Relays K33

4WS Relay board

Connectors C405

Intermediate connector (to C605)

C601

4WS Relay board

C602

4WS selection switch connector

C603

4WS re-alignment indicator switch

C604

Intermediate connector (to C405)

C605

Front axle proximity switch connector

C606

Rear axle proximity switch connector

C607

4WS solenoid connector

C608

Crab solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–61

J09–02–62

1

1

TV040703

B

OV

1

1

S

C603

1

C606

1

C603

2

Y/G

1

Y/G

S

B21

H31

Y/G

1 C605

C603

C603

4

3

1

1

C605

OV

H30

B20

Y/G

5

4 WS Reset LED Front Axle Proximity Switch

R

R

12V

R

C606

12V

R

R

4 WS Reset LED Rear Axle Proximity Switch

Steer Mode

1

B

B

6

1

1

Y/G

1

2

Y/G

C

LG/P

2

LG/P

4

1

B

S/O

1

S/O

6

6

1

5

1

C602

4

1

Steer Mode Switch

Y/G

Y/G

5

Y/G

C603

S50

4 WS Realignment switch

S/G

3

S/G

3

C602

1

S37

B

R

8

1

C608

C608

1

Y27

4WS Solenoid

Four Wheel Steer Relay Board

B

R

7

1

1

1

C607

C607

1

C601

B

20 B

4

R

16 R

Y28

GND (31)

C601

1

C604

C405

J9 1

K33

10A

F26

.

IGN (15) RLY

Crab Solenoid

A2

ELECTRICS

ELECTRICS WIRING DIAGRAMS — CONSOLE PANELS WIRING DIAGRAM — FRONT CONSOLE PANEL SYNCHROSHUTTLE Components A2

Fuse and relay board

B6

Speed sensor (Optional)

H42

Parking brake warning lamp

H43

Main beam indicator lamp

H44

Neutral position indicator lamp

H45

Glow plug indicator lamp

H47

Direction indicator lamp

H48

Engine fault lamp

P2

Front console panel

P3

Side console panel

P10

Speedometer (Optional)

S4

Handbrake switch

S8

Direction lever (Forward / Reverse)

S19

Ignition key switch

Relays K32

Auxiliary relay

Connectors C201

Intermediate connector (to C302)

C202a/b

Handbrake switch connector

C210

Front console panel connector

C211

Direction lever (Forward / Reverse) connector

C307

Ignition switch connector (pin 3)

C308

Side console panel connector

C429

Speed sensor connector (optional)

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–63

BHJ0902TM

J09–02–64

TV040704

4

15

H45

IGN (15)

N/K

4

20

B

Y

Y

Auxiliary

8

B

1

B

G/R C202b

19

9

H42

1

G

10

C202a

C210

GND (31)

B

8

S4

20 IGN (15)

14

87 < K3

.

GND (31)

3

B/W

GND (31)

P10

2

B/Y

18

LG

GND (31)

13

S/B

13

6

N/W

H44

11

S8

10

LG/K

IGN (15)

C211

REV

C211

Forward/Reverse Switch

FWD

IINSTRUMENT PACK ILLUMINATION

12

K/R

3

3A

J9

F16

7

11

B/Y

10A

12

10

B/W

C429

B6

Front Console Panel

Transmission Speed Sensor

F30

.

IGN (15) RLY

K32

GND (31)

J10

C307

2

IGN (15)

3A

F31

.

BAT +(30)

BAT+ (30)

GND (31)

J1

C201

3

W/LG

4

S19

Ignition Switch Hand Brake Switch

Front Console Panel Syncroshuttle

11

U/W

19

J1

H43

2

6

S

14

K/U

IGN (15)

86 < K1

K12

GND

J1

GND (31)

H47

J3

9

B

17

Engine Fault Lamp

H49

IGN (15)

C210

J3

J7

C308

P2

A2

P3

ELECTRICS

ELECTRICS WIRING DIAGRAM — FRONT CONSOLE PANEL POWERSHIFT Components A2

Fuse and relay board

APC71

Transmission controller

H42

Parking brake warning lamp

H43

Main beam indicator lamp

H44

Neutral position indicator lamp

H45

Glow plug indicator lamp

H47

Direction indicator lamp

H48

Float lamp

H49

Engine fault lamp

P2

Front console panel

P3

Side console panel

P10

Speedometer (optional)

S4

Handbrake switch

S8

Direction lever (Forward / Reverse)

S19

Ignition key switch

Relays K12

Indicator / Flasher unit

K32

Auxiliary relay

Connectors C201

Intermediate connector (to C302)

C202a/b

Handbrake switch connector

C210

Front console panel connector

C214

Transmission controller (APC71) connector

C216

Transmission control lever connector

C307

Ignition switch connector (pin 3)

C308

Side console panel connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–65

J09–02–66

TV040705

3

15

H45

IGN (15)

B/W

4

20

B

Y

Y

3

8

B

W/LG

4

BAT+ (30)

1

K32

14

1

G

IGN (15)

20

B

GND (31)

14

K/U

H49

IGN (15)

18

LG

GND (31)

INSTRUMENT PACK ILLUMINATION

12

K/R

12

3A

8

F16

10A

3A GND (31)

.

F30

87 < K3

9

B

.

J7

C308

GND (31)

H48

13

S/B

13

GND (31)

6

N/W J1

11

H44

10

LG/K

IGN (15)

C216

S8

11

U/W

19

J16

J1

A2

H43

9

G/R

IGN (15)

86 < K1

K12

3

G/R

GND (31)

H47

J3

Forward/Reverse Switch Front Console Illumination Panel

F31

3

6

S

17

P3

Panel Illumination

Engine Fault Lamp

.

10

S19

IGN (15) RLY

GND (31)

J10

C307

2

Ignition Switch

GND (31)

J1

C201

Auxiliary

Front Console Panel Powershift

19

B

H42

IGN (15)

C202b

2

B/Y

25

P10

C210

C214

P2

APC 71

Transmission Controller

S4

GND (31)

C202a

Parking Brake Switch

ELECTRICS

ELECTRICS WIRING DIAGRAM — SIDE CONSOLE PANEL Components A2

Fuse and relay board

B1

Engine air filter pressure switch

B2

Engine coolant temperature sensor

B3

Engine oil pressure switch

B4

Hydraulic oil filter pressure switch

B5

Transmission oil temperature switch

P3

Side console panel

P4

Fuel tank level sensor

P12

Fuel level gauge

P13

Engine coolant temperature gauge

H19

Engine coolant warning lamp

H21

Engine air filter pressure warning lamp

H36

Engine oil pressure warning lamp

H37

Transmission oil temperature warning lamp

H38

Hydraulic oil filter warning lamp

Connectors C308

Side console panel connector

C403

Intermediate connector (to C309)

C419

Fuel tank level sensor connector

C434

Hydraulic oil filter (eyelet) connection

C443

Transmission oil temperature switch connector

C502

Intermediate connector (to C432)

C504

Air filter pressure switch connector

C505

Oil pressure switch connector

C509

Coolant temperature sensor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–67

J09–02–68

TV040706

B

B

B

W/N

C505

B

B3

C5 G/B

C4

A5

C1

W/N

A3

G/B

B

B

W/N

C1

6

19

C502

GND (31)

IGN (15)

3

18

R/U

C419

C419

P12

IGN (15)

Fuel Level Sensor

8

H36

IGN (15)

1

4

BAT+ (30)

1

10A

3A

G

F30

2

.

F31

IGN (15) RLY

.

N/K

BAT+ (30)

Engine Oil Pressure Switch

Side Control Panel

3A

F16

.

P4

11

LG/G

A4

LG/G

A4

LG/G

GND (31)

INSTRUMENT PACK ILLUMINATION

87 (K3)

C504

C504

H21

IGN (15)

B

4

20

Engine Air Filter Pressure Switch

B1

G/U

A1 B/P

A2

A1 B/P

G/U

A2

7 B/P

5

P13

IGN (15)

G/U

GND (31)

C308

J7

A2

Engine Coolant Temperature Sensor

GND (31)

Side Control Panel

C509

C502

H19

IGN (15)

B2

N/B

B4

N/B

12

C434

H38

IGN (15)

Hydraulic Oil Filter Pressure Switch

B4

LG/W

C3

LG/W

10

B5

P3

Syncroshuttle

C443

C403

C308

H37

IGN (15)

Transmission Oil Temperature Switch

ELECTRICS

ELECTRICS WIRING DIAGRAMS — LIGHTING

BHJ0902TN

WIRING DIAGRAM — ILLUMINATION FRONT Components A2

Fuse and relay board

E10

Left hand dipped beam light

E11

Left hand main beam light

E12

Left hand side light

E14

Right hand dipped beam light

E15

Right hand main beam light

E16

Right hand side light

S7

Direction indicator / Lights / Front horn switch

Relays K1

Main beam headlight relay

K2

Dippped beam light relay

K3

Side light/Number plate light/Console illumination relay

Connectors C206

Left hand front light connector

C207

Right hand front light connector

C209

Light switch connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–69

J09–02–70

U/W

B

TV040707

2

10

GND (31)

C206

E11

BAT+ (30)

Left Main Beamlight

Illumination Front

7,5A

7,5A

E10

F3

F1

U/K

.

.

5

.

IGN (15) F33

E12

R/W

R/B

E16

BAT+ (30)

6

C206

Light Switch Right Side Light

7

3A

F5

K2

16 BAT+ (30)

19

K1

IGN (15) F33

U/K

Left Side Light

U/W

Left Dip Beamlight

3A

F6

.

U/K

4

1

E14

K3

IGN (15) F33

R/O

Right Dip Beamlight

7,5A

F4

.

U/W

3

C207

E15

C207

10

B

7,5A

F2

.

GND (31)

J1

C209

Right Main Beamlight

B

9

J2

GND (31)

S7

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — ILLUMINATION REAR Components A2

Fuse and relay board

E1

Left hand brake light

E3

Left hand rear side light

E4

Right hand brake light

E6

Right hand rear side light

E7

Registration plate light

E8

Registration plate light

S5

Brake light switch

S7

Direction indicator / Lights / Front horn switch

Relays K3

Side light / Number plate light / Console illumination relay

K4

Brake light relay

Connectors C204a/b

Brake light switch connector

C209

Light switch connector

C412

Right hand rear light cluster connector

C413

Rear number plate light connector

C414

Rear number plate light connector

C415

Left hand rear light cluster connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–71

J09–02–72

G/P

B

TV040708

8

18

GND (31)

E1

C415

E3

3A

3A

R/B

F5

17

.

F14

K4

IGN (15) F33

Left Rear Side Light

.

BAT+ (30)

C415

Left Brake Light

Illumination Rear

B

16 R/W

12

16

5

GND (31)

B

G/P

C204b

C414

C414

E7

S5

B

14

1

C413

C413

GND (31)

R/O

Light Switch

GND (31)

10

B

Registration Plate Light

GND (31)

J3

C204a

Brake Light Switch

E8

J1

C209

B

9

GND (31)

13 R/LG

BAT+ (30) F32

S7

C412

E6

3A

F6

.

K3

BAT+ (30)

Right Rear Side Light

G/P

15

E4

C412

J5A

3A

F15

.

Right Brake Light

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM —DIRECTION INDICATORS WITH CABIN Components A2

Fuse and relay board

E2

Left hand rear indicator light

E5

Right hand rear indicator light

E13

Left hand front indicator light

E17

Right hand front indicator light

H47

Direction indicator lamp

P2

Front console panel

S7

Direction indicator / Lights / Front horn switch

S20

Side console switch pack

Relays K5

Hazard enable relay

K6

Hazard light relay

K12

Direction indicator flasher unit

Connectors C206

Left hand front light connector

C207

Right hand front light connector

C208

Direction indicator / Front horn switch connector

C210

Front console panel connector

C310

Side console switch pack connector

C412

Right hand rear light connector

C415

Left hand rear light connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–73

9

18

TV040709

6

R

2

LG/K

S11

J09–02–74

B

G/R

C206

E13

10

GND (31)

BAT+ (30) F32

8

S49A

G/W

E17

B

9

C207

J2

GND (31)

GND (31)

31

F7

10A

10

LG/K

11

C

K6

5A

.

S49

IGN (15) F33

F8

K5

BAT+ (30)

.

BAT+ (30)

GND (31)

J4

C310

H47

C210

J3

Direction Indicator Lamp

3A

20

B

7

S20

Right Hand Front Indicator Light

F31

.

1

BAT+ (30)

BAT+ (30)

Left Hand Front Indicator Light

Side Console Switch Pack

Direction Indicators with Cab

P2

K12

5

LG

B

J1

C208

C415

GND (31)

E2

18

4

3

G/W

G/R

2

G/R

Left Hand Rear Indicator Light

Direction Indicator Switch

S7

3 G/W

E5

B

9

C412

J5A

GND (31)

Right Hand Rear Indicator Light

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — DIRECTION INDICATORS WITHOUT CABIN (ROPS) Components A2

Fuse and relay board

E2

Left hand rear indicator light

E5

Right hand rear indicator light

E13

Left hand front indicator light

E17

Right hand front indicator light

H47

Direction indicator lamp

S7

Direction indicator / Lights / Front horn switch

S11

Hazard warning switch

Relays K5

Hazard enable relay

K6

Hazard light relay

K12

Direction indicator flasher unit

Connectors C206

Left hand front light connector

C207

Right hand front light connector

C208

Direction indicator / Front horn switch connector

C210

Front console panel connector

C315

Hazard switch connector

C316

Hazard switch illumination connector

C412

Right hand rear light connector

C415

Left hand rear light connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–75

J09–02–76

B

G/R

TV040710

10

10

18

1

B

LG/K

20

E13

C206

GND (31)

3

LG/K

GND (31)

C315

G/W

8

J4

C316

E17

B

9

C207

J2

GND (31)

31

10

LG/K

11

S49A

5A

S49

F7

10A

C

K6

.

F8

IGN (15) F33

H47

C210

J3

Front Console Panel

.

GND (31)

K5

BAT+ (30)

S11

Right Hand Front Indicator Light

Switch Illumination

BAT+ (30) F32

BAT+ (30)

GND (31)

B

Left Hand Front Indicator Light

Hazard Warning Switch

Direction Indicators without Cab (ROPS)

P2

K12

5

LG

G/R

4

2

G/R

E2

B

18

3

G/W

C415

GND (31)

J1

C208

S7

Left Hand Rear Indicator Light

Direction Indicator Switch

G/W

3

E5

B

9

C412

J5A

GND (31)

Right Hand Rear Indicator Light

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — OPTIONAL ROOF REAR LIGHTS (ROPS) Components A2

Fuse and relay board

E35

Left hand brake light

E36

Right hand brake light

E37

Left hand side light

E38

Right hand side light

H39

Left hand rear indicator light

H40

Right hand rear indicator light

Connectors C112

Intermediate connector (to C405)

C114

Right hand rear light connector

C119

Left hand rear light connector

C405

Intermediate connector (to C112)

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–77

J09–02–78

G/K

C2

B

B2

TV040711

8

18

GND (31)

Brake Light

C119

E35

C1

E37

3A

3A

R/B

F5

F14

17

.

.

Left Rear Side Light

Optional Roof Rear Lights (ROPS)

B1

G/R

4

E39

C119

Left Hand Rear Indicator Light

B4

G/W

3

GND (31)

B5

B

9

Right Hand Rear Indicator Light

C114

E40

C4

R/LG

13

E38

Right Rear Side Light

3A

F6

.

C5

G/P

15

E36

C114

C122

C405

J5A

3A

F15

.

Right Brake Light

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — WORKLIGHTS WITH CABIN Components A2

Fuse and relay board

E18

Left hand front worklight

E19

Left hand front worklight

E20

Right hand front worklight

E21

Right hand front worklight

E25

Left hand rear worklight (outer)

E26

Left hand rear worklight (inner)

E27

Right hand rear worklight (inner)

E28

Right hand rear worklight (outer)

S20

Side console switch pack

S25

Front worklight switch

S27

Rear worklight switch

Relays K13

Front worklight relay

K14

Rear worklight relay

Connectors C113

Right hand front worklight connector

C115

Right hand rear worklight connector (outer)

C116

Right hand rear worklight connector (inner)

C117

Left hand front worklight connector

C120

Left hand rear worklight connector (inner)

C121

Left hand rear worklight connector (outer)

C310

Side console switch pack connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–79

J09–02–80

TV040712

U/G

U/Y

E19

17

7

BAT+ (30)

R 9

U/G

14

C117

E18

C117

B

J6B

U/Y

15A

15A

5

F9

F10

GND (31)

.

.

J6A

8

6

S25

E21

U/G

18

BAT+ (30)

20

B

7

C113

E20

C113

16

G/N

10

B

6 J6B

GND (31)

3A

F31

.

GND (31)

BAT+ (30)

J6A

Right Front Worklight (Twin Bulb)

Side Console Switch Pack

1

K13

IGN (15) F33

Left Front Worklight (Twin Bulb)

Worklights with Cab

G/N

12

J4

C121

C121

J6A

E25

15A

F12

.

IGN (15) F33

C310

S27

B

3 J6B

P/S

11

K14

GND (31)

BAT+ (30)

Left Rear Worklight

S20

Outer

C120

C120

J6A

Inner

B

4

E26

15A

F11

.

J6B

GND (31)

P/S

10

C116

C116

B

3

GND (31)

G/N

13

Right Rear Worklight

E27

Inner

C115

C115

Outer

E28

B

2

J6A

GND (31)

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — WORKLIGHTS WITHOUT CABIN (ROPS) Components A2

Fuse and relay board

E18

Left hand front worklight

E19

Left hand front worklight

E20

Right hand front worklight

E21

Right hand front worklight

E25

Left hand rear worklight (outer)

E26

Left hand rear worklight (inner)

E27

Right hand rear worklight (inner)

E28

Right hand rear worklight (outer)

S25

Front worklight switch

S27

Rear worklight switch

Relays K13

Front worklight relay

K14

Rear worklight relay

Connectors C113

Right hand front worklight connector

C115

Right hand rear worklight connector (outer)

C116

Right hand rear worklight connector (inner)

C117

Left hand front worklight connector

C120

Left hand rear worklight connector (inner)

C121

Left hand rear worklight connector (outer)

C311

Front worklight switch connector

C312

Front worklight switch illuminator connector

C323

Rear worklight switch connector

C324

Rear worklight switch illumination connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–81

J09–02–82

TV040713

U/G

U/Y

E19

17

7

BAT+ (30)

B 20

U/G

14

C117

E18

C117

B

5

J6B

U/Y

8

15A

15A

J6A

F9

F10

GND (31)

.

.

K13

IGN (15) F33

Left Front Worklight (Twin Bulb)

Worklights without Cab (ROPS)

E21

U/G

18

B

C113

E20

B

6

G 11

J6B

G/N

13

C312

GND (31)

GND (31)

C113

J6A

10 GND (31)

C311

Front Worklight Switch Right Front Worklight (Twin Bulb)

C121

C121

J6A

B

3

E25

15A

F12

.

10A

F30

.

IGN (15) RLY

S25

Outer

J6B

11

P/S

GND (31)

Left Rear Worklight

C120

C120

J6A

BAT+ (30)

Inner

B

4

E26

15A

F11

.

J6B

10

P/S

GND (31)

K14

IGN (15) F33

C324

J4

C116

E27

B

3

12

G/N

GND (31)

S27

Right Worklight Switch Right Rear Worklight

C323

C116

16

G/N

Inner

C115

C115

Outer

E28

B

2

J6A

GND (31)

A2

ELECTRICS

ELECTRICS WIRING DIAGRAMS — WARNING FUNCTIONS WIRING DIAGRAM — WARNING FUNCTIONS WITH CABIN Components A2

Fuse and relay board

E22

Right front beacon

E23

Left rear beacon

H1

Front horn

H2

Rear horn

H3

Reverse alarm (optional)

S7

Direction indicator / Lights / Front horn switch

S20

Side console switch pack

S26

Rotating beacon switch

S34

Rear horn switch

Relays K11

Front / Rear horn relay

K15

Rotating beacon relay

Connectors C112

Right front beacon connector

C118

Left rear beacon connector

C208

Direction indicator / Front horn connector

C310

Side switch pack connector

C409

Reverse alarm connector

C410a/b

Rear horn connections

C424a/b

Front horn connections

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–83

BHJ0902TP

J09–02–84

TV040714

C424b

H1

B

P/Y

C424a

11

J8

6 P/Y

C410a

C410b

H2

B

10

2 Y/P

GND (31)

K11

87 < K24

H3

11

C409

C409

B

J5A

1 P/K

GND (31)

3A

J4

C310

C112

C112

E22

GND (31)

J6A

20

10A

BAT+ (30)

15

B

P/K

R 9

7

9

S26

6

BAT+ (30)

F31 BAT+ (30) F32

5

P/Y

15

S34

Right Front Beacon

.

GND (31)

J1

S7

Reverse Alarm (Optional)

F22

GND (31)

4

P/Y

C208

Rear Horn (Optional)

Side Console Switch Pack

.

10

B

12

BAT+ (30)

Front Horn

Front Horn Switch

Warning Functions with Cab

B

2

S20

J6B

9 P/K

GND (31)

BAT+ (30)

C118

C118

J6A

15A

F13

.

E23

B

1

J6B

GND (31)

K15

BAT+ (30) F32

Left Rear Beacon

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — WARNING FUNCTIONS WITHOUT CABIN (ROPS) Components A2

Fuse and relay board

E22

Right front beacon

E23

Left rear beacon

H1

Front horn

H2

Rear horn

H3

Reverse alarm (optional)

S7

Direction indicator / Lights / Front horn switch

S26

Rotating beacon switch

S34

Rear horn switch

Relays K11

Front / Rear horn relay

K15

Rotating beacon relay

Connectors C112

Right front beacon connector

C118

Left rear beacon connector

C208

Direction indicator / Front horn connector

C313

Front / Rear beacon switch connector

C314

Front / rear beacon switch illumination connector

C325

Horn switch connector

C409

Reverse alarm connector

C410a/b

Rear horn connections

C424a/b

Front horn connections

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–85

TV040715

10

B

J09–02–86

H1

B

P/Y

C424b

6

C410a

H2

10

2

H3

11

GND (31)

1

J8

P/Y

GND (31)

K11

C410b

B

Y/P

C409

C409

B

J5A

P/K

C112

C112

J6A

IGN (15) RLY

GND (31)

E22

10A

18

B

10A

87 < K24

GND (31)

11

G

C314

F30

GND (31)

20

B

C325B

S34

Rotating Beacon Switch Right Front Beacon

.

5

P/Y

C325A

Rear Horn Switch Reverse Alarm (Optional)

F22

S7

Rear Horn (Optional)

.

11

C424a

J1

C208

BAT+ (30) F32

4

P/Y

12

BAT+ (30)

GND (31)

Horn Switch Front Horn

Warning Functions without Cab (ROPS)

B

2

J6B

9

C118

C118

J6A

BAT+ (30)

J4

P/K

GND (31)

15

P/K

C313

B

1

J6B

GND (31)

K15

BAT+ (30) F32

E23

15A

F13

.

S26

Left Rear Beacon

A2

ELECTRICS

ELECTRICS WIRING DIAGRAMS — OPERATORS ENVIRONMENT WIRING DIAGRAM — WIPER WASH Components A2

Fuse and relay board

M2

Front wiper motor

M3

Rear wiper motor

M4

Front washer pump motor

M5

Rear washer pump motor

S9

Front washer switch

S10

Front wiper switch

S20

Side console switch pack

S24

Right front console switch pack

S28

Rear wiper switch

S29

Rear washer switch

Relays K7

Front wiper relay

K8

Rear wiper relay

K9

Front washer relay

K10

Rear washer relay

Connectors C108

Rear wiper motor connector

C110

Front wiper motor connector

C205

Right front console switch pack connector

C310

Side console switch pack connector

C422

Front windscreen washer motor connector

C423

Rear windscreen washer motor connector

C409

Reverse alarm connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–87

BHJ0902TQ

J09–02–88

B

LG/Y

TV040716

15

C422

J8

GND (31)

K9

IGN (15) F33

O/G

O/B

O/R

J6A B

8

C110

J6B

GND (31)

K7

IGN (15) F33

10A

15A

12

O/B

4

S10

GND (31)

F30

20

B

5

.

15

IGN (15) RLY

IGN (15)

F20

M4

17

11

16

G

LG/B

6

1

2

S9

Right Front Console Switch Pack Front Wiper Motor

.

16

BAT+ (30)

Front Washer Pump

Wiper Washer

M2

J1

C205

17 B

LG/B

C423

J8

GND (31)

M5

K10

IGN (15) F33

18

S24

Rear Washer Pump

O/Y

5

12

LG/Y

12

S29

.

O/LG

4

O/U

14

3A

F31

20

J6A

B

7

C108

J6B

GND (31)

K8

M3

17

O/B

11

S28

GND (31)

IGN (15) F33

BAT+ (30)

B

R 9

7

6

BAT+ (30)

Side Console Switch Pack Rear Wiper Motor

J4

C310

A2

S20

ELECTRICS

ELECTRICS WIRING DIAGRAM — INTERIOR ILLUMINATION SWITCH PACK Components A2

Fuse and relay board

A5

Radio

E9

Cigar lighter

E24

Interior light

S20

Side console switch pack

S24

Right front console switch pack

Connectors C109a/b

Radio connections

C111a/b

Interior light connections

C205

Right front console switch pack connector

C305

Cigar lighter connector

C310

Side console switch pack connector

C422

Front windscreen washer motor connector

C423

Rear windscreen washer motor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–89

TV040717

R/P

12

J09–02–90

C109b

C109a

Radio

9

11

A5

B

R/K

C111b

C111a

10

E24

B

J6B

2

K/O

C305

C305

E9

B

10

15A

7.5A

GND (31)

F28

GND (31)

.

F21

BAT+ (30)

Cigar Lighter

.

Interior Light

Interior llumination Switch Pack

J10

GND (31)

7

16

LG

13

C310

C310

87 < K3

B

20

S20

3A

F16

.

J4

GND (31)

Side Console Switch Pack

5

7

LG

18

C205

C205

S24

B

20

J1

GND (31)

Right Front Console Switch Pack

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — HEATING AND AIR CONDITIONING Components A2

Fuse and relay board

Y10

Air conditioning compressor

E31

Heater unit

S36

Air conditioning switch

S40

Heater switch

Connectors C101

Heater unit connector

C102

Heater switch connector

C103

Heater switch connector

C104

Heater switch connector

C105

Heater switch connector

C106

Air conditioning switch connector

C107

Air conditioning switch connector

C507

Air conditioning compressor connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–91

J09–02–92

TV040718

P/B

C5

P/B

17

C507

C501

J9

Y10

Compressor Magnetic Clutch

A3

P/G

4

Heater and Air Air Conditioning

G

C1

A2

C107

S36

C106

P/L

P/R

3

C103

1

C2

G/Y

2

3

4

C102

C105

C3

G/R

C104

S40

25A

LG

F29

7.5A

1

.

F27

IGN (15) RLY

Heater Unit

Heater Switch

.

IGN (15) RLY

Air Conditioning Switch

B1

B

5

C101

J11

GND (31)

E31

A2

ELECTRICS

ELECTRICS WIRING DIAGRAMS — HYDRAULIC SYSTEMS WIRING DIAGRAM — RIDE CONTROL AND HOSE BURST Components A2

Fuse and relay board

B12

Hose burst pressure switch

Y5

Ride control solenoid

Y6

Ride control solenoid

Y23

Hose burst solenoid

Y24

Hose burst solenoid

S14

Ride control switch

S24

Right front console switch pack

Relays K17

Ride control solenoid relay

K18

Hose burst relay

Connectors C205

Right front console switch pack connector

C417

Ride control connector

C418

Ride control connector

C420

Hose burst intermediate connector

C439

Hose burst pressure switch connector

C440

Hose burst solenoid connector

C441

Hose burst solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–93

BHJ0902TR

J09–02–94

B

TV040719

1

Y/O

3

GND (31)

C418

C418

14

Y5

B

5

K22

IGN (15) RLY

10A

Y/O

C417

C417

Y6

B

B

19

GND (31)

10A

F30

IGN (15) RLY

B

5

20

.

J8

IGN (15)

F23

2

G 17

Y/O

GND (31)

1

8

S14

Ride Control Solenoid

Right Front Console Switch Pack

.

IGN (15) RLY

Ride Control Solenoid

Ride Control, Hose Burst

B

Y/B

Y/B

15

GND (31)

J1

C205

C440

C440

S24

Y23

Hose Burst Solenoid

B

Y/B

C441

C441

Y24

13

W/B

W/B

B

C439

C439

C420

J9

B12

K26

IGN (15) RLY

Float Switch

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — LOADER WITH CABIN Components A2

Fuse and relay board

B7

Return to dig sensor

Y3

Loader valve solenoid

Y13

Return to dig solenoid

S2

Loader valve switch

S20

Side console switch pack

S33

Hydraulic pump flow switch

S35

Return to dig switch

Relays K19

Return to dig relay

K20

Un-loader relay

Connectors C310

Side console switch pack connector

C407

Return to dig solenoid connector

C416

Hose burst intermediate connector

C431

Return to dig sensor connector

C435

Loader valve solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–95

J09–02–96

P/O

B

TV040720

1

6

GND (31)

C407

C407

5 4 J5B

B7

9

10

J8

Y13

K19

B P/W

C431

B

O/W

C435

C435

3A

Y3

K20

IGN (15) F33

F31

5A

IGN (15) F33

.

BAT+ (30)

F19

GND (31)

20

1

9

R

B

P/LG

GND (31)

6

7

BAT+ (30)

Unloader Valve Solenoid

4

S35

Return to Dig Switch

Side Console Switch Pack

.

IGN (15) RLY

Return to Dig Solenoid

Loader with Cab

O/R

2

4

O/P

14

J4

C310

S33

B

7

C416

J9

GND (31)

S20

Unloader Valve Switch

S2

A2

On Loader Lever

ELECTRICS

ELECTRICS WIRING DIAGRAM — LOADER, RETURN TO DIG WITHOUT CABIN (ROPS) Components A2

Fuse and relay board

B7

Return to dig sensor

Y3

Loader valve solenoid

Y13

Return to dig solenoid

S2

Loader valve switch

S33

Hydraulic pump flow switch

S35

Return to dig switch

Relays K19

Return to dig relay

K20

Un-loader relay

Connectors C317

Return to dig switch

C318

Return to dig switch illumination connector

C319

Hydraulic pump flow switch connector

C320

Hydraulic pump flow switch illumination connector

C407

Return to dig solenoid connector

C416

Loader valve switch connector

C431

Return to dig sensor connector

C435

Loader valve solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–97

J09–02–98

P/O

B

TV040721

1

6

GND (31)

C407

C407

Y13

B

5 J5B

K/W C431

1

4

B 20

P/LG

Return to Dig Switch

K19

IGN (15) F33

5A

F19

.

IGN (15) RLY

Return to Dig Solenoid

Loader, Return to Dig without Cab (ROPS)

B7

B

9

G 11

O/W

10

GND (31)

GND (31)

B 10 GND (31)

C317

C435

C435

J8

C318

Unloader Valve Solenoid

Y3

K20

IGN (15) F33

10A

F30

.

IGN (15) RLY

S35

C320

J4

0.5

B

7

C416

J9

GND (31)

S33

Unloader Valve Switch on Loader Lever

O/R

2

4

O/P

C319

Unloader Valve Switch On Side Panel Loader Valve Switch

S2

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — QUICK ATTACH AND CHANGE OVER WITH CABIN Components A2

Fuse and relay board

Y4

Loader quick attach solenoid

Y11

Sideshift clamp solenoid

Y12

Bucket quick attach solenoid

Y26

Change over valve

S15

Loader quick attach switch

S20

Side console switch pack

S24

Right front console switch pack

S30

Backhoe boom unlock switch

S31

Backhoe quick attach switch

S51

Change over selector switch

Relays K17

Clamp relay

K18

Bucket quick attach relay

K21

Loader quick attach relay

Connectors C205

Right front console switch pack

C304

Change over valve connector

C321

Connector

C322

Sideshift / Centremount switch illumination connector

C326

Backhoe quick attach switch connector

C327

Backhoe quick attach switch illumination connector

C329a/b

Change over selector switch connector

C330

Change over valve connector

C408

Bucket quick attach solenoid connector

C411

Sideshift clamp solenoid connector

C430

Loader quick attach solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–99

J09–02–100

TV040722

B

7

J5B

GND (31)

K/B

5

C411

C411

J5A

J5A

13

Y4

5

.

IGN (15) RLY

Y11

K17

IGN (15) RLY

B

J5B O/U

C408

C408

Y12

K18

IGN (15) RLY

B

O/P

14

C430

C430

J8

GND (31)

K21

LG

R

C329a

C329b

J1

C205

S51

15

O/N

9

S15

IGN (15)

10A

17

G

1

F30

7

GND (31)

IGN (15) RLY

20

B

5

3A

.

J4

C310

IGN (15)

B

C330

C330

C304

J10

GND (31)

S24

6

Change over Selector Switch and Valve

7.5A

BAT+ (30)

GND (31)

2

O/U

5

S31

S20

Loader Quick Attach Solenoid

Right Front Console Switch Pack

F31

8

9

19

GND (31)

B

R

K/B

20

7

6

BAT+ (30)

3

S30

Backhoe Quick Attach Solenoid

Side Console Switch Pack

F18

.

IGN (15) RLY

Side Shift Clamp Solenoid

Quick Attach, Change over with Cab

Y26

A2

ELECTRICS

ELECTRICS WIRING DIAGRAM — QUICK ATTACH AND CHANGE OVER WITHOUT CABIN (ROPS) Components A2

Fuse and relay board

Y4

Loader quick attach solenoid

Y11

Sideshift clamp solenoid

Y12

Bucket quick attach solenoid

Y26

Change over valve

S15

Loader quick attach switch

S24

Right front console switch pack

S30

Backhoe boom unlock switch

S31

Backhoe quick attach switch

S51

Change over selector switch

Relays K17

Clamp relay

K18

Bucket quick attach relay

K21

Loader quick attach relay

Connectors C205

Right front console switch pack

C304

Change over valve connector

C321

Connector

C322

Sideshift / Centremount switch illumination connector

C326

Backhoe quick attach switch connector

C327

Backhoe quick attach switch illumination connector

C329a/b

Change over selector switch connector

C330

Change over valve connector

C408

Bucket quick attach solenoid connector

C411

Sideshift clamp solenoid connector

C430

Loader quick attach solenoid connector

Fuses Refer to Fuse and Relay identification numbers Fuse board connections (J) Refer to Fuse board connector information

J09–02–101

J09–02–102

TV040723

7

B

J5B

GND (31)

19

GND (31)

K/B

5

IGN (15) RLY

B

20

K/B

C321

GND (31)

C411

C411

Y11

B

8

K17

J5B

7 O/U

J5A

C408

C408

10A

C327

Y12

B

13

14 O/P

J4

C430

C430

J8

GND (31)

2

O/U

C326

Y4

Backhoe Quick Attach Switch Loader Quick Attach Solenoid

K18

IGN (15) RLY

F30

.

IGN (15) RLY

7.5A

GND (31)

C322

S30

Backhoe Quick Attach Solenoid

F18

.

G 11

IGN (15) RLY

J5A

10

B

Sideshift Clamp Switch Side Shift Clamp Solenoid

Quick Attach, Change over without Cab

S31

5

C329a

C329b

IGN (15)

S51

K21

15

O/N

GND (31)

IGN (15) RLY

20

B

S15

J1

C205

6

C330

C330

C304

J10

GND (31)

S24

Right Front Console Switch Change over Selector Switch and Valve

Y26

A2

ELECTRICS

ELECTRICS WIRING DIAGRAMS — SERVO LEVER CONTROL WIRING DIAGRAM — SERVO LEVER CONTROL Components 1

Fuse and relay board

2

Fuse

3

Left-hand side control lever

4

Right-hand side control lever

6

Servo arm switch

7

Servo Control valve

8

Fuse and relay board

Relays 5

Servo Lever R elay

J09–02–103

BHJ0902TS

ELECTRICS

Servo Lever Control LH Lever Contol

RH Lever Control

Fuse Relay Board

IGN (15)

Servo Lever Relay

1

OG/RD 2

10 A

OG/RD

OG/RD

OG/RD 3

OG

OG/RD 4

OG

OG

OG

7

30

OG

OG

6 BN

BN

BN 8 GND (31)

TV074060

J09–02–104

5

ELECTRICS CONNECTOR LOCATIONS

BHJ0902TF

CONNECTOR LOCATIONS — CHASSIS HARNESS SYNCHROSHUTTLE Components 1

Mega fuse 125 amp

G1

Battery

2

Auxiliary fuse box

J5a

18 way

Fuse board connector

J5b

12 way

Fuse board connector

J8

20 way

Fuse board connector

J9

20 way

Fuse board connector

J12

Eyelet

Fuse board connection

J13

Eyelet

Fuse board connection

J14

Eyelet

Fuse board connection

J15

Eyelet

Fuse board connection

Relays K28

Ignition relay

K29

Starter relay

Connectors C401

Ignition switch (pin 1)

C402

Ignition switch (pin 4)

C403

Intermediate connector (to IG C309)

C404

Intermediate connector (to UC C122)

C405

Intermediate connector (to 4WS C604)

C406

Intermediate connector (to IG C303)

C407

Return to dig solenoid connector

C408

Quick attach solenoid connector (optional)

C409

Reverse alarm connector (optional)

C410a/b

Rear horn connections (optional)

C411

** Sideshift clamp connector

C412

Right hand rear light cluster connector

C413

Rear number plate light connector

C414

Rear number plate light connector

C415

Left hand rear light cluster connector

C416

Transmission de-clutch / Un-loader switch connector

C417

Ride control connector

J09–02–105

ELECTRICS

J09–02–106

ELECTRICS Connectors (continued) C418

Ride control connector

C419

Fuel tank lever sensor connector

C420

Hose-burst (optional)

C421

Alternator eyelet connection

C422

Front windscreen washer motor connector

C423

Rear windscreen washer motor connector

C424a/b

Front horn connector

C425

Forward solenoid connector

C426

Differential lock solenoid connector

C427

Reverse solenoid connector

C428

Four wheel drive solenoid connector

C429

Speed sensor connector (optional)

C430

Front quick attach connector (optional)

C431

Bucket return to dig potentiometer (intermediate) connector

C432

Intermediate connector (to EN C502)

C433

Intermediate connector (to EN C501)

C434

Hydraulic oil filter eyelet connection

C435

Loader valve solenoid connector

C436

Battery positive eyelet connection

C437

Battery negative eyelet connection

C443

Transmission oil temperature connector

C442

Transmission dump solenoid connector

J09–02–107

ELECTRICS

J09–02–108

ELECTRICS CONNECTOR LOCATIONS — CHASSIS HARNESS POWERSHIFT AND FOUR WHEEL STEER Components 1

Mega fuse 125 amp

G1

Battery

2

Auxiliary fuse box

J5a

18 way

Fuse board connector

J5b

12 way

Fuse board connector

J8

20 way

Fuse board connector

J9

20 way

Fuse board connector

J12

Eyelet

Fuse board connection

J13

Eyelet

Fuse board connection

J14

Eyelet

Fuse board connection

J15

Eyelet

Fuse board connection

Relays K28

Ignition relay

K29

Starter relay

Connectors C401

Ignition switch (pin 1)

C402

Ignition switch (pin 4)

C403

Intermediate connector (to IG C309)

C404

Intermediate connector (to UC C122)

C405

Intermediate connector (to 4WS C604)

C406

Intermediate connector (to IG C303)

C407

Return to dig solenoid connector

C408

Quick attach solenoid connector (optional)

C409

Reverse alarm connector (optional)

C410a/b

Rear horn connections (optional)

C411

** Sideshift clamp connector

C412

Right hand rear light cluster connector

C413

Rear number plate light connector

C414

Rear number plate light connector

C415

Left hand rear light cluster connector

C416

Transmission de-clutch / Un-loader switch connector

C417

Ride control connector

J09–02–109

ELECTRICS

J09–02–110

ELECTRICS Connectors (continued) C418

Ride control connector

C419

Fuel tank lever sensor connector

C420

Hose-burst intermediate connector (optional)

C421

Alternator eyelet connection

C422

Front windscreen washer motor connector

C423

Rear windscreen washer motor connector

C424a/b

Front horn connector

C430

Front quick attach connector (optional)

C431

Bucket return to dig potentiometer (intermediate) connector

C432

Intermediate connector (to EN C502)

C433

Intermediate connector (to EN C501)

C434

Hydraulic oil filter eyelet connection

C435

Loader valve solenoid connector

C436

Battery positive eyelet connection

C437

Battery negative eyelet connection

Four wheel steer connectors C601

4WS relay board

C602

4WS selection switch connector

C603

4WS reset switch

C604

Intermediate connector (to C405)

C605

Front axle proximity switch connector

C606

Rear axle proximity switch connector

C607

4WS solenoid connector

C608

Crab solenoid connector

J09–02–111

ELECTRICS

J09–02–112

ELECTRICS CONNECTOR LOCATIONS — ENGINE HARNESS Connectors C501

Intermediate connector (to C433)

C502

Intermediate connector (to C432)

C503

Fuel lift pump connector

C504

Air filter pressure switch connector

C505

Oil pressure switch connector

C506

Engine stop solenoid connector

C507

Air conditioning compressor clutch connector

C508

Fuel enrichment sensor connector

C509

Coolant temperature sensor connector

C510

Alternator eyelet (phase terminal)

C511

Alternator eyelet (warning light)

C512

Starter motor connector

Component B1

Air filter pressure switch

B2

Coolant temperature sensor

B3

Oil pressure switch

Y1

Engine stop solenoid

Y2

Fuel enrichment sensor

Y10

Air conditioning compressor (optional)

Y25

Fuel lift pump

G2

Alternator (phase terminal)

G2

Alternator (warning light)

M1

Starter motor

J09–02–113

ELECTRICS

TV040395

J09–02–114

ELECTRICS Connectors C501

Intermediate connector (to C433)

C502

Intermediate connector (to C432)

C503

Fuel lift pump connector

C504

Air filter pressure switch connector

C505

Oil pressure switch connector

C506

Engine stop solenoid connector

C507

Air conditioning compressor clutch connector

C508

Fuel enrichment sensor connector

C509

Coolant temperature sensor connector

C510

Alternator eyelet (phase terminal)

C511

Alternator eyelet (warning light)

C512

Starter motor connector

Component B1

Air filter pressure switch

B2

Coolant temperature sensor

B3

Oil pressure switch

Y1

Engine stop solenoid

Y2

Fuel enrichment sensor

Y10

Air conditioning compressor (optional)

Y25

Fuel lift pump

G2

Alternator (phase terminal)

G2

Alternator (warning light)

M1

Starter motor

J09–02–115

ELECTRICS

J09–02–116

ELECTRICS CONNECTOR LOCATIONS — FRONT CONSOLE CABIN LOWER HARNESS 1

Headlamp extension harness

J1

20 way

Fuse board connector

J2

12 way

Fuse board connector

J13

16 way

Fuse board connector

J16

8 way

Fuse board connector

Connectors C201

Intermediate connector (to C302)

C202 a/b

Handbrake switch connector

C203

Differential lock switch connector

C204 a/b

Brake light switch connector

C205

Right front console switch pack connector

C206

Left hand front light connector

C207

Right hand front light connector

C208

Direction indicator / Horn switch connector

C209

Light switch connector

C210

Front console instrument connector

C211

Direction lever (FWD/REV) switch connector (Synchroshuttle)

** C216

Transmission control lever switch connector (Powershift)

C212

Four wheel brake switch connector

C213

Transmission connector (Powershift)

C214

Transmission controller APC71 (Powershift)

C215

Transmission test probe (Powershift)

C217

Air seat intermediate connector (to C218)

Air Suspension seat harness J16

Fuse board connector

C218

Intermediate connector (to C217)

C219

Air seat motor connector

J09–02–117

ELECTRICS

J09–02–118

ELECTRICS CONNECTOR LOCATIONS — SIDE CONSOLE IGNITION HARNESS J4

20 way

Fuse board connector

J7

8 way

Fuse board connector

J10

12 way

Fuse board connector

J12

Eyelet

Fuse board connection

Connectors C301

Engine glow plug connector (to engine)

C302

Intermediate connector (to C201)

C303

Intermediate connector (to C406)

C304

Change over valve connector (optional)

C305

Cigar lighter connector

C306

Ignition switch connector (pin 2)

C307

Ignition switch connector (pin 3)

C308

Side console instruments connector

C309

Intermediate connector (to C403)

C310

Side switch pack connector

Relays K30

Glow plug relay

K31

Fuel pump relay

K32

Auxiliary relay

J09–02–119

ELECTRICS

J09–02–120

ELECTRICS CONNECTOR LOCATIONS — ROPS SIDE CONSOLE IGNITION HARNESS J4

20 way

Fuse board connector

J7

8 way

Fuse board connector

J10

12 way

Fuse board connector

J12

Eyelet

Fuse board connection

Connectors C301

Engine glow plug connector (to engine)

C302

Intermediate connector (to C201)

C303

Intermediate connector (to C406)

C304

Change over valve connector (optional)

C305

Cigar lighter connector

C306

Ignition switch connectors (Pin 2)

C307

Ignition switch connectors (Pin 3)

C308

Side console instrument / Warning lamps

C309

Intermediate connector (to C403)

C310

Side switch pack connector

C311

Front worklight switch connector

C312

Front worklight switch illumination connector

C313

Front / Rear beacon switch connector

C314

Front / Rear beacon switch illumination connector

C315

Hazard switch connector

C316

Hazard switch illumination connector

C317

Return to dig switch connector

C318

Return to dig switch illumination connector

C319

Pump dump switch connector

C320

Pump dump switch illumination connector

C321

Sideshift switch connector * Centremount switch connector

C322

Sideshift / Centremount switch illumination connector

C323

Rear work lamp switch connector

C324

Rear work lamp switch illumination connector

C325

Horn switch connector

C326

Quick attach switch connector

C327

Quick attach switch illumination connector

Relays K30

Glow plug relay

K31

Fuel pump relay

K32

Auxiliary relay

J09–02–121

ELECTRICS

J09–02–122

ELECTRICS CONNECTOR LOCATIONS — CABIN UPPER HARNESS 1

Front worklights

2

Rear worklights

J6a

18 way

Fuse board connector

J6b

12 way

Fuse board connector

J11

7 way

Fuse board connector

Connectors C101

Intermediate connector Heating / Air conditioning unit

C102

Heater switch connector

C103

Heater switch connector

C104

Heater switch connector

C105

Heater switch connector

C106

Air conditioning connector

C107

Air conditioning connector

C108

Rear wiper motor connector

C109 a/b

Radio connectors

C110

Front wiper motor connector

C111 a/b

Interior light connectors

C112

Front beacon connector

C113

Right hand front worklight connector

C114

Right hand rear light cluster connector

C115

Right hand rear outer worklight connector

C116

Right hand rear inner worklight connector (optional)

C117

Left hand front worklight connector

C118

Rear beacon connector

C119

Left hand rear light cluster connector

C120

Left hand rear inner worklight connector (optional)

C121

Left hand rear outer worklight connector

C122

Intermediate connector (to C404)

J09–02–123

ELECTRICS

J09–02–124

ELECTRICS CONNECTOR LOCATIONS — ROPS CABIN UPPER HARNESS 1

Front worklights

2

Rear worklights

J6a

18 way

Fuse board connector

J6b

12 way

Fuse board connector

Connectors C112

Front beacon connector

C113

Right hand front worklight connector

C114

Right hand rear light cluster connector

C115

Right hand rear outer worklight connector

C116

Right hand rear inner worklight connector (optional)

C117

Left hand front worklight connector

C118

Rear beacon connector

C119

Left hand rear light cluster connector

C120

Left hand rear inner worklight connector (optional)

C121

Left hand rear outer worklight connector

C122

Intermediate connector (to C404)

J09–02–125

ELECTRICS

J09–02–126

ELECTRICS CONNECTOR LOCATIONS — BATTERY HARNESS M1

Starter motor

G1

Battery

S1

Battery isolation switch

1

125 Amp Mega fuse

2

Auxiliary fuse box

3

Battery cable negative

4

Battery cable positive (starter motor)

5

Chassis harness

6

Battery cable negative (starter motor)

7

Ground cables

Fuses F40

80 Amp Ignition cabin fuse

F41

20 Amp Ignition switch fuse

F42

40 Amp Starter relay fuse

F43

80 Amp Relay fuse board

J09–02–127

ELECTRICS

J09–02–128

ELECTRICS

Note: This page intentionally left blank.

J09–02–129

CHASSIS AND BODYWORK

K10 SECTION

REMOVAL AND INSTALLATION — REAR FENDER . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . K10–01–1 REMOVAL AND INSTALLATION — HARDNOSE / TOOL BOX . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . K10–01–3 REMOVAL AND INSTALLATION — HOOD .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . K10–01–5 REMOVAL AND INSTALLATION — FRONT FENDER . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . K10–01–7 SPECIFICATIONS — CHASSIS AND BODYWORK .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . K10–01–9

CHASSIS AND BODYWORK REMOVAL AND INSTALLATION — REAR FENDER

BHK1001RA

Operation: Removing and Installing the Rear Fender

Job Code: 10 12 13 xx

None

Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the cab lower front trim panel.

TV040025

3. Remove the cab left-hand side rear trim panel retaining screws and position it to one side.

TV040186

4. Remove the rear fender rear retaining bolts.

TV040187

K10–01–1

CHASSIS AND BODYWORK Note: • Assistance may be required. 5. Remove the rear fender.

TV040026

Installation Note: • After installation on machines with four-wheel steer facility, operate the four-wheel steer system. Make sure the rear wheels do not foul the rear fender. 1. To install, reverse the removal procedure.

K10–01–2

CHASSIS AND BODYWORK REMOVAL AND INSTALLATION — HARDNOSE / TOOL BOX

BHK1001RB

Operation: Removing and Installing the Hardnose / Tool Box Suitable lifting equipment

Job Code: 10 14 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Open the hood.

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

3. Using suitable lifting equipment, support the front tool box (1). 4. Remove the front tool box upper retaining bolts (2). 5. Remove the tool box lower retaining bolts and remove the tool box (3).

TV040053

Installation 1. To install, reverse the removal procedure. 2. Tighten (2) to 58Nm (43 lb.ft). 3. Tighten (3) to 240Nm (177 lb.ft).

TV040053

K10–01–3

CHASSIS AND BODYWORK

Note: This page intentionally left blank.

K10–01–4

CHASSIS AND BODYWORK REMOVAL AND INSTALLATION — HOOD

BHK1001RC

Operation: Removing and Installing the Hood Suitable lifting equipment

Job Code: 10 02 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Open the hood.

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

3. Using suitable lifting equipment, support the hood. 4. Remove the hood pivot retaining bolts.

TV040055

Note: • Position the telescopic strut clear of the hood. 5. Detach the hood telescopic struts and remove the hood. Left-hand side shown, right-hand side similar.

TV040054

Installation 1. To install, reverse the removal procedure.

K10–01–5

CHASSIS AND BODYWORK 2. Tighten to 11Nm (8 lb.ft).

TV040055

K10–01–6

CHASSIS AND BODYWORK REMOVAL AND INSTALLATION — FRONT FENDER

BHK1001RD

Operation: Removing and Installing the Front Fender

Job Code: 10 11 13 xx

None

Standard tools

Removal 1. Position the loader bucket flat on the ground. 2. Remove the front fender.

TV040780

Installation 1. To install, reverse the removal procedure. 2. Tighten to 190Nm (140 lb.ft).

TV040780

K10–01–7

CHASSIS AND BODYWORK

Note: This page intentionally left blank.

K10–01–8

CHASSIS AND BODYWORK SPECIFICATIONS — CHASSIS AND BODYWORK

BHK1001SA

Torque Values Description

Nm

Lb.ft

Front Fender Retaining Bolts

190

140

Rear Fender Retaining Bolts

28

21

Hood Retaining Bolts

11

8

Hardnose/Toolbox to Chassis Retaining Bolts

240

177

Hardnose/Toolbox Upper Retaining Bolts

58

43

K10–01–9

FRONT AXLE AND STEER SYSTEM

L11 SECTION

DESCRIPTION AND OPERATION — TWO-WHEEL DRIVE FRONT AXLE.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–01–1 DIAGNOSING AND TESTING — TWO-WHEEL DRIVE FRONT AXLE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–01–3 REMOVAL AND INSTALLATION — TWO-WHEEL DRIVE FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–01–5 REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–01–9 DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–01–11 DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–01–13 DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–01–21 GENERAL PROCEDURE — TOE-IN ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–01–25 SPECIFICATIONS — TWO-WHEEL DRIVE FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–01–27 DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–02–1 DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–02–3 REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–02–9 REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–13 DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–17 DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP . .. .. .. .. .. .. .. .. .. .. .. L11–02–19 DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–23 DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–33 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–37 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–49 DISASSEMBLY AND ASSEMBLY — PINION GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–53 GENERAL PROCEDURE — TOE-IN ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–61 GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–63 GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL .. .. .. .. .. L11–02–65 GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–67 SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–02–69 DESCRIPTION AND OPERATION — FOUR-WHEEL STEER FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–03–1 DIAGNOSING AND TESTING — FOUR-WHEEL STEER FRONT AXLE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–03–3 REMOVAL AND INSTALLATION — FOUR-WHEEL STEER FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–03–9 DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP (FOUR-WHEEL STEER). .. .. L11–03–13 DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR-WHEEL STEER) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–03–15 DISASSEMBLY AND ASSEMBLY — FRONT WHEEL HUB GROUP (FOUR-WHEEL STEER). .. .. .. L11–03–21 DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP (FOUR-WHEEL STEER) . .. .. .. .. .. .. .. .. L11–03–31 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP (FOUR-WHEEL STEER) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–03–37 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER) . .. .. .. .. .. .. L11–03–47 DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER) . .. .. .. .. .. .. .. .. .. .. .. L11–03–53 GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) . .. .. .. .. .. .. .. .. .. .. .. .. L11–03–63 GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT (FOUR-WHEEL STEER) .. .. .. .. .. L11–03–65 GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL (FOUR-WHEEL STEER) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–03–67 GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER). .. .. L11–03–69 SPECIFICATIONS — FOUR WHEEL STEER FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–03–71 DESCRIPTION AND OPERATION — TWO-WHEEL STEER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–04–1 DESCRIPTION AND OPERATION — FOUR-WHEEL STEER . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–04–3 REMOVAL AND INSTALLATION — STEERING COLUMN .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–04–9 REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR UP TO 2007 .. .. .. .. .. .. .. .. .. .. L11–04–15 REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR 2007 ONWARDS .. .. .. .. .. .. .. L11–04–19 REMOVAL AND INSTALLATION — FOUR-WHEEL STEER (4WS) CHANGEOVER VALVE.. .. .. .. .. L11–04–21 REMOVAL AND INSTALLATION — TIE ROD END . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–04–23 GENERAL PROCEDURE — FOUR-WHEEL STEER MISALIGNMENT CORRECTION.. .. .. .. .. .. .. .. L11–04–25 SPECIFICATIONS — STEERING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–04–27 DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–05–1

DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–05–3 REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..L11–05–9 REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–13 DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–17 DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP . .. .. .. .. .. .. .. .. .. .. .. L11–05–19 DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–23 DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–35 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–39 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–51 DISASSEMBLY AND ASSEMBLY — PINION GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–55 GENERAL PROCEDURE — TOE-IN ADJUSTMENT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–63 GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–65 GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL .. .. .. .. .. L11–05–67 GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–69 SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. L11–05–71

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FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — TWO-WHEEL DRIVE FRONT AXLE

BHL1101OA

General Description

1

2

3 TV40984

1

Axle Beam Group

2

Steering Cylinder Group

3

Wheel Hub Group

The axle described in this manual consists of the following groups: • AXLE BEAM GROUP: load-bearing structure of the axle.

• •

STEERING CYLINDER GROUP: steering cylinder parts with adjusting system. WHEEL HUB GROUP: wheel support parts.

L11–01–1

FRONT AXLE AND STEER SYSTEM

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L11–01–2

FRONT AXLE AND STEER SYSTEM DIAGNOSING AND TESTING — TWO-WHEEL DRIVE FRONT AXLE Problem Axle beam body bent

Worn out or pitted bearings

Grease leakage from seals

Possible Cause

• • • • • • • •

Vehicle overloaded.

•

BHL1101TA

Action

• • • • • • • •

REPLACE axle beam body.

Wheel hub seal assembled incorrectly.

•

REPLACE the gasket or seal and matching surface if damaged.

•

Seal lip damaged.

•

REPLACE the gasket or seal and matching surface if damaged.

•

Contaminated oil.

•

REPLACE the gasket or seal and matching surface if damaged.

Vehicle accident. Load bump. Insufficient lubrication. Contaminated grease. Excessive use. Normal wear out. Insufficient lubrication.

REPLACE axle beam body. REPLACE axle beam body. REPLACE bearings. REPLACE bearings. REPLACE bearings. REPLACE bearings. REPLACE the gasket or seal and matching surface if damaged.

Axle Problem and Diagnosis Problem Noise while driving

Constant noise

Action

Possible Cause

• • • •

• Wheel hub bearings insufficient •

REPLACE.

• •

REPLACE.

Worn out bearings.

ADD grease.

lubrication.

Poor or wrong lubricant. Worn out bearings.

L11–01–3

REPLACE.

FRONT AXLE AND STEER SYSTEM

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L11–01–4

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — TWO-WHEEL DRIVE FRONT AXLE

BHL1101RA

Operation: Removing and Installing the Two-Wheel Drive Front Axle Suitable transmission jack

Job Code: 11 24 13 xx Standard tools

Removal 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installa-tion. Note: Always Install blanking plugs to avoid con-tamination.

•

2. Remove the hardnose / tool box. For additional information, refer to Section K10-01 HARDNOSE / TOOLBOX, PAGE K10–01–3 . 3. Raise the front loader to full height and install the safety stop.

TV040056

4. Roll the loader bucket fully forward. 5. Detach the front axle pivot pin grease point (1). Note: • Discard the locking nut. 6. Remove the front axle pivot pin retaining bolt (2).

1

2 TV040061

L11–01–5

FRONT AXLE AND STEER SYSTEM 7. Disconnect the power steering supply pipes.

TV040982

•

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury. Warning: Secure the front axle to the transmission jack. Failure to follow this instruction may result in personal injury

Note: • Mark the axle pivot pin before removal to aid installation. 8. Using a suitable transmission jack (1), support the front axle. 9. Using a suitable slide hammer (2), remove the front axle pivot pin and remove the front axle.

2

1

TV040064

Installation Note: • Remove any dirt or burrs before installing the front axle pivot pin. 1. To install, reverse the removal procedure. Note: • Install a new locking nut. 2. Tighten (2) to 98Nm (73 lb.ft). 3. Check and adjust the hydraulic oil level as required.

L11–01–6

FRONT AXLE AND STEER SYSTEM 4. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

1

2 TV040061

L11–01–7

FRONT AXLE AND STEER SYSTEM

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L11–01–8

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP

BHL1101RB

Operation: Removing and Installing the Steering Cylinder Group

Job Code: 11 20 13 xx

Suitable lifting equipment

Standard tools

Removal 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always Install blanking plugs to avoid contamination. 2. Disconnect the power steering supply pipes.

TV040982

3. Disconnect the inner track rod end from the steering cylinder group (both sides).

TV040964

L11–01–9

FRONT AXLE AND STEER SYSTEM

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

4. Remove the steering cylinder group retaining bolts (2) from the cylinder heads (1). Using a soft faced hammer, remove the steering cylinder group (3).

1

3

2

3

2

TV040983

Installation 1. To install, reverse the removal procedure. 2. Thoroughly clean and de-grease the axle beam/cylinder heads (1) mating surfaces. Apply Loctite 638 to the axle beam/cylinder head mating surfaces. 3. Apply Loctite 270 to the threads of the retaining bolts (2). 4. Tighten (2) to 335Nm (247 lb.ft).

1

TV040983

5. Check and adjust the hydraulic oil level as required. 6. Tighten the tie rod joint to 300Nm (221 lb.ft).

TV040964

L11–01–10

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP

BHL1101DA

Operation: Disassembly and Assembly of the Steering Cylinder Group

Job Code: 11 20 17 xx

Suitable lifting equipment

Standard tools, Piston ring compressor

1 2 3 4 5 6 7 8 9

10 11 12 13

TV040978

1

Cylinder Head

2

Wiper Seal

3

Sealing Ring

4

O-Ring

5

Cylinder

6

Piston Rod Assembly

7

Back-up Seal

8

Piston Sealing Ring

9

Back-up Seal

10

O-Ring

11

Sealing Ring

12

Wiper Seal

13

Cylinder Head

L11–01–11

FRONT AXLE AND STEER SYSTEM Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (5) in a vice. 3. Remove the cylinder heads (1) and (13) from the steering cylinder group. 4. Remove the piston rod assembly (6) from the cylinder (5). 5. Remove the sealing rings (3) and (11), wiper seals (2) and (12) and the O-rings (4) and (10) from the cylinder heads (1) and (13). 6. Remove the back-up seal (7), piston sealing ring (8) and back-up seal (9) from the piston rod assembly (6).

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the back-up seal (7), piston sealing ring (8) and back-up seal (9) on the piston rod assembly (6). 2. Install the O-rings (4) and (10), wiper seals (2) and (12) and the sealing rings (3) and (11) into the cylinder heads (1) and (13). 3. Lubricate the inside of the cylinder (5) and the piston rod assembly (6) with clean oil. Use a piston ring compression tool to hold the new back-up seals (7) and (9) and the piston sealing ring (8) in place.

•

Caution: Be careful not to damage the back-up seals and piston sealing ring.

4. Install the piston rod assembly into the cylinder (5) until the compression tool is pushed off the piston rod assembly. 5. Install the cylinder heads (1) and (13) on the steering cylinder group.

L11–01–12

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP

BHL1101DB

Operation: Disassembly and Assembly of the Wheel Hub Group

Job Code: 11 08 17 xx

Suitable lifting equipment

Standard tools, Ball joint separator, CA715491, CA715504, CA715085

16

21

15 11 10 9 20

8

19

7

3 12

18 17

2 13 1

6 14

5 4 TV040969

L11–01–13

FRONT AXLE AND STEER SYSTEM 1

Plug

2

Wheel Hub Cover

3

O-Ring

4

Retaining Bolt

5

Thrust Washer

6

Taper Roller Bearing

7

Stud

8

Wheel Hub

9

Taper Roller Bearing

10

Oil Seal

11

Swivel Housing

12

Cone

13

Lower Kingpin

14

Retaining Bolt

15

Upper Kingpin

16

Retaining Bolt

17

Lock Nut

18

Steering Angle Adjustment Bolt

19

Belleville washers

20

Axle

21

Belleville Washers

L11–01–14

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–3 .

•

Caution: Leave the tie rod end nut on the tie rod end a few turns to prevent damage to the stud while using the ball joint separator.

2. Loosen the tie rod end nut and using a suitable ball joint separator, disconnect the tie rod assembly from the swivel housing.

TV041082

3. Remove the plug (1). 4. Using a suitable extractor or lever, remove the wheel hub cover (2). 5. Remove and discard the O-ring (3). 6. Remove the wheel hub retaining bolts (4). 7. Remove the thrust washer (5).

5 4 3 2 1

TV040972

8. Using a suitable soft faced hammer, remove the front axle hub. Note: • Recover the outer taper roller bearing.

TV040970

L11–01–15

FRONT AXLE AND STEER SYSTEM 9. Using a suitable lever, remove and discard the hub oil seal (1). 10. Using a suitable drift, remove the inner and outer taper roller bearing cones (2).

2

1

TV040849

11. Using a suitable puller, remove the inner taper roller bearing.

TV040971

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: • Using suitable lifting equipment, support the swivel housing assembly . 12. Remove the upper and lower kingpin retaining bolts and remove the kingpins. 13. Remove the swivel housing assembly.

TV041083

L11–01–16

FRONT AXLE AND STEER SYSTEM 14. Remove the belleville washers.

TV040975

Assembly 1. Lubricate the kingpin seats with suitable grease. For additional information, refer to SPECIFICATIONS, PAGE L11–01–27 in this section. 2. Install the belleville washers.

TV040975

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment, support the swivel housing assembly .

•

3. Install the swivel housing assembly. Note: • Make sure the belleville washers do not move from their seats. 4. Install the upper and lower kingpins and kingpin retaining bolts. 5. Tighten the lower kingpin retaining bolts to 190Nm (140 lb.ft). 6. Tighten the upper kingpin retaining bolts to 120Nm (89 lb.ft).

L11–01–17

FRONT AXLE AND STEER SYSTEM 7. Lubricate the upper and lower kingpins with suitable grease. For additional information, refer to SPECIFICATIONS, PAGE L11–01–27 in this section.

TV040973

8. Lubricate the taper roller bearing with suitable grease. For additional information, refer to SPECIFICATIONS, PAGE L11–01–27 in this section. 9. Using the special tool CA715491 — Driver for taper roller bearing , install the inner taper roller bearing.

TV040971

10. Using a suitable hydraulic press and the special tools CA715504 — Driver for the inner taper roller bearing cone and CA715085 — Driver for the outer taper roller bearing cone , install the inner and outer taper roller bearing cones.

TV040925

L11–01–18

FRONT AXLE AND STEER SYSTEM Note: • Lubricate the oil seal with a light grease. 11. Using the special tool CA715525 — Driver for oil seal , install a new hub oil seal.

TV040926

12. Fill the wheel hub with 0.25 Kg of suitable grease. For additional information, refer to SPECIFICATIONS, PAGE L11–01–27 in this section. 13. Install the front axle hub and the outer taper roller bearing.

TV040970

Note: • Lubricate the O-ring with a light grease. 14. Install the thrust washer (5). 15. Apply Loctite 270 to the wheel hub retaining bolts (4) and install the wheel hub retaining bolts (4). 16. Tighten (4) to 120Nm (89 lb.ft). 17. Install a new O-ring (3). 18. Install the wheel hub cover (2). 19. Install the plug (1) in the wheel hub cover (2). 20. Tighten (1) to 25Nm (18 lb.ft).

5 4 3 2 1

TV040972

L11–01–19

FRONT AXLE AND STEER SYSTEM

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L11–01–20

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP

BHL1101DD

Operation: Disassembly and Assembly of the Axle Beam Group

Job Code: 11 07 17 xx

None

Standard tools, CA715448, CA715451, CA715549, CA715164

2 4 3

1 5 6 9 10

7 8

TV040974

1

Axle Beam

2

Plug

3

Bush

4

Oil Seal

5

Belleville Washer

6

Kingpin Bush

7

Ball Bearing Cup

8

Belleville Washers

9

Bush

10

Oil Seal

L11–01–21

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE L11–01–13 in this section. 2. Using a suitable extractor, remove the upper king pin bush (1) and the ball bearing cup (2) from the king pin housings (both sides).

1

2 TV040976

3. Remove and discard the oil seals (1) and (3) from the axle beam.

•

Caution: Be careful not to damage the bush housing.

4. Remove and discard the bushes (2) and (4) from the axle beam.

1 2 4

TV040977

Assembly Note: • To make the assembly easier, it is advisable to cool the upper bushings and the lower ball bearing cups at a temperature lower than –100°C. 1. Using the special tool CA715448 — Driver for upper kingpin bush , install the bush (1) in the upper kingpin seat (both sides).

L11–01–22

3

FRONT AXLE AND STEER SYSTEM 2. Using the special tool CA715451 — Driver for lower kingpin ball bearing cup , install the ball bearing cup (2) in the lower kingpin seat (both sides).

1

2 TV040976

Note: • To make the assembly easier, it is advisable to cool the bushings at a temperature lower than –100°C. 3. Using the special tool CA715549 — Driver for bush , install the bushes (2) and (4) in the axle beam. Note: Lubricate the oil seal with a light grease.

•

4. Using the special tool CA715164 — Driver for oil seal , install the oil seals (1) and (3) in the axle beam.

1 2 4

TV040977

L11–01–23

3

FRONT AXLE AND STEER SYSTEM

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L11–01–24

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — TOE-IN ADJUSTMENT

BHL1101GA

Operation: General Procedure Toe-in Adjustment None

Job Code: 11 13 01 xx Standard tools, Two one-metre-long bars

General Procedure The toe-in of the front wheels must be between 12 and 24mm toe-in as measured 500mm from the centre of the wheel hub. To check the exact value of the toe-in setting, proceed as follows. 1. With the front wheels in the central position, remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • The bars must be fixed flat against the wheel hub flange and have an equal distance from the centre of the wheel hub. 2. Install two equal one-metre-long bars to the wheel side of the wheel hubs and lock in place with two wheel retaining nuts.

500mm

500mm

TV040979

3. Measure the distance (A) between the ends of the two bars. 4. Measure the distance (B) between the ends of the two bars. 5. The distance (A) must be 12 to 24mm less than distance (B).

A

B TV040980

L11–01–25

FRONT AXLE AND STEER SYSTEM Note: • Make sure the same number of threads are visible at the end of the left-hand and right-hand inner track rod end ball joints. 6. If it is necessary to correct the toe-in adjustment. Loosen the lock nut (1) on the left-hand and the right-hand side. Turn the inner track rod end ball joints (2) equally to achieve the specified toe-in adjustment. 7. Tighten (1) to 120Nm (86 lb.ft).

1

2

TV040981

L11–01–26

FRONT AXLE AND STEER SYSTEM SPECIFICATIONS — TWO-WHEEL DRIVE FRONT AXLE

BHL1101SA

Special Tools Tool No.

Description

CA119033

Interchangeable Handle

CA715085

Driver for Bearing Cone

CA715164

Driver for Oil Seal

CA715448

Driver for Bush

CA715549

Driver for Bush

CA715451

Driver for Ball Bearing Cup

CA715491

Driver for Bearing

CA715504

Driver for Bearing Cone

CA715525

Driver for Hub Seal

Torque Values Description

Nm

Lb.ft

Wheel

180

133

Wheel Hub Cover Plug

25

18

Wheel Hub

120

89

Upper Kingpin

120

89

Lower Kingpin

190

140

Grease Nipple

8

6

Tie-Rod End

165

122

Tie-Rod Locking Nut

120

89

Swivel Joint

300

221

Steering Cylinder

335

247

General Specifications Description

Value

Dry Weight

179 Kg

Steering Angle

Max. 56°30’ ± 1°30’

Toe-in

12–24mm

Wheel Hub Grease Each Side

0.25 Kg

Grease Type

AGIP GREASE 33FD AGIP MU/EP2 (Kingpin only)

L11–01–27

FRONT AXLE AND STEER SYSTEM

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L11–01–28

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE

BHL1102OA

General Description

1

2

3

7 4

5

6

TV040947

1

Epicyclic Reduction Gear Group

2

Axle Housing Group

3

Differential Support Group

4

Pinion Group

5

Steering Cylinder Group

6

Differential Group

7

Wheel Hub Group

The axle described in this manual consists of the following groups: • WHEEL HUB GROUP: wheel support parts containing the epicyclic reduction gears.

• •

EPICYCLIC REDUCTION GEAR GROUP: planetary carrier with reduction/transmission parts. AXLE HOUSING GROUP: load-bearing shell structure of the axle.

L11–02–1

FRONT AXLE AND STEER SYSTEM • •

DIFFERENTIAL SUPPORT GROUP: differential housing with crown wheel gear adjusting system. DIFFERENTIAL GROUP: differential parts with crown wheel gear.

• •

PINION GROUP: pinion with adjusting and support parts. STEERING CYLINDER GROUP: steering cylinder parts with adjusting system.

L11–02–2

FRONT AXLE AND STEER SYSTEM DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE Problem Ring gear tooth broken at the outer side

Ring gear tooth broken on the inside

Pinion or ring gear teeth worn

BHL1102TA

Possible Cause

Action

•

Excessive gear load compared to the design specification.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (excessive backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Load bump.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (insufficient backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

•

Contaminated oil.

• •

•

L11–02–3

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

FRONT AXLE AND STEER SYSTEM Problem Pinion or ring gear teeth worn (continued)

Action

Possible Cause

•

Incorrect lubrication or depleted additives.

• •

•

•

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

• •

•

Overheated ring and pinion teeth. Check if gear teeth are showing signs of wear.

Pinion teeth pitting

Axle beam body bent

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals. REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

Prolonged functioning at high temperatures.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Incorrect lubrication.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Low oil level.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

• • •

Vehicle overloaded.

• • •

REPLACE axle beam body.

Vehicle accident. Load bump.

L11–02–4

REPLACE axle beam body. REPLACE axle beam body.

FRONT AXLE AND STEER SYSTEM Problem Worn out or pitted bearings

Oil leakage from gaskets and seals

Action

Possible Cause

•

Insufficient lubrication.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Normal wear out.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Pinion nut loosened.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Prolonged functioning at high temperature of the oil.

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

• •

Oil gasket assembled incorrectly.

• •

•

Seal lip damaged.

• •

•

Contaminated oil.

• •

L11–02–5

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

FRONT AXLE AND STEER SYSTEM Problem Excessive wearing out of input flange spline

Action

Possible Cause

•

Heavy use.

• • •

•

Pinion nut loosened.

• • •

•

Pinion axle backlash.

• • •

Fatigue failure of pinion teeth. See if the fracture line is well defined (wave lines, beach lines)

• •

Heavy use.

Pinion and ring teeth breakage

•

Side gear spline worn out. Replace all scratched washers (Excessive backlash)

•

Thrust washer surface worn out or scratched

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required. REPLACE bevel gear set.

Crash load of differential components.

•

CHECK and/or REPLACE other differential components.

Excessive use.

•

Insufficient lubrication.

• •

REPLACE differential gear group. REPLACE half shaft if required.

Continuous overload.

•

Incorrect lubrication.

• • •

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

• •

•

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

Contaminated oil.

• • •

L11–02–6

REPLACE bevel gear set.

USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones.

FRONT AXLE AND STEER SYSTEM Problem

Action

Possible Cause

•

Excessive use.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive pinion axial backlash.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

Bent or broken half shaft

•

Vehicle intensively operated or overloaded.

•

REPLACE half shaft.

Half shaft broken at wheel side

•

Wheel support loosened.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

•

Beam body bent.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

Inner diameter of tapered roller bearing worn out

L11–02–7

FRONT AXLE AND STEER SYSTEM Axle Problem and Diagnosis Problem Noise while driving

Noise whilst driving in neutral

Intermittent noise Constant noise

Noise while steering

Possible Cause

Action

•

Excessive backlash between pinion and ring gear.

•

ADJUST.

• • • •

Worn out pinion and gear ring.

• • • •

REPLACE.

• • • • • • •

Worn out differential bearings.

• • • • • • •

REPLACE.

•

Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing the speed.

•

REPLACE.

• • • •

Pinion or input flange worn out.

• • • • •

Worn out bearings.

• •

Worn out pinion bearings. Pinion bearings loosened. Excessive axial pinion backlash. Differential bearings loosened. Ring gear out of roundness. Low Lubricant level. Poor or wrong lubricant. Bent half shaft. Noise coming from axle is usually heard when vehicle moves in neutral gear but is not loud.

• Ring gear damaged. • Differential box bolts loosened. • Ring gear teeth or pinion •

REPLACE. ADJUST. ADJUST.

ADJUST. REPLACE. OIL level. REPLACE. REPLACE. REPLACE or ADJUST (see above).

ADJUST. REPLACE bevel gear set. TIGHTEN to torque. REPLACE bevel gear set.

damaged.

• • • • •

REPLACE.

Differential thrust washers worn out.

•

REPLACE.

Half shaft spline worn out.

•

REPLACE.

Pinion spline worn out. Bent half shaft. Worn out differential gears. Worn out differential box or spider.

L11–02–8

REPLACE. REPLACE. REPLACE. REPLACE.

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE

BHL1102RA

Operation: Removing and Installing the Four-Wheel Drive Front Axle Suitable transmission jack

Job Code: 11 24 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Remove the hardnose / tool box. For additional information, refer to Section K10-01 HARDNOSE / TOOLBOX, PAGE K10–01–3 . 3. Raise the front loader to full height and install the safety stop. 4. Roll the loader bucket fully forward.

TV040056

5. Detach the front axle pivot pin grease point (1). Note: • Discard the locking nut. 6. Remove the front axle pivot pin retaining bolt (2).

1

2 TV040061

L11–02–9

FRONT AXLE AND STEER SYSTEM 7. Disconnect the power steering supply pipes.

TV040062

8. Loosen the propeller shaft locking ring.

TV040063

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

•

Warning: Secure the front axle to the transmission jack. Failure to follow this instruction may result in personal injury

Note: • Mark the axle pivot pin before removal to aid installation. 9. Using a suitable transmission jack (1), support the front axle. Note: • Secure the propeller shaft to one side when removing the front axle. Using a suitable slide hammer (2), remove the front axle pivot pin and remove the front axle.

2

1

TV040064

L11–02–10

FRONT AXLE AND STEER SYSTEM Installation Note: • Remove any dirt or burrs before installing the front axle pivot pin. Note: Make sure the propeller shaft is aligned with the front axle differential shaft when raising the axle into position.

•

1. To install, reverse the removal procedure. Note: • Install a new locking nut. 2. Tighten (2) to 98Nm (72 lb.ft).

1

2 TV040061

3. Check and adjust the hydraulic oil level as required. 4. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

L11–02–11

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–02–12

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP

BHL1102RC

Operation: Removing and Installing the Steering Cylinder Group

Job Code: 11 20 13 xx

Suitable lifting equipment

Standard tools

Removal Note: • Make a note of the position of any hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Disconnect the power steering supply pipes.

TV040062

3. Remove the union from the steering cylinder group.

TV040962

L11–02–13

FRONT AXLE AND STEER SYSTEM 4. Disconnect the inner track rod end from the steering cylinder group (both sides).

TV040964

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

5. Remove the steering cylinder group retaining bolts (1), and remove the steering cylinder group (2).

1

1

TV040965

Installation 1. To install, reverse the removal procedure. 2. Tighten (1) to 120Nm (89 lb.ft).

1

1

TV041131

L11–02–14

2

FRONT AXLE AND STEER SYSTEM 3. Tighten to 300Nm (221 lb.ft).

TV040964

4. Check and adjust the hydraulic oil level as required. 5. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

L11–02–15

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–02–16

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP

BHL1102DA

Operation: Disassembly and Assembly of the Steering Cylinder Group None

Job Code: 11 20 17 xx Standard tools, Suitable piston ring compression tool

12

10

9 11

8 7 6 5 3 1

4 2 TV0400582

1

Wiper Seal

2

Sealing Ring

3

Flange

4

O-Ring

5

Piston Rod Assembly

6

Back-up Seal

7

Piston Sealing Ring

8

Back-up Seal

9

O-Ring

10

Cylinder

11

Sealing Ring

12

Wiper Seal

L11–02–17

FRONT AXLE AND STEER SYSTEM Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (10) in a soft jawed vice. 3. Remove the flange (3) from the steering cylinder group. 4. Remove the piston rod assembly (5) from the cylinder (10). 5. Remove the wiper seal (1), sealing ring (2) and the O-ring (4) from the flange (3). 6. Remove the back-up seal (6), piston sealing ring (7) and back-up seal (8) from the piston rod assembly (5). 7. Remove the O-ring (9), sealing ring (11) and the wiper seal (12) from the cylinder (10).

Assembly Note: • Install new O-ring seals, seals and rings. Note: lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (12), sealing ring (11) and the O-ring (9) to the cylinder (10). 2. Install the back-up seal (8), piston sealing ring (7) and the back-up seal (6) to the piston rod assembly (5). 3. Install the O-ring (4), sealing ring (2) and the wiper seal (1) to the flange (3). 4. Lubricate the inside of the cylinder (10) and the piston rod assembly (5) with clean oil. Use a piston ring compression tool to hold the new back-up seals (6),(8) Piston Sealing Ring (7) in place.

•

Caution: Be careful not to damage the back-up seals and piston sealing ring.

5. Start the cylinder (10) onto the piston rod assembly (5). Push the cylinder onto the piston rod (5) assembly until the compression tool is pushed off the piston rod assembly. 6. Install the flange (3) onto the steering cylinder group.

L11–02–18

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP

BHL1102DB

Operation: Disassembly and Assembly of the Epicyclic Reduction Gear Group None

Job Code: 11 05 17 xx Standard tools

9 10 7 5

4 8 6 2

3

1 TV040598

1

Epicyclic Reduction Gear Carrier

2

Drain/Refill Plug

3

Retaining Stud

4

Retaining Screw

5

Pin

6

Washer

7

Needle Bearings

8

Epicyclic Reduction Gear

9

Triangular plate

10

Circlip

L11–02–19

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–3 . 2. Drain the hub oil. For additional information, refer to DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 in this section. 3. Remove the epicyclic reduction gear retaining screws (1), and studs (2) and remove the epicyclic reduction gear.

2 1

TV040812

Note: • On disassembly of the epicyclic reduction gear clean the contact surfaces of the epicyclic reduction gear and wheel hub and check it for excess wear. 4. Using suitable circlip pliers, remove the epicyclic reduction gear retaining circlips.

TV040841

5. Remove the epicyclic reduction gear triangular plate.

TV040842

L11–02–20

FRONT AXLE AND STEER SYSTEM 6. Remove the epicyclic reduction gears (1). 7. Recover the needle roller bearings (2).

1

2

TV040843

Assembly Note: • When installing new epicyclic reduction gears, install new needle bearings. 1. Install the epicyclic reduction gears (1). Note: • Use a suitable installation.

light

greese

to

aid

2. Install the needle roller bearings (2).

1

2

TV040843

3. Install the epicyclic reduction gear triangular plate.

TV040842

L11–02–21

FRONT AXLE AND STEER SYSTEM 4. Install the epicyclic reduction gear retaining circlips.

TV040841

5. Clean and degrease the mating surfaces. Apply a bead of suitable sealant following the the pattern shown. For additional information, refer to SPECIFICATIONS, PAGE L11–01–27 in this section.

TV040844

6. Install the epicyclic reduction gear to the wheel hub. Note: • Before installing the epicyclic reduction gear retaining studs, apply approved sealant (Loctite 542) to the studs. 7. Install the epicyclic reduction gear retaining screws (1), and studs (2). 8. Tighten (1) to 70Nm (52 lb.ft). 9. Tighten (2) to 80Nm (59 lb.ft). 10. Fill the hub with oil. For additional information, refer to DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 in this section. 11. Install the wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–3 .

2 1

TV040812

L11–02–22

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP

BHL1102DC

Operation: Disassembly and Assembly of the Wheel Hub Group

Job Code: 11 05 17 xx

Suitable lifting equipment

Standard tools, Ball joint separator, Ca715026, Ca715027, Ca119143

27 19 18

24

14 13 26

12

11

22

23

10

25

8 7 4 3

15

1

16 9 17 2

5

6

TV040600

L11–02–23

20

21

FRONT AXLE AND STEER SYSTEM 1

Circlip

2

Sun Gear

3

Universal-Joint Shaft Washer

4

Epicylic Ring Gear

5

Retaining Bolt

6

Center Bushes

7

Epicylic Hub

8

Steel Lock Ring

9

Taper Roller Bearing

10

Stud

11

Wheel Hub

12

Taper Roller Bearing

13

Oil Seal

14

Swivel Housing

15

Cone

16

Lower Kingpin

17

Retaining Bolt

18

Upper Kingpin

19

Retaining Bolt

20

Lock Nut

21

Steering Angle Adjustment Bolt

22

Bush

23

Oil seal

24

Universal-Joint Shaft End

25

Belleville washers

26

Axle

27

Belleville Washers

Disassembly

1. Remove the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE L11–03–15 in this section.

L11–02–24

FRONT AXLE AND STEER SYSTEM

•

Caution: Leave the tie rod end nut on the tie rod end a few turns to prevent damage to the stud while using the ball joint separator.

2. Using a suitable ball joint separator, disconnect the tie rod assembly from the wheel hub.

TV040202

3. Remove the lock ring (1), sun gear (2) and spacer (3) from the double Universal-joint shaft.

3 2 1

TV040845

4. Remove the wheel hub retaining bolts.

TV040846

L11–02–25

FRONT AXLE AND STEER SYSTEM 5. Using two hub retaining bolts, extract the epicyclic group.

TV040200

6. Remove the snap ring (1) and remove the epicyclic gear hub (2) from the epicyclic ring gear (3). 7. Using the special tool CA715027 — Driver for bush remove the wheel hub centering bushes.

1

2

3 TV040771

8. Using a suitable soft faced hammer, remove the front axle hub. Note: • Recover the outer taper roller bearing.

TV040848

L11–02–26

FRONT AXLE AND STEER SYSTEM 9. Using a suitable lever, remove and discard the hub seal (1). 10. Recover the outer taper roller bearing. Using a suitable drift, remove the inner and outer taper roller bearing cones (2).

2

1

TV040849

11. Using a suitable puller, remove the inner taper roller bearing.

TV040773

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: • Using suitable lifting equipment, support the wheel hub assembly . 12. Remove the upper (1) and lower (2) kingpin retaining bolts and remove the kingpins. 13. Remove the swivel hub assembly.

1 1

2 TV040203

L11–02–27

2

FRONT AXLE AND STEER SYSTEM 14. Remove the swivel thrust washers. orientation to aid installation.

Note the

TV040854

Note: • Position the swivel hub on a suitable flat surface. 15. Using a suitable lever, remove the oil seal. 16. Using a suitable lever, remove the oil seal. Note: Discard the oil seal.

•

TV040851

17. Using a suitable drift, remove the swivel housing bush.

TV040852

Assembly 1. Using the special tool CA119043 — Driver for bush , install the bush.

L11–02–28

FRONT AXLE AND STEER SYSTEM 2. Using the special tool CA119117 — Driver for oil seal , install the oil seal.

TV040853

3. Install the swivel thrust washers.

TV040854

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment, support the swivel hub assembly .

•

4. Install the swivel hub assembly. Note: • Make sure the double universal-joint shaft is fully installed into the axle housing. 5. Install the upper (1) and lower (2) kingpins and kingpin retaining bolts. 6. Tighten to 190Nm (140 lb.ft).

1 1

2 TV040203

L11–02–29

2

FRONT AXLE AND STEER SYSTEM 7. Install the inner taper roller bearing.

TV040850

8. Using a suitable hydraulic press and the special tool CA715026 — Driver for bearing race , install the inner and outer taper roller bearing cones.

TV040925

Note: • Lubricate the oil seal with a light grease. 9. Using the special tool CA119143 — Driver for oil seal , install a new hub oil seal.

TV040926

10. Install the front axle hub.

TV040938

L11–02–30

FRONT AXLE AND STEER SYSTEM 11. Install the outer taper roller bearing.

TV040857

12. Install the epicyclic hub (2) to the epicyclic ring gear (3) and install the snap ring (1).

1

2

3 TV040771

Note: • Install two bushes slightly higher that the hub surface level to be used as dowel pins. 13. Using the special tool CA715027 — Driver for bush partially install the hub centering bushes.

TV040930

14. Assemble the epicyclic group on the front wheel hub using the two protruding centering bushes as dowel pins.

TV040200

L11–02–31

FRONT AXLE AND STEER SYSTEM 15. Using the special tool CA715027 — Driver for bush , install the remaining centering bushes.

TV040931

16. Install the epicyclic hub retaining bolts. 17. Tighten to 230Nm (170 lb.ft).

TV040846

18. Install the spacer (1), sun gear (2) and circlip (3) onto the double universal-joint shaft.

1 2 3

TV040939

19. Install the track rod end into the wheel hub. 20. Tighten to 220Nm (162 lb.ft). 21. Install the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE L11–03–15 in this section.

TV040937

L11–02–32

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP

BHL1102DD

Operation: Disassembly and Assembly of the Axle Housing Group None

Job Code: 11 07 17 xx Standard tools, CA715034, CA715505, CA715163, CA715164, CA715701

Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE L11–02–23 in this section. 2. Drain the axle oil into a suitable container. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL, PAGE L11–02–65 in this section. 3. Remove the two double Universal-Joints from the axle housing (both sides).

TV040861

4. Remove the oil seal (2) from the axle housing (both sides). Note: • Discard the oil seal rings.

•

Caution: Be careful not to damage the bush housing.

5. Remove the bushes (1) from the axle housing (both sides). 6. Using a suitable extractor remove the upper king pin bush (3) and the ball bearing cup (4) from the king pin housings (both sides).

3

1

4 2 TV040862

L11–02–33

FRONT AXLE AND STEER SYSTEM 7. Remove the oil seals (1) and (3) from the axle housing. Note: • Discard the oil seals. 8.

Remove the bushes (2) and (4) from the axle housing.

•

Caution: Be careful not to damage the bush housing.

2

1 3

4 TV040863

9. Using a suitable lever, remove the cover from the differential support .

TV040864

10. Remove the oil seal (1) and the O-ring (2) from the cover (3). Note: • Discard the oil seals.

1 2 3 TV040865

L11–02–34

FRONT AXLE AND STEER SYSTEM Assembly Note: • Install new oil seals. 1. Using the special tool CA715034 , install the king pin bush (3) in the axle housing (both sides). 2. Using the special tool CA175034 — Driver , install the ball bearing cup (4) in the axle housing (both sides). 3. Using the special tool CA715505 — Driver , install the bush (1) and the oil seal (2).

3

1

4 2 TV040862

4. Install the bush (1) and the oil seal (2) as shown.

1

TV040866

5. Install the two double Universal-Joints into the axle housing (both sides).

TV040861

L11–02–35

2

FRONT AXLE AND STEER SYSTEM 6. Using the special tool CA715163 — Driver install the bushes (2) and (4) on the axle housing. Note: • Lubricate the oil seal with a light grease. Using the special tool CA715164 — Driver install the oil seals (2) and (3) on the axle housing.

2

1 3

4 TV040863

Note: • Lubricate the oil seal with a light grease. 7. Using the special tool CA715701 — Driver Install the oil seal (1) to the cover (8). 8. Install the O-ring seal (2) to the cover (3).

1 2 3 TV040865

•

Caution: Cover the pinion shaft spline to protect the oil seal from damage.

9. Install the cover to the axle housing. 10. Install the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE L11–02–23 in this section. 11. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL, PAGE L11–02–65 in this section.

TV040864

L11–02–36

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP

BHL1102DE

Operation: Disassembly and Assembly of the Differential Support Group

Job Code: 11 03 13 xx

Suitable lifting equipment

Standard tools, CA119030, CA715116

13 12

9 11 10

8 7 6 2

5 4 1

3

TV040605

1

Differential Support

2

Retaining Bolt

3

Adjustment Nut

4

Taper Roller Bearing

5

Differential Assembly

6

Taper Roller Bearing

7

Adjustment Nut

8

Locking Tab

9

Retaining Bolt

10

Dowel

11

Differential Half-Collers

12

Retaining Bolt

13

Dowel

L11–02–37

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the axle housing group. For additional information, refer to AXLE HOUSING GROUP, PAGE L11–02–33 in this section.

•

Warning: Support the differential support. Failure to follow this instruction may result in personal injury.

2. Remove the differential support from the axle housing.

TV040867

3. Remove the locking tab retaining bolts (1) and remove the adjustment nut locking tabs (2).

1

1

2

2

TV040868

4. Mark the differential half-collers and the differential adjustment nuts to aid installation.

TV040869

L11–02–38

FRONT AXLE AND STEER SYSTEM 5. Using the special tool CA119030 — Wrench (1), Remove the differential adjustment nuts (2).

2 2

1

TV040870

6. Remove the half-collers retaining bolts.

TV040877

7. Remove the half–collers (1). Note: • Recover the half-coller dowels (2).

1

2

2 TV040871

L11–02–39

FRONT AXLE AND STEER SYSTEM

•

•

Caution: If the taper roller bearings are not to be replaced, make sure the taper roller bearing and cone remain a matched pair. Caution: Make a note of the differential position to aid installation.

8. Remove the differential assembly. Note: • Recover the taper roller bearing cones.

TV040872

L11–02–40

FRONT AXLE AND STEER SYSTEM Assembly 1. Install the pinion shaft. For further information refer to PINION GROUP, PAGE L11–02–53 in this section.

•

Caution: Make sure the taper roller bearing and cone remain a matched pair.

•

Caution: Make sure the differential is installed in the correct orientation.

2. Install the differential assembly.

TV040872

3. Install the half-coller dowels (2). 4. Install the half–collers (1).

1

2

2 TV040871

Note: • Do not tighten at this stage. 5. Install the half-collers retaining bolts.

TV040877

L11–02–41

FRONT AXLE AND STEER SYSTEM

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Only tighten the differential adjustment nut until the bearing backlash is removed and nominal pre-load is achieved.

•

6. Using the special tool CA119030 — Wrench (1), Install the differential adjustment nuts (2). Note: • Using a suitable soft-faced hammer, settle the differential taper roller bearings.

2 2

TV040870

7. Lock the pinion shaft. 8. Using a suitable measuring device, measure the pinion to crown wheel backlash. 9. Repeat the measurement in a further two positions 120° apart and compare the average of the three values. 10. The pinion to crown wheel backlash should be within the following range: 0.18mm — 0.23mm

TV040873

L11–02–42

1

FRONT AXLE AND STEER SYSTEM Note: • Make sure the differential adjustment nuts are adjusted equally to retain the nominal bearing pre-load and no free play. 11. Using the special tool CA119030 — Wrench , adjust the differential adjustment nuts until the correct pinion to crown wheel backlash is achieved. • Measured backlash is greater than the specified range — (A) , adjust the differential assembly closer to the pinion shaft by loosening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment nut equal amounts. • Measured backlash is less than the specified range — (B) , adjust the differential assembly away from the pinion shaft by tightening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment nut equal amounts.

A

A

B

B

TV040874

12. Once the correct pinion to crown wheel backlash is achieved, check that the differential taper roller bearings have no free play and no pre-load is evident. 13. Repeat steps 7 to 12 the whole sequence of the above mentioned operations until the indicated conditions are reached.

L11–02–43

FRONT AXLE AND STEER SYSTEM

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Using a suitable soft-faced hammer, settle the differential taper roller bearings.

•

Note: Rotate the differential assembly while tightening the adjustment nuts to seat the bearing rollers on their track.

•

14. Using a suitable measuring device with the cord wound round the pinion shaft spline, measure the total rotational torque.

TV040875

15. The total rotational torque should be within the following range excluding breakaway torque. (4.3 + P) to (6.45 + P) daN P = Measured pinion shaft rotational torque. For additional information refer to PINION GROUP, PAGE L11–02–53 in this section.

L11–02–44

FRONT AXLE AND STEER SYSTEM Note: • Make sure the differential adjustment nuts are adjusted equally to retain the set backlash. 16. Using the special tool CA119030 — Wrench , adjust the differential adjustment nuts until the correct differential taper roller bearing pre-load is achieved. • Total pre-load is less than the specified range — (A) , increase the differential taper roller bearing pre-load by tightening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment equal amounts. • Total pre-load is higher than the specified range — (B) , decrease the differential taper roller bearing pre-load by loosening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment equal amounts.

A

A

B

B

TV040876

L11–02–45

FRONT AXLE AND STEER SYSTEM Testing After Adjustment Note: • The marking test should always be carried out on both sides of the crown wheel teeth. 17. To test the marks of the crown wheel teeth, paint the ring gear with engineer’s blue.

TV040836

18. Check the contact pattern: OK = Correct contact — If the crown wheel is well adjusted, the mark on the teeth surfaces will be regular. Z = Excessive contact on the tooth tip — Adjust the pinion towards the crown wheel and then adjust the crown wheel away from the pinion in order to adjust the backlash. X = Excessive contact at the tooth base — Adjust the pinion away from the crown wheel and then adjust the crown wheel towards the pinion in order to adjust the backlash.

OK

Z

X

TV040837

Movements to correct 19. Adjust as required: 1 = move the pinion for type X contact adjustment. 2 = move the pinion for type Z contact adjustment.

2 1 TV040838

L11–02–46

FRONT AXLE AND STEER SYSTEM 20. Install the adjustment nut locking tabs (2) and install the locking tab retaining bolts (1). 21. Tighten to 13Nm (10 lb.ft).

1

1

2

2

TV040868

22. Tighten the half-collers retaining bolts to 266Nm (196 lb.ft).

TV040877

Note: • Make sure the two dowel pins are installed into the axle housing. 23. Thoroughly clean and de-grease the mating surfaces. Apply a bead of sealant following the pattern shown.

TV040878

24. Install the differential support onto the axle housing. 25. Tighten to 169Nm (125 lb.ft).

L11–02–47

FRONT AXLE AND STEER SYSTEM 26. Install the axle housing group. For additional information, refer to AXLE HOUSING GROUP, PAGE L11–02–33 in this section.

TV040867

L11–02–48

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP

BHL1102DF

Operation: Disassembly and Assembly of the Differential Group None

Job Code: 11 03 17 xx Standard tools, Suitable puller

7

8

9

10

6 5 4 3 2 1

12 6 7

TV0400879

1

Taper Roller Bearing

2

Housing

3

Thrust Plate

4

Sun Gear

5

Planetary Shaft

6

Planetary Gear

7

Thrust Washer

8

Sun Gear

9

Thrust Plate

10

Housing

11

Taper Roller Bearing

12

Locking Pin

L11–02–49

11

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–02–37 in this section. 2. Position the differential in a suitable vice. 3. Remove the crown wheel retaining bolts (1) and remove the crown wheel (2).

1

2

TV040880

•

Caution: Make sure the internal differential components remain with the bottom housing.

Note: • Mark the differential carrier disassembly to aid installation.

prior

to

4. Remove the housing (1) from the housing (2). 5. Disassemble all of the internal differential components. 6. Check for wear of the components. Replace as necessary.

1 2

TV0400881

7. Using a suitable bearing puller remove the taper roller bearings from the housings.

TV040882

L11–02–50

FRONT AXLE AND STEER SYSTEM Assembly 1. Using the special tool CA119230 — Driver , install the taper roller bearings on the housings.

TV040882

2. Install the internal differential components into the bottom housing. 3. Install the housing (1) onto the housing (2).

1 2

TV0400881

Note: • Before installing the crown wheel retaining bolts, apply approved sealant (Loctite 270) to the bolts. 4. Install the crown wheel (2). 5. Tighten (1) to 95Nm (70 lb.ft). 6. Install the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–02–37 in this section.

1

2

TV040880

L11–02–51

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–02–52

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — PINION GROUP

BHL1102DG

Operation: Disassembly and Assembly of the Pinion Group None

Job Code: 11 09 17 xx Standard tools, CA119099, CA715170, CA119225, CA715023, CA119182. CA119226, CA715179

10 9 8 7

4 6 5

3 2 1

TV040603

1

Pinion Shaft Retaining Nut

2

Retaining Lock Washer

3

Taper Roller Bearing

4

Differential Support

5

Washer

6

Collapsable Spacer

7

Washer

8

Taper Roller Bearing

9

Adjustment Shim

10

Pinion Shaft

Disassembly 1. Remove the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–02–37 in this section.

L11–02–53

FRONT AXLE AND STEER SYSTEM 2. Position the differential support group in a suitable vice. 3. Using the special tools CA119099 — Wrench (1) and CA715170 — Wrench (2) release the pinion shaft retaining nut.

1

2 TV040883

4. Remove and discard the pinion shaft retaining nut (1). 5. Remove the retaining lock washer (2).

2 1

TV040884

6. Using a suitable soft faced hammer, remove the pinion shaft (1). 7. Remove and discard the collapsable spacer (2). 8. Recover the washers (3) and taper roller bearing (4).

2 1

4

3 TV040885

9. Place the differential support on a suitable flat surface.

L11–02–54

FRONT AXLE AND STEER SYSTEM 10. Using a suitable drift, remove the taper roller bearing cones (1) and (2).

1

2 TV040886

11. Using a suitable bearing puller, remove the taper roller bearing (1). 12. Recover the adjustment shim (2).

1

2

TV40887

13. Check all pinion components for wear. Replace as necessary.

L11–02–55

FRONT AXLE AND STEER SYSTEM Assembly 1. Place the differential support on a suitable flat surface. 2. Using the special tool CA119225 — Driver , install the taper roller bearing cones (1) and (2).

1

2 TV040886

3. Install the special tool CA715023 — false pinion (1) with the pinion shaft taper roller bearings (2) and (3).

•

Caution: Do not over-tighten.

4. Install the pinion shaft retaining nut (4). 5. Tighten until the free play is eliminated.

1

4 2

3 TV040888

6. Install the special tools CA119182 — false differential bearings (1) and CA119226 — false differential shaft (2) into the differential support. 7. Secure the special tools into position with the differential half-collers (3).

3

2

TV040889

L11–02–56

1

FRONT AXLE AND STEER SYSTEM 8. Using a suitable depth gauge, measure through the false differential shaft (CA119226) This measurement is “X” . X = The distance between the axis of the differential taper roller bearings and the point at which the pinion head is supported, or base of the bearing.

X

TV040890

9. Determine the pinion shaft position adjustment shim “S” as follows: subtract the value “V” (requested conical distance) from the calculated value “X” . S=X—V Example: Shim thickness S = 109.9 – 107.00 = 2.9mm. Shim thickness “S” = 2.9mm.

107.00 00

V

TV040811

SHIM RANGE Thickness (mm)

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

3.3

3.4

10. Remove the differential half-collers (3). 11. Remove the special tools CA119182 — false differential bearings (1) and CA119226 — false differential shaft (2) from the differential support.

3

2

TV040889

12. Remove the pinion shaft retaining nut (4).

L11–02–57

1

FRONT AXLE AND STEER SYSTEM 13. Remove the special tool CA715023 — false pinion (1) with the pinion shaft taper roller bearings (2) and (3).

1

4 2

3 TV040888

14. Install the pinion shaft position adjustment shim (2) with chamfer against the gear. 15. Using a suitable hydraulic press and the special tool CA715179 — Driver install the rear taper roller bearing (1).

1

2

TV40887

•

Caution: Always install a new collapsable spacer.

16. Install the pinion shaft (1), new collapsable spacer (2) and the washers (3) into the differential support. 17. Using the special tool CA715179 — Driver , install the taper roller bearing (4).

2 1

4

3 TV040885

L11–02–58

FRONT AXLE AND STEER SYSTEM 18. Install a new retaining lock washer (2).

•

Caution: Always install a new pinion shaft retaining nut.

Note: Do not tighten at this stage.

•

19. Install a new pinion shaft retaining nut (1).

2 1

TV040884

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: • Using a suitable soft faced hammer, settle the pinion shaft bearings. Note: Rotate the pinion shaft several times to settle the pinion shaft bearings, before measuring the pinion shaft rotational torque.

•

20. Using a suitable measuring device with the cord wound round the pinion shaft spline, measure the pinion shaft rotational torque. 21. The rotational torque should be within the following range excluding breakaway torque. 9.2 to 13.7 daN

TV040891

L11–02–59

FRONT AXLE AND STEER SYSTEM

•

Caution: If the stated rotational torque range is exceeded the collapsable spacer must be replaced and the procedure repeated.

22. The adjustment is carried out by increasing the pinion shaft retaining nut torque setting gradually using the special tools CA119099 — Wrench (1) and CA715170 — Wrench (2), being careful not to exceed the stated range.

1

2 TV040883

23. Once the correct rotational torque is achieved, secure the pinion shaft retaining nut. Note: • Do not install a new pinion shaft oil seal at this stage. 24. Install the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–02–37 in this section.

TV040892

L11–02–60

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — TOE-IN ADJUSTMENT

BHL1102GA

Operation: General Procedure Toe-in Adjustment None

Job Code: 11 13 01 xx Standard tools, Two one-metre-long bars

General Procedure The toe-in of the front wheels must be between 0 and 5mm toe-in as measured 500mm from the centre of the wheel hub. To check the exact value of the toe-in setting, proceed as follows. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • The bars must be fixed flat against the wheel hub flange and have an equal distance from the centre of the wheel hub. 2. Install two equal one-metre-long bars to the wheel side of the wheel hubs and lock in place with two wheel retaining nuts.

500mm

500mm

TV040979

3. Measure the distance (A) between the ends of the two bars. 4. Measure the distance (B) between the ends of the two bars. 5. The distance (A) must be 0 to 5mm less than distance (B).

A

B TV040980

L11–02–61

FRONT AXLE AND STEER SYSTEM Note: • Make sure the same number of threads are visible at the end of the left-hand and right-hand inner track rod end ball joints. 6. If it is necessary to correct the toe-in adjustment. Loosen the lock nut (1) on the left-hand and the right-hand side. Turn the inner track rod end ball joints (2) equally to achieve the specified toe-in adjustment. 7. Tighten (1) to 120Nm (89 lb.ft).

1

2

TV040981

L11–02–62

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT

BHL1102GB

General Procedure

1

50º 2 A

3 TV040966

1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Turn the steering wheel until the front wheel hubs are on full left-hand lock. 3. Place a straight edge (3) against the axle input flange or against the machine hardnose. Make sure the straight edge is parallel with the axle centre-line. 4. Place a second straight edge (2) against the wheel hub flange (1).

•

Caution: Make sure the steering angle does not exceed 52 degrees. Failure to follow this instruction may result in excessive wear to the drive shaft universal joints.

5. Measure the angle (A) at which both straight edges intersect. Subtract angle A from 90 degrees to give the steering lock. Angle A = 40 Steering angle 90 – 40 = 50 degrees. 6. Adjust the left-hand stop for maximum left steering lock and right-hand stop for maximum right steering lock. 7. Loosen the lock nut (1) and adjust the steering stop adjuster bolt (2) until the bolt head touches the steering stop. Tighten the lock nut (1) to 150Nm.

L11–02–63

FRONT AXLE AND STEER SYSTEM 8. Turn the steering wheel until the front wheel hubs are on full right-hand lock and repeat the procedure for the right-hand side.

1 2

TV040967

L11–02–64

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL Operation: Draining and Filling the Front Axle Housing Oil None

BHL1102GC

Job Code: 11 07 09 xx Standard tools

Draining 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Loosen the refill plug (1) to release any pressure. 3. Remove the drain plug (2) and drain the oil into a suitable container.

Filling 1. Install the drain plug (2) and tighten to 60Nm (44 lb.ft). 2. Fill with oil until the refill hole (1) level is reached. 3. Install the refill plug (1) and tighten to 60Nm (44 lb.ft).

1

2 TV040946

L11–02–65

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–02–66

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL

BHL1102GD

Draining 1. Position the hub until the drain/refill plug is positioned at the top. Loosen the drain plug to release any pressure. 2. Position the hub until the drain/refill plug is positioned at the bottom. Remove the drain/refill plug and drain the hub oil into a suitable container.

TV040197

Filling 1. Position the hub until the drain/refill plug is at the 3 o’clock position. Fill with oil until the drain/refill hole level is reached. 2. Install the drain/refill plug and tighten to 60Nm (44 lb.ft).

TV040934

L11–02–67

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–02–68

FRONT AXLE AND STEER SYSTEM SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE

BHL1102SA

Special Tools Tool No.

Description

CA119030

Wrench

CA119033

Interchangeable Handle

CA119043

Driver

CA119099

Wrench for Lock Nut

CA715026

Driver for Bearing Race

CA715027

Driver for Bush

CA119117

Driver

CA119143

Driver

CA119182

False Differential Box

CA119225

Driver

CA119226

False Differential Box

CA119230

Driver

CA715023

False Pinion

CA715034

Driver

CA715035

Driver

CA715163

Driver

CA715164

Driver

CA715170

Wrench

CA715179

Driver

CA715505

Driver

CA715506

Driver

CA715701

Driver

L11–02–69

FRONT AXLE AND STEER SYSTEM Torque Values Description

Nm

Lb.ft

Epicyclic Reduction Hub

80

59

Wheel Hub

230

170

Axle Drain/Fill Plugs

60

44

Wheel Studs

70

52

King Pin

190

140

Crown Wheel

95

70

Grease Nipple

8

6

Differential Adjustment Nut Locking Tabs

13

10

Differential Housing

169

125

Differential Half Collers

266

196

Breather

10

7

Blanking Plug

25

18

Steering Cylinder

120

89

Swivel Joint

300

221

Tie-Rod Locking Nut

250

184

Tie-Rod End

220

162

Steering Angle Adjustment Locking Nut

150

111

General Specifications Description

Value

Crown Wheel Gear Ratio

2.133/1

Epicyclic Reduction Gear Ratio

6.00/1

Total Ratio

12.80/1

Dry Weight

303 Kg

Input Rotation

Clockwise (C.W.)

Steering Angle

55° 0–2mm

Toe-in

0–5mm

Crown Wheel / Pinion Backlash

0.18 – 0.23mm

Pinion Shaft Bearing Pre-Load “P”

“P” = 9.2 – 13.7 daN

Total Pinion/Differential Bearing Pre-load

(4.3 + P) — (6.45 + P) daN

Axle Housing Oil Capacity

6.5 Litres

Epicyclic Reduction Hub Oil Capacity

1.0 Litre

Oil Type (Use recommended oil enriched in Additives)

API GL5 (for possible alternatives see – GENERAL INFORMATION – FLUIDS AND LUBRICANTS at the start of this manual).

Grease Type

TECNOLUBE SEAL PLOYMER 400/L (DIN = KHER1R ISO-I-XMR-XM2) AGIP MU/EP2 (King pin only)

Sealant

Silastic 732

L11–02–70

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — FOUR-WHEEL STEER FRONT AXLE

BHL1103OA

General Description 1

2

3

4 6 7

5

TV041104

1

Wheel Hub Group

2

Axle Beam Group

3

Differential Group

4

Differential Support Group

5

Pinion Group

6

Steering Cylinder Group

7

Epicyclic Reduction Gear Group

The axle described in this manual consists of the following groups: • WHEEL HUB GROUP: wheel support parts containing the epicyclic reduction gears. • AXLE BEAM GROUP: load-bearing shell structure of the axle. • DIFFERENTIAL GROUP: differential parts with crown wheel gear. • DIFFERENTIAL SUPPORT GROUP: differential housing with crown wheel gear adjusting system.

• • •

PINION GROUP: pinion with adjusting and support parts. STEERING CYLINDER GROUP: steering cylinder parts with adjusting system. EPICYCLIC REDUCTION GEAR GROUP: planetary carrier with reduction/transmission parts.

L11–03–1

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–2

FRONT AXLE AND STEER SYSTEM DIAGNOSING AND TESTING — FOUR-WHEEL STEER FRONT AXLE Problem Ring gear tooth broken at the outer side

Ring gear tooth broken side

Pinion or ring gear teeth worn

BHL1103TA

Possible Cause

Action

•

Excessive gear load compared to the one foreseen.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (excessive backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Load bump.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (insufficient backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

•

Contaminated oil.

• •

•

L11–03–3

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

FRONT AXLE AND STEER SYSTEM Problem Pinion or ring gear teeth worn (continued)

Action

Possible Cause

•

Incorrect lubrication or depleted additives.

• •

•

•

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

• •

•

Overheated ring and pinion teeth. Check if gear teeth have faded.

Pinion teeth pitting

Axle beam body bent

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals. REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

Prolonged functioning at high temperatures.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Incorrect lubrication.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Low oil level.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

• • •

Vehicle overloaded.

• • •

REPLACE axle beam body.

Vehicle’s accident. Load bump.

L11–03–4

REPLACE axle beam body. REPLACE axle beam body.

FRONT AXLE AND STEER SYSTEM Problem Worn out or pitted bearings

Oil leakage from gaskets and seals

Action

Possible Cause

•

Insufficient lubrication.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Normal wear out.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Pinion nut loosened.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Prolonged functioning at high temperature of the oil.

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

• •

Oil gasket assembled incorrectly.

• •

•

Seal lip damaged.

• •

•

Contaminated oil.

• •

Problem Excessive wearing out of input flange spline

Heavy use.

• • •

L11–03–5

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. Action

Possible Cause

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

FRONT AXLE AND STEER SYSTEM Problem

Action

Possible Cause

•

Pinion nut loosened.

• • •

•

Pinion axle backlash.

• • •

Fatigue failure of pinion teeth. See if the fracture line is well defined (wave lines, beach lines)

• •

Heavy use.

Pinion and ring teeth breakage

•

Side gear spline worn out. Replace all scratched washers (Excessive backlash)

•

Thrust washer surface worn out or scratched

•

REPLACE bevel gear set.

Crash load of differential components.

•

CHECK and/or REPLACE other differential components.

Excessive use.

•

Insufficient lubrication.

• •

REPLACE differential gear group. REPLACE half shaft if required.

Continuous overload.

•

Incorrect lubrication.

• • •

•

Contaminated oil.

• • •

Problem Inner diameter of tapered roller bearing worn out

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

• •

•

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

REPLACE bevel gear set.

USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0.1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0.1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0.1 mm thickness lower than the new ones. Action

Possible Cause

•

Excessive use.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive pinion axial backlash.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

L11–03–6

FRONT AXLE AND STEER SYSTEM Problem

Action

Possible Cause

•

Insufficient lubrication.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

Bent or broken half shaft

•

Vehicle intensively operated or overloaded.

•

REPLACE half shaft.

Half shaft broken at wheel side

•

Wheel support loosened.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

•

Beam body bent.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

Axle Problem and Diagnosis Problem Noise while driving

Noise whilst driving in neutral

Intermittent noise Constant noise

Possible Cause

Action

•

Excessive backlash between pinion and ring gear.

•

ADJUST.

• • • •

Worn out pinion and gear ring.

• • • •

REPLACE.

• • • • • • •

Worn out differential bearings.

• • • • • • •

REPLACE.

•

Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing the speed.

•

REPLACE.

• • • •

Pinion or input flange worn out.

Worn out pinion bearings. Pinion bearings loosened. Excessive axial pinion backlash. Differential bearings loosened. Ring gear out of roundness. Low Lubricant level. Poor or wrong lubricant. Bent half shaft. Noise coming from axle is usually heard when vehicle moves in neutral gear but is not loud.

• Ring gear damaged. • Differential box bolts loosened. • Ring gear teeth or pinion • damaged.

L11–03–7

REPLACE. ADJUST. ADJUST.

ADJUST. REPLACE. OIL level. REPLACE. REPLACE. REPLACE or ADJUST (see above).

ADJUST. REPLACE bevel gear set. TIGHTEN to torque. REPLACE bevel gear set.

FRONT AXLE AND STEER SYSTEM Problem

Noise while steering

Action

Possible Cause

• • • • •

Worn out bearings.

• •

• • • • •

REPLACE.

Differential thrust washers worn out.

•

REPLACE.

Half shaft spline worn out.

•

REPLACE.

Pinion spline worn out. Bent half shaft. Worn out differential gears. Worn out differential box or spider.

L11–03–8

REPLACE. REPLACE. REPLACE. REPLACE.

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — FOUR-WHEEL STEER FRONT AXLE

BHL1103RA

Operation: Removing and Installing the Four-Wheel Drive Front Axle (Four-Wheel Steer) Suitable transmission jack

Job Code: 11 24 13 xx Standard tools

Removal Note: • Make a note of the position of any hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Remove the hardnose/tool box. For additional information, refer to Section K10-01 HARDNOSE/TOOLBOX, PAGE K10–01–3 . 3. Raise the front loader to full height and install the safety stop. 4. Roll the loader bucket fully forward.

TV040056

5. Remove the front axle pivot pin grease point (1). Note: • Discard the locking nut. 6. Remove the front axle pivot pin retaining bolt (2).

1

2 TV040061

L11–03–9

FRONT AXLE AND STEER SYSTEM 7. Disconnect the power steering supply pipes (1). 8. Loosen the propeller shaft locking ring (2).

1

2 TV041094

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

•

Warning: Secure the front axle to the transmission jack. Failure to follow this instruction may result in personal injury.

Note: Mark the axle pivot pin before removal to aid installation.

•

9. Using a suitable transmission jack (1), support the front axle. Note: • Secure the propeller shaft to one side when removing the front axle. Using a suitable slide hammer (2), remove the front axle pivot pin and remove the front axle.

2

1

TV040064

Installation Note: • Remove any dirt or burrs before installing the front axle pivot pin. Note: Make sure the propeller shaft is aligned with the front axle differential shaft when raising the axle into position.

•

1. To install, reverse the removal procedure.

L11–03–10

FRONT AXLE AND STEER SYSTEM Note: • Install a new locking nut. 2. Tighten (2) to 98Nm (72 lb.ft). 3. Check and adjust the hydraulic oil level as required. 4. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

1

2 TV040061

L11–03–11

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–12

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Steering Cylinder Group (Four-Wheel Steer) None

BHL1103DA

Job Code: 11 20 17 xx Standard tools, Suitable piston ring compression tool

1

2

3

4 5 6 7

8 9

10 TV041095

1

Wiper Seal

2

Sealing Ring

3

Cylinder Head

4

Cylinder

5

O-ring

6

O-ring

7

Piston Rod Assembly

8

Back-up Seal

9

Cylinder Head

10

Sealing Ring

11

Wiper Seal

Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

L11–03–13

11

FRONT AXLE AND STEER SYSTEM

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (4) in a soft jawed vice. 3. Remove the cylinder heads (3) and (9) from the steering cylinder group. 4. Remove the piston rod assembly (7) from the cylinder (4). 5. Remove the wiper seal (1), sealing ring (2) from the cylinder head (3). 6. Remove the wiper seal (11), sealing ring (10) from the cylinder head (9). 7. Remove the back-up seal (5), piston sealing ring (6) and back-up seal (8) from the piston rod assembly (5).

Assembly Note: • Install new O-ring seals, seals and rings. Note: Lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the back-up seal (8), piston sealing ring (6) and the back-up seal (5) to the piston rod assembly (7). 2. Install the O-ring (4), sealing ring (2) and the wiper seal (1) to the cylinder head (5). 3. Lubricate the inside of the cylinder (10) and the piston rod assembly (5) with clean oil. Use a piston ring compression tool to hold the new back-up seals (6),(8) Piston Sealing Ring (7) in place.

•

Caution: Be careful not to damage the back-up seals and piston sealing ring.

4. Start the cylinder (10) onto the piston rod assembly (5). Push the cylinder onto the piston rod (5) assembly until the compression tool is pushed off the piston rod assembly. 5. Install the wiper seal (1), sealing ring (2) to the cylinder head (3). 6. Install the wiper seal (11), sealing ring (10) to the cylinder head (9). 7. Install the cylinder heads (3) and (9) onto the steering cylinder group.

L11–03–14

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Epicyclic Reduction Gear Group None

BHL1103DB

Job Code: 11 05 17 xx Standard tools Suitable container

10 9 7 6 5 4 3 2

11

8 1

TV041092

1

Drain Plug

2

Retaining Screw

3

Epicyclic Reduction Gear Carrier

4

Thrust Washer

5

Needle Roller Bearings

6

Epicyclic Gear

7

Washer

8

Dowel Pin

9

Washer

10

Retaining Bolt

11

O-Ring

L11–03–15

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the front wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–5 . 2. Drain the hub oil. For additional information, refer to L11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 3. Remove the epicyclic reduction gear carrier. Note: • Remove and discard the O-ring oil seal.

TV040763

4. Remove the epicyclic gear retaining bolt (1) and washer (2).

TV040764

5. Remove the locating washer (1) and the epicyclic gear (2). Note: • Recover the set of needle roller bearings and the needle roller bearings spacers.

TV040767

L11–03–16

FRONT AXLE AND STEER SYSTEM 6. Remove the locating pin (1) and the wear washer (2). 7. Repeat steps 4 to 6 to remove the remaining epicyclic gears. 8. If the pinion pins are damaged, a new epicyclic reduction gear carrier assembly should be installed.

TV040768

9. If the half-shaft stop (1) is damaged, a new epicyclic reduction gear carrier assembly should be installed.

TV040770

Assembly 1. Install the wear washer (2) and the locating pin (1).

TV040768

L11–03–17

FRONT AXLE AND STEER SYSTEM 2. Install the epicyclic gear (1) and the set of needle roller bearings (2).

TV040803

3. Install the locating washer.

TV040805

4. Install the washer (2) and epicyclic gear retaining bolt (1). 5. Tighten (1) to 79Nm (58 lb.ft).

TV040764

6. Repeat steps 1 to 5 to install the remaining epicyclic gears. Note: • Install a new O-ring oil seal. 7. Install the epicyclic reduction gear carrier.

L11–03–18

FRONT AXLE AND STEER SYSTEM 8. Tighten to 25Nm (18 lb.ft).

TV040763

9. Fill the hub with oil. For additional information, refer toL11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 . 10. Install the front wheel. For additional information, refer toM12-01 FRONT WHEEL, PAGE M12–01–5 .

L11–03–19

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–20

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — FRONT WHEEL HUB GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Front Wheel Hub Group (Four-Wheel Steer)

BHL1103DC

Job Code: 11 08 17 xx

Suitable lifting equipment

Standard tools, Ball joint separator, CA715026, CA715027, CA119143 CA119117 CA119087

28 19 18 14

25

13 12 11

27

10

26 23

24

8 7 15

22 21

4 3

16

1 17 9 6 2

5

TV041091

L11–03–21

20

FRONT AXLE AND STEER SYSTEM 1

Lock Ring

2

Universal-Joint Shaft Washer

3

Universal-Joint Shaft Washer

4

Epicylic Ring Gear

5

Retaining Bolt

6

Centre Bushes

7

Epicylic Hub

8

Steel Lock Ring

9

Taper Roller Bearing

10

Stud

11

Wheel Hub

12

Taper Roller Bearing

13

Oil Seal

14

Swivel Housing

15

Cone

16

Lower Kingpin

17

Retaining Bolt

18

Upper Kingpin

19

Retaining Bolt

20

Bush

21

Lock Nut

22

Steering Angle Adjustment Bolt

23

Bush

24

Oil Seal

25

Universal-Joint Shaft End

26

Belleville Washers

27

Axle

28

Belleville Washers

Disassembly 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–5 . 2. Remove the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section. 3. Remove the wheel carrier circlip and spacers (1). 4. Remove the wheel carrier retaining bolts (2).

TV040199

L11–03–22

FRONT AXLE AND STEER SYSTEM 5. Using 2 wheel carrier retaining bolts, extract the wheel carrier.

TV040200

6. Remove the snap ring (1) and remove the epicyclic gear hub (2) from the epicyclic ring gear (3).

1

2

3 TV040771

7. Using a suitable soft faced hammer, remove the front axle hub (1) and the outer roller bearing (2).

1

2

TV040772

8. Using a suitable lever, remove and discard the hub oil seal (1). 9. Recover the outer taper roller bearing. Using a suitable drift, remove the inner and outer taper roller bearings (2).

2

1

TV040849

L11–03–23

FRONT AXLE AND STEER SYSTEM

•

Caution: Leave the tie rod end nut on the tie rod end a few turns to prevent damage to the stud while using the ball joint separator.

10. Remove the retaining nut and using a suitable ball joint separator, detach the tie rod assembly from the wheel hub.

TV040202

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment, support the wheel hub assembly .

•

11. Remove the upper (1) and lower (2) kingpin retaining bolts and remove the kingpins. 12. Remove the swivel hub assembly.

1 1

2 TV040203

13. Remove the swivel thrust washers. orientation to aid installation.

Note the

TV040854

L11–03–24

2

FRONT AXLE AND STEER SYSTEM Note: • Position the swivel hub on a suitable flat surface 14. Using a suitable lever, remove the oil seal. 15. Using a suitable lever, remove the oil seal. Note: Discard the oil seal.

•

TV040851

16. Using a suitable drift, remove the swivel housing bush.

TV040852

Assembly 1. Using the special tool CA715108 — Driver , install the swivel housing bush. 2. Using the special tool CA119117 — Driver for oil seal , install the oil seal.

TV040853

L11–03–25

FRONT AXLE AND STEER SYSTEM 3. Install the swivel thrust washers.

TV040854

4. Install the front hub carrier. 5. Tighten to 300Nm (221 lb.ft).

1 1

2 TV040203

6. Install the tie rod end.

TV040202

7. Using a suitable hydraulic press and the special tool CA715026 — Driver for bearing race , install the inner and outer taper roller bearing cones.

TV040925

L11–03–26

2

FRONT AXLE AND STEER SYSTEM Note: • Lubricate the oil seal with a light grease. 8. Using the special tool CA119087 — Driver for oil seal , install a new hub seal.

TV040926

9. Install the inner taper roller bearing.

TV040773

10. Install the front axle hub (1). 11. Install the outer taper roller bearing (2).

1

2

TV040772

12. Install the epicyclic hub (2) to the epicyclic ring gear (3) and install the snap ring (1).

1

2

3 TV040771

L11–03–27

FRONT AXLE AND STEER SYSTEM Note: • Install two bushes slightly higher that the hub surface level to be used as dowel pins. 13. Using the special tool CA715027 — Driver for bush partially install the hub centering bushes.

TV040930

14. Assemble the epicyclic group on the front wheel hub using the two protruding centering bushes as dowel pins.

TV040200

15. Using the special tool CA715027 — Driver for bush , fully install the remaining centering bushes.

TV040931

L11–03–28

FRONT AXLE AND STEER SYSTEM 16. Install the front wheel hub retaining bolts and tighten to 230Nm (170 lb.ft).

TV040769

17. Install the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section. 18. Install the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–5 .

L11–03–29

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–30

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — AXLE BEAM GROUP (FOUR-WHEEL STEER)

BHL1103DD

Operation: Disassembly and Assembly of the Axle Beam Trumpets and Brake Group

Job Code: 11 07 17 xx

Suitable lifting equipment

Standard tools, CA715386, CA715387 CA715034 CA715505

1 2

3 4 5

7 8

9

13 12

11 10 TV041127

1

Central Body

2

O-Ring

3

Axle Beam

4

Retaining Bolts

5

Upper King Pin Bush

6

Ball Bearing Bush

7

Bush

8

Sealing Ring

9

Universal Joint

10

Sealing Ring

11

Bushe

12

Bushe

13

Sealing Ring

Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section.

L11–03–31

6

FRONT AXLE AND STEER SYSTEM 2. Drain the axle oil into a suitable container. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 3. Remove the two double universal joints from the axle beam trumpets (both sides).

TV040861

4. Mark the axle beam trumpet prior to disassembly to aid installation.

TV041145

•

Warning: Support the axle beam trumpet. Failure to follow this instruction may result in personal injury.

5. Remove the axle beam trumpet retaining bolts and remove the axle beam trumpet (both sides). Note: • Remove and discard the O-rings.

TV041145

6. Remove the oil seal (2) from the axle beam trumpet (both sides). Note: • Discard the oil seal rings.

L11–03–32

FRONT AXLE AND STEER SYSTEM

•

Warning: Be careful not to damage the bush housing.

7. Remove the bushes (1) from the axle beam trumpet housing (both sides). 8. Using a suitable extractor remove the upper king pin bush (3) and the ball bearing cup (4) from the king pin housing (both sides).

3

1

4 2 TV040862

9. Remove the sealing rings (1) and (2) from the central body. Note: • Discard the oil seal rings.

2

1 TV041116

•

Caution: Take care not to damage the bush housing.

10. Remove the bushes (1) and (2) from the axle central body. Note: Discard the oil seal rings.

•

2

1 TV041118

L11–03–33

FRONT AXLE AND STEER SYSTEM Assembly Note: • Install new oil seals. 1. Using the special tool CA715034 , install the king pin bush (3) in the axle housing (both sides). 2. Using the special tool CA715034 , install the ball bearing cup (4) in the axle housing (both sides). 3. Using the special tool CA715505 , install the bush (1) and the oil seal (2).

3

1

4 2 TV040862

4. Install the bush (1) and the oil seal (2) as shown.

1

TV040866

•

Warning: Support the axle beam trumpet. Failure to follow this instruction may result in personal injury.

Note: Install a new axle beam trumpet O-ring.

•

Note: Rear axle shown.

•

5. Install the axle beam trumpet. 6. Tighten to 130Nm (96 lb.ft).

TV040782

L11–03–34

2

FRONT AXLE AND STEER SYSTEM Note: • Install the bushes with the machined edges facing in. 7. Using the special tool CA715163 — Driver for bush install the bushes (1) and (2) in the axle central body.

2

1 TV041114

8. Using the special tool CA715164 — Driver for bush install the sealing rings (1) and (2) in the axle central body.

2

1 TV041116

9. Install the two double Universal-Joints into the axle beam trumpet housing (both sides).

TV040861

10. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 11. Install the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section.

L11–03–35

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–36

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Differential Support Group

BHL1103DE

Job Code: 11 03 13 xx

Suitable lifting equipment

Standard tools, CA715386, CA715387, CA715034, CA715505, CA119030, CA715456, CA715116.

1

2

3

4 5

6 7

8 9

TV041112

1

Central Body

2

Differential Group

3

Bearing Cup

4

O-Ring

5

Differential Support

6

Retaining Bolt

7

Adjuster Ring Nut

8

Adjuster Ring Nut Retainer

9

Retaining Screw

Disassembly 1. Remove the axle beam group. For additional information, refer to AXLE BEAM GROUP, PAGE N13–04–19 in this section.

L11–03–37

FRONT AXLE AND STEER SYSTEM 2. Remove the retaining bolt (6) and remove the differential support (5) from the central body (1). Note: • Remove and discard the O-ring.

2 3

1 TV041113

3. Remove the retaining screw (1) and remove adjuster ring nut retainer (2).

2

1

TV041148

4. Using the special tool CA119030 — Wrench , remove the adjuster ring nut retainer (7) from the differential support (5). 5. Remove the bearing cup (6) from the differential support (5).

1 2 TV041120

L11–03–38

3

FRONT AXLE AND STEER SYSTEM 6. Remove the differential group (2).

TV041149

Assembly Note: • Some of the following pictures may not show exactly your axle, but the indicated operations are correct. Note: It is important to begin the assembly on the left side of the central body to make possible the assembly of the differential support.

•

Note: • Install a new O-ring into the differential support. 1. Using special tool CA715299 — Driver , install the bearing cup (1) to the left differential support (2). 2. Using the special tool CA119030 — Wrench , install the adjuster ring nut (3) into the left differential support (2).

1 2 TV041120

•

Caution: Secure the differential support with at least three retaining bolts. Failure to follow this instruction may result in damage to the axle.

3. Assemble the left differential support (2) to the central body (3).

L11–03–39

3

FRONT AXLE AND STEER SYSTEM 4. Tighten (6) to 95Nm (70 lb.ft).

1 3

2 TV041124

5. Install the differential to the central body

TV041149

Note: • Install a new O-ring into the differential support. 6. Using the special tool CA715299 — Driver install the baring cup (1) to the right differential support. 7. Using the special tool CA119030 — Wrench , install the adjuster bring nut (3) into the right differential support (2).

•

Caution: Secure the differential support with at least three retaining bolts. Failure to follow this instruction may result in damage to the axle.

1 2 TV041120

8. Assemble the right differential into the central body (1).

L11–03–40

3

FRONT AXLE AND STEER SYSTEM 9. Assemble the right differential support (5) into the central body (1).

2 3

1 TV041113

Note: • Make sure the differential adjustment nuts are adjusted equally to retain the nominal bearing pre-load and no free play. 10. Using the special tool CA119030 — Wrench , adjust the differential adjustment nuts until the correct pinion to crown wheel backlash is achieved.

TV041147

11. Using a suitable measuring device and special tool CA715456 — Kit for backlash measurement , measure the pinion to crown wheel backlash. 12. The pinion to crown wheel backlash should be within the following range: 0.18mm – 0.23mm

TV040833

L11–03–41

FRONT AXLE AND STEER SYSTEM 13.

•

•

Measured backlash is greater than the specified range — (A) , adjust the differential assembly closer to the pinion shaft by loosening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment nut equal amounts. Measured backlash is less than the specified range — (B) , adjust the differential assembly away from the pinion shaft by tightening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment nut equal amounts.

A

A

B

B

TV041125

14. Once the correct pinion to crown wheel backlash is achieved, check that the differential taper roller bearings have no free play and no pre-load is evident. 15. Repeat steps 10 to 13 of the whole sequence of the above mentioned operations, until the indicated conditions are reached.

TV040834

16. Install the special tool CA715116 — Measurement onto the pinion shaft.

L11–03–42

FRONT AXLE AND STEER SYSTEM

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Using a suitable soft-faced hammer, settle the differential taper roller bearings.

•

Note: Rotate the differential assembly while tightening the adjustment nuts to seat the bearing rollers on their track.

•

17. Using a suitable measuring device (with the cord wound on the 104.6 mm diameter of the special tool CA715780 — measurement ), measure the total rotational torque.

TV040835

18. The total rotational torque should be within the following range excluding breakaway torque. (6.14 + P) to (9.16 + P) N P = Measured pinion shaft rotational torque. For additional information refer to PINION GROUP, PAGE L11–02–53 in this section. Note: Make sure the differential adjustment nuts are adjusted equally to retain the set backlash.

•

19. Using the special tool CA119030 — Wrench for differential housing lock nut , adjust the differential adjustment nuts until the correct differential taper roller bearing pre-load is achieved.

TV040832

L11–03–43

FRONT AXLE AND STEER SYSTEM 20.

•

•

Total pre-load is less than the specified range — (A) , increase the differential taper roller bearing pre-load by tightening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment equal amounts. Total pre-load is higher than the specified range — (B) , decrease the differential taper roller bearing pre-load by loosening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment equal amounts.

A

A

B

B

TV041126

Testing After Adjustment Note: The marking test should always be carried out on both sides of the crown wheel teeth.

•

21. To test the marks of the crown wheel teeth, paint the ring gear with red lead paint.

TV040836

L11–03–44

FRONT AXLE AND STEER SYSTEM 22. Check the contact pattern: OK = Correct contact — If the crown wheel is well adjusted, the mark on the teeth surfaces will be regular. Z = Excessive contact on the tooth tip — Adjust the pinion towards the crown wheel and then adjust the crown wheel away from the pinion in order to adjust the backlash. X = Excessive contact at the tooth base — Adjust the pinion away from the crown wheel and then adjust the crown wheel towards the pinion in order to adjust the backlash.

OK

Z

X

TV040837

23. Movements to correct Adjust as required: 1 = move the pinion for type X contact adjustment. 2 = move the pinion for type Z contact adjustment.

2 1 TV040838

L11–03–45

FRONT AXLE AND STEER SYSTEM 24. Lock the differential adjustment nuts in position with the locking tabs (1) and secure with the retaining bolts (2). 25. Tighten to 13Nm (10 lb.ft).

1

2

TV041085

26. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 27. Install axle beam group. For additional information, refer to AXLE BEAM GROUP, PAGE N13–04–19 in this section.

L11–03–46

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Differential Group

BHL1103DF

Job Code: 11 03 17 xx

None

Standard tools, CA715133

9 8

7 6 4

13

5

3

2

10

1

TV041111

1

Retaining Bolts

2

Bevel Gear Crown

3

Taper Roller Bearing

4

Housing

5

Thrust Plate

6

Sun Gear

7

Planetary Shaft

8

Planetary Gear

9

Thrust Washer

10

Sun Gear

11

Thrust Plate

12

Housing

13

Taper Roller Bearing

Disassembly 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Position the differential in a suitable vice.

L11–03–47

11

12

FRONT AXLE AND STEER SYSTEM Note: • Mark the differential carrier disassembly to aid installation.

prior

to

3. Remove the crown wheel.

TV040796

4. Remove the thrust plate (1) and sun gear (2).

TV040797

5. Remove the planetary shafts (1) and the planetary gears (2). Note: • Recover the thrust washers (3).

2 3

1 TV040798

6. Remove the sun gear (1) and thrust plate (2).

TV040799

L11–03–48

2

FRONT AXLE AND STEER SYSTEM 7. Remove the snap ring (1). 8. Using a suitable puller, remove the right-hand side taper roller bearing.

TV040801

9. Using a suitable puller, remove the left-hand side taper roller bearing (1) and the crown wheel (2).

TV040802

L11–03–49

FRONT AXLE AND STEER SYSTEM Assembly 1. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the left-hand side differential taper roller bearing (1) and the crown wheel assembly (2).

TV040802

2. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the right-hand side differential taper roller bearing.

TV040801

3. Install the thrust washer (2) and the sun gear (1).

TV040799

4. Install the Planetary shafts (1), planetary gears (2) and the trust washers (3).

2 3

1 TV040798

L11–03–50

2

FRONT AXLE AND STEER SYSTEM 5. Install the sun gear (2) and the thrust washer (1).

TV040797

6. Install the crown wheel. Note: • Before installing the crown wheel retaining bolts, apply approved sealant (Loctite 270) to the bolt. 7. Tighten to 155Nm (114 lb.ft). 8. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

TV040796

L11–03–51

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–52

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Pinion Group None

BHL1103DG

Job Code: 11 09 17 xx Standard tools, CA119099, CA715022, CA715380, CA715128, CA715388, CA715004, Suitable measuring device.

7 6 5 4 3 2 1

13 12 11 10 9 8 TV041101

1

Retaining screws

2

Flange

3

Sealing Ring

4

Lock Nut

5

Retaining Washer

6

Bearing

7

Differential Housing

8

Washer

9

Collapsible Spacer

10

Washer

11

Bearing

12

Shim

13

Pinion Shaft

L11–03–53

FRONT AXLE AND STEER SYSTEM Disassembly Note: • Some of the following pictures may not show exactly your axle, but the indicated operations are correct. 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Remove and flange from the differential housing.

TV041102

3. Remove the O-ring (1) and the spacer (2). Note: • Discard the O-ring seal.

2 1

TV040806

L11–03–54

FRONT AXLE AND STEER SYSTEM

•

Caution: Release the pinion shaft retaining nut locking tabs. Failure to follow this instruction may result in damage to the machine.

4. Using the special tools CA119099 — Wrench for lock nut and CA715022 — Pinion shaft lock tool , remove the pinion shaft retaining nut and washer. Note: • Recover the lock washer.

1

2 TV040813

5. Using a suitable soft faced hammer, remove the pinion shaft from the differential housing. Note: • Recover the outer taper roller bearing, two washers and discard the elastic spacer.

TV040814

6. Using a suitable puller, remove the taper roller bearing from the pinion shaft. Note: • Recover the pinion end float adjustment shim.

TV040927

L11–03–55

FRONT AXLE AND STEER SYSTEM 7. Using a suitable drift, remove the pinion shaft taper roller bearing cups from the differential housing.

TV040816

L11–03–56

FRONT AXLE AND STEER SYSTEM Assembly Note: • Some of the following pictures may not show exactly your axle, but the indicated operations are correct. 1. Using the special tool CA715380 — Bearing races insertion kit install the taper roller bearing cups into the differential housing.

TV040818

2. Install the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

•

Caution: Do not overtighten.

3. Install the lock washer (1) and the pinion shaft retaining nut (2). 4. Tighten until the free play is eliminated.

TV040928

5. Install the left-hand side differential support with three retaining bolts 120° apart. 6. Tighten to 79Nm (58 lb.ft).

L11–03–57

FRONT AXLE AND STEER SYSTEM 7. Repeat steps 5 and 6 for the right-hand side differential support.

TV041081

Note: • Ensure the false differential box is inserted in both differential supports. 8. Install the special tool CA715388 — false differential box into the differential housing.

TV040820

B A

X

C

9. Using a suitable depth gauge, measure through the false pinion CA715128 — False pinion. This measurement is “A” . 10. Determine the value “X” as follows: X = (conical distance to be measured) A = (measured value) B = 100mm C = 50mm X = (A + C) — B Example: A = 159.9mm therefore: X = (159.9 + 50) – 100mm X = 109.9mm

TV040821

L11–03–58

FRONT AXLE AND STEER SYSTEM 11. Determine the pinion shaft position adjustment shim “S” as follows: subtract the value “V” (requested conical distance) from the calculated value “X” . S=X—V Example: Shim thickness S = 109.9 – 107.00 = 2.9mm. Shim thickness “S” = 2.9mm

107.00 00

V

TV040811

SHIM RANGE Th ickness (mm)

2.5

2.6

2.7

2.8

2.9

12. Remove the special tool CA715388 — false differential box from the differential housing.

TV040820

13. Remove the differential support (both sides).

TV041081

L11–03–59

3.0

3.1

3.2

3.3

3.4

FRONT AXLE AND STEER SYSTEM 14. Remove the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

15. Install the pinion shaft adjustment shim (1) with chamfer against the gear. 16. Using a suitable hydraulic press and the special tool CA715004 — Driver for bearing install the rear taper roller bearing (2).

2 1

TV040823

Note: • Always use a new elastic spacer. 17. Install the washers and the new elastic spacer onto the pinion shaft. 18. Install the pinion shaft assembly (1) and the front taper roller bearing (2) into the differential housing.

1

2

TV040824

19. Install a new lock washer (1).

L11–03–60

FRONT AXLE AND STEER SYSTEM Note: • Do not tighten at this stage. 20. Install a new pinion shaft retaining nut (2).

TV040928

21. Install the special tool CA715116 — Measurement onto the pinion shaft. Note: Using a suitable soft faced hammer, settle the pinion shaft bearings.

•

22. Using a suitable measuring device (with the cord wound on the special tool CA715116 — measurement ), measure the pinion shaft rotational torque. 23. The rotational torque should be within the following range excluding breakaway torque. 9.2 to 13.7 daN

TV040825

•

Caution: If the stated rotational torque range is exceeded the elastic spacer must be replaced and the procedure repeated

24. The adjustment is carried out by increasing the pinion shaft retaining nut torque setting gradually, being careful not to exceed the stated range.

L11–03–61

FRONT AXLE AND STEER SYSTEM 25. Once the correct rotational torque is achieved, secure the pinion shaft retaining nut.

TV040892

26. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

1

2 TV040813

27. Install the flange onto the differential housing.

TV041102

L11–03–62

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) Operation: General Procedure Toe-in Adjustment None

BHL1103GA

Job Code: 11 13 01 xx Standard tools, Two one-metre-long bars

General Procedure The toe-in of the front wheels must be between 0 and 5mm toe-in as measured 500mm from the centre of the wheel hub. To check the exact value of the toe-in setting, proceed as follows. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • The bars must be fixed flat against the wheel hub flange and have an equal distance from the centre of the wheel hub. 2. Install two equal one-metre-long bars to the wheel side of the wheel hubs and lock in place with two wheel retaining nuts.

500mm

500mm

TV040979

3. Measure the distance (A) between the ends of the two bars. 4. Measure the distance (B) between the ends of the two bars. 5. The distance (A) must be 0 to 5mm less than distance (B).

A

B TV040980

L11–03–63

FRONT AXLE AND STEER SYSTEM Note: • Make sure the same number of threads are visible at the end of the left-hand and right-hand inner track rod end ball joints. 6. If it is necessary to correct the toe-in adjustment. Loosen the lock nut (1) on the left-hand and the right-hand side. Turn the inner track rod end ball joints (2) equally to achieve the specified toe-in adjustment. 7. Tighten (1) to 120Nm.

1

2

TV040981

L11–03–64

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT (FOUR-WHEEL STEER)

BHL1103GB

General Procedure

1

57º 2 A

3

TV041106

1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Turn the steering wheel until the front wheel hubs are on full left-hand lock. 3. Place a straight edge (3) against the axle input flange or against the machine hardnose. Make sure the straight edge is parallel with the axle centre-line. 4. Place a second straight edge (2) against the wheel hub flange (1).

•

Caution: Make sure the steering angle does not exceed 59 degrees. Failure to follow this instruction may result in excessive wear to the drive shaft universal joints.

5. Measure the angle (A) at which both straight edges intersect. Subtract angle (A) from 90 degrees to give the steering lock. Angle (A) = 33 degrees Steering angle 90 – 33= 57 degrees. 6. Adjust the left-hand stop for maximum left steering lock and right-hand stop for maximum right steering lock.

L11–03–65

FRONT AXLE AND STEER SYSTEM 7. Loosen the lock nut (1) and adjust the steering stop adjuster bolt (2) until the bolt head touches the steering stop. 8. Tighten the lock nut (1) to 150Nm. 9. Turn the steering wheel until the front wheel hubs are on full right-hand lock and repeat the procedure for the right-hand side.

1 2

TV040967

L11–03–66

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL (FOUR-WHEEL STEER) Operation: Draining and filling the four wheel steer front axle housing oil Suitable Container

Job Code: 11 07 09 xx Standard tools

Draining 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Loosen the filler/level plug to release any pressure.

TV041099

3. Remove the drain plug and drain the oil into a suitable container.

TV041100

Filling 1. Install the drain plug and tighten to 60Nm.

TV041100

L11–03–67

BHL1103GC

FRONT AXLE AND STEER SYSTEM 2. Fill with oil until the filler/level hole is reached.

TV041098

3. Install the filler/level plug and tighten to 60Nm.

TV041099

L11–03–68

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER) Draining 1. Position the hub until the drain/filler plug is positioned at the top. Loosen the drain plug to release any pressure. 2. Position the hub until the drain/filler plug is positioned at the bottom. Remove the drain/filler plug and drain the hub oil into a suitable container.

TV040197

Filling 1. Position the hub until the drain/filler plug is at the 3 o’clock position. Fill with oil until the drain/filler hole level is reached. 2. Install the drain/filler plug and tighten to 60Nm.

TV040934

L11–03–69

BHL1103GD

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–03–70

FRONT AXLE AND STEER SYSTEM SPECIFICATIONS — FOUR WHEEL STEER FRONT AXLE

BHL1103SA

Special Tools Tool No.

Description

CA119030

Wrench

CA119033

Interchangeable Handle

CA119043

Driver

CA119099

Wrench for Lock Nut

CA715026

Driver for Bearing Race

CA715027

Driver for Bush

CA119117

Driver

CA119143

Driver

CA119182

False Differential Box

CA119225

Driver

CA119226

False Differential Box

CA119230

Driver

CA715023

False Pinion

CA715034

Driver

CA715035

Driver

CA715163

Driver

CA715164

Driver

CA715170

Wrench

CA715179

Driver

CA715505

Driver

CA715506

Driver

CA715701

Driver

L11–03–71

FRONT AXLE AND STEER SYSTEM Torque Values Description

Nm

Lb.ft

Epicyclic Reduction Hub

80

59

Wheel Hub

230

170

Axle Drain/Fill Plug

60

44

Axle Trumpet Housing

320

236

Wheel Stud

70

52

King Pin

190

140

Crown Wheel

95

70

Grease Nipple

8

6

Differential Adjustment Nut Locking Tab

13

10

Differential Housing

169

125

Differential Half Coller

266

196

Breather

10

7

Blanking Plug

25

18

Steering Cylinder

220

162

Swivel Joint

300

221

Tie-Rod Locking Nut

250

184

Tie-Rod End

260

162

Steering Angle Adjustment Locking Nut

150

111

General Specifications Description

Value

Bevel Gear Ratio

2.5/1

Epicyclic Reduction Gear Ratio

6.923/1

Total Ratio

17.307/1

Dry Weight

444 Kg

Input Rotation

Counter Clockwise (C.W.)

Steering Angle

33° 0–2mm

Toe-in

0–5mm

Crown Wheel / Pinion Backlash

0.18 – 0.23mm

Pinion Bearing Pre-Load “P” (measured on D=34.874mm without seals)

“P” = 9.18 – 13.77 daN

Total Pinion-Ring Gear Bearing Preloading

(4.3 + P) — (6.45 + P) daN

Axle Housing Oil Capacity

7.5 Litres

Epicyclic Reduction Hub Oil Capacity

1.5 Litre

Oil Type (Use recommended oil enriched in Additives)

API GL5 or MIL-L-2105 D (for possible alternatives see – GENERAL INFORMATION – FLUIDS AND LUBRICANTS at the start of this manual).

Grease Type

TECNOLUBE SEAL PLOYMER 400/L (DIN = KHER1R ISO-I-XMR-XM2) AGIP MU/EP2 (King pin only)

Sealant

Silastic 732

L11–03–72

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — TWO-WHEEL STEER

BHL1104OA

Steering System Overview

2

3

1

4

5

9

6 8

7

TV040959

1

Front Steering Cylinder

2

Reservoir Hose

3

Steering Wheel

4

Orbitrol Steering Motor

5

Load Sensing Line

6

Steering Priority/Unloader Valve Hose

7

Steering Priority/Unloader Valve

8

Steering Cylinder Hose

9

Steering Cylinder Hose

The two-wheel steering system consists primarily of a front steering cylinder (1), orbitrol steering motor (4) and a steering priority/unloader valve (6). Oil is

supplied to the orbitrol steering motor (4) from the steering priority/unloader valve (8) through the hose (6). Hose (5) is used to sense when a steering request

L11–04–1

FRONT AXLE AND STEER SYSTEM is made to allow the steering to take priority over other hydraulic requests. When a steering request is made, the oil is supplied to the front steering cylinder (1) through the hose (9) (steering left) or hose (10)

(steering right) to move the cylinder piston rod in the required direction. Excess oil is returned to the hydraulic oil reservoir through hose (2).

L11–04–2

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — FOUR-WHEEL STEER

BHL1104OB

Steering System Overview

2

1

3 4 5

6

7 10 9

8 TV040960

1

Front Steering Cylinder

2

Reservoir Hose

3

Steering Wheel

4

Orbitrol Steering Motor

5

Load Sensing Line

6

Changeover Valve Hose

7

Steering Priority/Unloader Valve Hose

8

Steering Priority/Unloader Valve

9

Steering Cylinder Hose

10

Changeover Valve Hose

The four-wheel steering system consists primarily of a front steering cylinder (1), orbitrol steering motor

(4), steering priority/unloader valve (8), rear hydraulic cylinder and a changeover valve (see changeover

L11–04–3

FRONT AXLE AND STEER SYSTEM valve overview). Oil is supplied to the orbitrol steering motor (4) from the steering priority/unloader valve (8) through the hose (7). Hose (5) is used to sense when a steering request is made to allow the steering to take priority over other hydraulic requests. When in two-wheel steer mode and a steering request is made, the oil is supplied to the front steering cylinder (1) through the hose (9) (steering left) or hose (10) (steering right) to move the cylinder piston rod. Hose (6) is linked directly to the changeover valve and when

in two-wheel steer mode, the flow of oil is allowed to travel directly through the changeover valve and back to the front steering cylinder (1) through hose (10) therefore bypassing the rear steering cylinder and completing the circuit. The system also incorporates two proximity switches (one on each axle). These proximity switches enable the system to detect when the wheels are in the straight ahead position, allowing the system to avoid the rear wheels being locked when not aligned correctly.

L11–04–4

FRONT AXLE AND STEER SYSTEM Changeover Valve Overview 5 2 3

6

4

1

6

8

7

TV040961

1

Changeover Valve Hose

2

Changeover Valve Hose

3

Changeover Valve Solenoid

4

Changeover Valve Body

5

Changeover Valve Solenoid

6

Steering Cylinder Hose

7

Rear Steering Cylinder

8

Steering Cylinder Hose

The changeover valve is used to change the steering modes between two-wheel steer, four-wheel steer and crab steer. This is achieved by the use of two electrically controlled solenoids, which are installed to the changeover valve body. When activated, these solenoids actuate the valves in the changeover valve

body and change the direction of the oil flowing through it depending on which steering mode is selected. Hose (2) is linked directly to the orbitrol steering motor while hose (1) is linked to the front steering cylinder.

L11–04–5

FRONT AXLE AND STEER SYSTEM 2 Wheel Steer Operation

1

2

5

3

T

B

A

P

4

TV040954

1

Front Axle

2

Front Steering Cylinder

3

Changeover Valve

4

Rear Axle

5

Orbitrol Steering Motor

When two-wheel steer mode is selected, ports (A) and (B) of the changeover valve (3) are closed and will not allow oil to flow through them. The oil will be directed

through port (P) to port (T). This will not allow any oil to flow to the rear steering cylinder, which is locked in the straight ahead position.

L11–04–6

FRONT AXLE AND STEER SYSTEM Four- Wheel Steer Operation

1

2

6

3

T

B

A

P

5

4

TV040955

1

Front Axle

2

Front Steering Cylinder

3

Changeover Valve

4

Rear Axle

5

Rear Steering Cylinder

6

Orbitrol Steering Motor

When four-wheel steer is selected, the solenoids on the changeover valve (3) are actuated and oil is not permitted to flow between port (P) and port (T) and is redirected. Ports (A) and (T) of the changeover valve now allow oil to flow between them. Ports (P) and (B) will also allow oil to flow between them. As an example, when the steering wheel is moved to the right

the orbitrol steering motor will move the oil into port (P) and out of port (B) and into the rear steering cylinder (5). As the pressure moves the rear steering cylinder piston rod, oil is forced out from the steering cylinder and through port (A), out of port (T) and into the front steering cylinder. This system allows for proportional movement of the front and rear steering cylinders.

L11–04–7

FRONT AXLE AND STEER SYSTEM Crab Steer Operation

1

2

6

3

T

B

A

P

5

4

TV040956

1

Front Axle

2

Front Steering Cylinder

3

Changeover Valve

4

Rear Axle

5

Rear Steering Cylinder

6

Orbitrol Steering Motor

When crab steer is selected, the solenoids on the changeover valve (3) are actuated and redirect the flow of oil. Ports (P) and (A) of the changeover valve (3) now allow oil to flow between them. Ports (B) and (T) will also allow oil to flow between them. As an example, when the steering wheel is moved to the left the orbitrol steering motor will move the oil through the front steering cylinder (2). As the pressure moves the front steering cylinder piston rod, oil is forced out

from the steering cylinder and through port (T) of the changeover valve, out of port (B) and into the rear steering cylinder piston rod. As the pressure in the rear steering cylinder (5) moves the piston rod, oil is forced out the opposite end of the steering cylinder and through port (A) of the changeover valve, out of port (P) and back to the orbitrol steering motor. This system allows for proportional movement of the front and rear steering cylinders.

L11–04–8

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — STEERING COLUMN

BHL1104RA

Operation: Removing and Installing the Steering Column None

Job Code: 11 16 13 xx Standard tools, Suitable steering wheel puller

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the steering wheel centre cap.

TV040190

3. Remove the steering wheel retaining nut.

TV040191

4. Using a suitable steering wheel puller, remove the steering wheel.

TV040649

L11–04–9

FRONT AXLE AND STEER SYSTEM 5. Remove the front instrument panel trim covers.

TV040193

6. Remove the front console upper air vents.

TV040097

7. Remove the front console upper retaining bolts.

TV040098

8. Remove the front console.

TV040204

9. Detach the turn signal stalk (1).

L11–04–10

FRONT AXLE AND STEER SYSTEM 10. Remove the front instrument panel retaining bolts (2).

TV040194

11. Remove the turn signal stalk (1) 12. Remove the front instrument cluster (2). 13. Disconnect the differential electrical connector and wiper electrical connectors and remove the front instrument panel (3).

TV040195

14. Remove the tilt retaining clip and tilt pin (1) 15. Remove the steering column tilt bracket (2). Note: • Cut the cable ties. 16. Remove the steering column (3).

TV040196

Installation Note: • The splines on the steering column may be fitted into the orbital control valve in any position. Make sure the splines are seated correctly. Note: • Install new cable ties. 1. To install, reverse the removal procedure.

L11–04–11

FRONT AXLE AND STEER SYSTEM 2. Tighten to 58Nm.

TV040191

3. Tighten (3) to 55Nm

TV040196

4. Tighten (2) to 28Nm

TV040194

5. Tighten to 28Nm

TV040204

L11–04–12

FRONT AXLE AND STEER SYSTEM 6. Tighten to 28Nm

TV040098

L11–04–13

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–04–14

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR UP TO 2007 Operation: Removing and Installing the Orbitrol Steering Motor None

BHL1104RB

Job Code: 11 19 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the air cleaner. For additional information, refer to Section P14-01 AIR CLEANER, PAGE P14–01–33 . 3. Detach the exhaust stack spring and remove the exhaust stack.

TV040070

4. Loosen the exhaust silencer clamp (1). 5. Remove the exhaust silencer (2).

TV040071

6. Position the engine bay sound proofing to one side, in order to gain access to the orbitrol steering motor.

TV040596

L11–04–15

FRONT AXLE AND STEER SYSTEM Note: • Make a note of the position of the hydraulic hoses prior to disconnection, to aid installation. 7. Disconnect the hydraulic hoses from the orbitrol steering motor. Note: • Install blanking contamination.

plugs

to

avoid

TV040595

8. Remove the orbitrol steering motor retaining bolts and remove the orbitrol steering motor.

TV040597

Installation 1. To install, reverse the removal procedure. 2. Tighten (2) to 58Nm

TV040071

3. Tighten 24Nm

L11–04–16

FRONT AXLE AND STEER SYSTEM 4. Check and adjust the hydraulic oil level as required.

TV040597

L11–04–17

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–04–18

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR 2007 ONWARDS Operation: Removing and Installing the Orbitrol Steering Motor None

BHL1104RG

Job Code: 11 19 13 xx Standard tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the air cleaner. For additional information, refer to Section P14-01 AIR CLEANER, PAGE P14–01–33 . 3. Remove the exhaust silencer. For additional information, refer to Section P14-01 EXHAUST, PAGE P14–01–37 . 4. Position the engine bay sound proofing to one side, in order to gain access to the orbitrol steering motor.

TV040596

Note: • Make a note of the position of the hydraulic hoses prior to disconnection, to aid installation. 5. Disconnect the hydraulic hoses from the orbitrol steering motor. Note: • Install blanking contamination.

plugs

to

avoid

TV040595

L11–04–19

FRONT AXLE AND STEER SYSTEM 6. Remove the orbitrol steering motor retaining bolts and remove the orbitrol steering motor.

TV040597

Installation 1. To install, reverse the removal procedure. 2. Tighten 24Nm

TV040597

3. Check and adjust the hydraulic oil level as required.

L11–04–20

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — FOUR-WHEEL STEER (4WS) CHANGEOVER VALVE Operation: Removing and Installing the Four-Wheel Steer Changeover Valve None

Job Code: 11 15 13 xx Standard Tools

Removal 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Disconnect the 4WS changeover valve solenoid valve electrical connectors (1). Note: • Install blanking contamination.

plugs

to

avoid

3. Disconnect the 4WS changeover valve hydraulic hoses (2).

TV040188

Note: • Install blanking contamination.

plugs

to

avoid

4. Disconnect the 4WS changeover valve hydraulic hose (1). 5. Remove the 4WS changeover valve (2).

Installation 1. To install, reverse the removal procedure.

L11–04–21

BH1104RD

FRONT AXLE AND STEER SYSTEM 2. Tighten (2) to, 28Nm.

L11–04–22

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — TIE ROD END

BHL1104RF

Operation: Removing and Installing the Tie Rod End Suitable axle stands

Job Code: 11 13 13 xx Standard tools, Ball joint separator

Removal

1. Remove the front wheel. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis.

2. Loosen the tie rod end inner nut (1).

•

Caution: Leave the tie rod end nut on the tie rod end a few turns to prevent damage to the stud while using the ball joint separator.

3. Using the ball joint separator, disconnect the tie rod assembly from the wheel hub (2). Note: • Make a note of the number of turns required to remove the tie rod end, to aid installation. 4. Remove the tie rod end.

3

1

2

TV040933

Installation 1. Install a new outer tie rod end retaining nut. To install, reverse the removal procedure. 2. Check the toe-in alignment. For additional information, refer to section L11-02 TOE-IN ADJUSTMENT, PAGE L11–02–61 3. Tighten (1) to 250Nm

L11–04–23

FRONT AXLE AND STEER SYSTEM 4. Tighten (2) to 220Nm

3

1

2

TV040933

L11–04–24

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — FOUR-WHEEL STEER MISALIGNMENT CORRECTION Correction Note: • To select four-wheel steer mode, turn the steering wheel until the front wheels are in the straight ahead position. This is indicated by the LEDs located either side of the steering reset button illuminating. Then select four-wheel steer mode. Note: • To select two-wheel steer mode when in four-wheel steer mode, select two-wheel steer mode and turn the steering wheel until the wheels are in the straight ahead position. This is indicated by the LEDs located either side of the steering reset button illuminating. Four-wheel steer will now disengage. Note: To select crab steer mode, select crab mode and turn the steering wheel until the wheels are in the straight ahead position. This is indicated by the LEDs located either side of the steering reset button illuminating. Crab steer mode cannot be selected when in four-wheel steer mode and vice versa. Two-wheel steer must be engaged first.

•

Note: • In the event of major misalignment between the front and rear wheels or the steering system becoming locked in four-wheel steer or crab steer, the following procedure must be carried out. 1. Turn the steering wheel until the rear wheels are on full lock. 2. Using the steering mode selector switch, select two–wheel steer mode. 3. Press and hold the steering reset button.

TV040953

4. Turn the steering wheel until the front wheels are on the opposite full lock to the rear wheels and release the steering reset button. 5. Using the steering mode selector switch, select four–wheel steer mode. 6. Press and hold the steering reset button.

L11–04–25

BHL1104GB

FRONT AXLE AND STEER SYSTEM 7. Turn the steering wheel until the front wheels are in the straight ahead position and release the steering reset button. 8. Using the steering mode selector switch, select two–wheel steer mode. 9. Turn the steering wheel until the front wheels are in the straight to engage two-wheel steer mode.

TV040968

L11–04–26

FRONT AXLE AND STEER SYSTEM SPECIFICATIONS — STEERING

BHL1104SA

General Information Steering Orbitrol

Closed Center Type

Make

Rexroth 160cc

Dispaced Oil per Revolution MRV Setting Pressure

175bar (170min – 178max)

Antishock Valves Opening Pressure

240bar +/-5

MRV Adjustment

+1 Turn=+26.6bar

Antishock Valves Adjustment

+1 Turn=+105bar

Special Tool for Adjusting MRV / Rexroth P/N

E35/:36064

Special Tool for Adjusting AS Valves / Rexroth P/N

E35/:36949

Torque Values Description

Nm

Lb.ft

Steering Wheel Retaining Nut

58

43

Orbitrol Steering Motor Retaining Bolts

24

18

Steering Column Retaining Bolts

55

41

Front Console Upper Retaining Bolts

28

21

Front Console Lower Retaining Bolts

28

21

Front Instrument Panel Retaining Bolts

28

21

4WS Change Over Valve Retaining Bolts

28

21

Inner Tie Rod End

300

221

Outer tie Rod End

220

162

L11–04–27

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–04–28

FRONT AXLE AND STEER SYSTEM DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE

BHL1105OA

General Description

1

2

3

7 4

5

6

TV040947

1

Epicyclic Reduction Gear Group

2

Axle Housing Group

3

Differential Support Group

4

Pinion Group

5

Steering Cylinder Group

6

Differential Group

7

Wheel Hub Group

The axle described in this manual consists of the following groups: • WHEEL HUB GROUP: wheel support parts containing the epicyclic reduction gears.

• •

EPICYCLIC REDUCTION GEAR GROUP: planetary carrier with reduction/transmission parts. AXLE HOUSING GROUP: load-bearing shell structure of the axle.

L11–05–1

FRONT AXLE AND STEER SYSTEM • •

DIFFERENTIAL SUPPORT GROUP: differential housing with crown wheel gear adjusting system. DIFFERENTIAL GROUP: differential parts with crown wheel gear.

• •

PINION GROUP: pinion with adjusting and support parts. STEERING CYLINDER GROUP: steering cylinder parts with adjusting system.

L11–05–2

FRONT AXLE AND STEER SYSTEM DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE Problem Ring gear tooth broken at the outer side

Ring gear tooth broken on the inside

Pinion or ring gear teeth worn

BHL1105TA

Possible Cause

Action

•

Excessive gear load compared to the design specification.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (excessive backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Load bump.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Incorrect gear adjustment (insufficient backlash).

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Pinion nut loosened.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

•

Contaminated oil.

• •

•

L11–05–3

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

FRONT AXLE AND STEER SYSTEM Problem Pinion or ring gear teeth worn (continued)

Action

Possible Cause

•

Incorrect lubrication or depleted additives.

• •

•

•

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

• •

•

Overheated ring and pinion teeth. Check if gear teeth are showing signs of wear.

Pinion teeth pitting

Axle beam body bent

REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals. REPLACE bevel gear set. FOLLOW carefully the recommended operations for the adjustment of bevel gear set backlash. USE correct lubricants, FILL to the right level and REPLACE according to the recommended intervals.

•

Prolonged functioning at high temperatures.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Incorrect lubrication.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Low oil level.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bevel gear set. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• •

REPLACE bevel gear set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

• • •

Vehicle overloaded.

• • •

REPLACE axle beam body.

Vehicle accident. Load bump.

L11–05–4

REPLACE axle beam body. REPLACE axle beam body.

FRONT AXLE AND STEER SYSTEM Problem Worn out or pitted bearings

Oil leakage from gaskets and seals

Action

Possible Cause

•

Insufficient lubrication.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive use.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Normal wear out.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Pinion nut loosened.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Prolonged functioning at high temperature of the oil.

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

• •

Oil gasket assembled incorrectly.

• •

•

Seal lip damaged.

• •

•

Contaminated oil.

• •

L11–05–5

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

FRONT AXLE AND STEER SYSTEM Problem Excessive wearing out of input flange spline

Action

Possible Cause

•

Heavy use.

• • •

•

Pinion nut loosened.

• • •

•

Pinion axle backlash.

• • •

Fatigue failure of pinion teeth. See if the fracture line is well defined (wave lines, beach lines)

• •

Heavy use.

Pinion and ring teeth breakage

•

Side gear spline worn out. Replace all scratched washers (Excessive backlash)

•

Thrust washer surface worn out or scratched

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required. REPLACE bevel gear set.

Crash load of differential components.

•

CHECK and/or REPLACE other differential components.

Excessive use.

•

Insufficient lubrication.

• •

REPLACE differential gear group. REPLACE half shaft if required.

Continuous overload.

•

Incorrect lubrication.

• • •

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

• •

•

•

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE bevel gear set if required.

Contaminated oil.

• • •

L11–05–6

REPLACE bevel gear set.

USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to the right level. REPLACE at intervals recommended. REPLACED all scratched washers and those with 0,1 mm thickness lower than the new ones.

FRONT AXLE AND STEER SYSTEM Problem

Action

Possible Cause

•

Excessive use.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive pinion axial backlash.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to the right level and REPLACE at recommended intervals.

Bent or broken half shaft

•

Vehicle intensively operated or overloaded.

•

REPLACE half shaft.

Half shaft broken at wheel side

•

Wheel support loosened.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

•

Beam body bent.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

Inner diameter of tapered roller bearing worn out

L11–05–7

FRONT AXLE AND STEER SYSTEM Axle Problem and Diagnosis Problem Noise while driving

Noise whilst driving in neutral

Intermittent noise Constant noise

Noise while steering

Possible Cause

Action

•

Excessive backlash between pinion and ring gear.

•

ADJUST.

• • • •

Worn out pinion and gear ring.

• • • •

REPLACE.

• • • • • • •

Worn out differential bearings.

• • • • • • •

REPLACE.

•

Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing the speed.

•

REPLACE.

• • • •

Pinion or input flange worn out.

• • • • •

Worn out bearings.

• •

Worn out pinion bearings. Pinion bearings loosened. Excessive axial pinion backlash. Differential bearings loosened. Ring gear out of roundness. Low Lubricant level. Poor or wrong lubricant. Bent half shaft. Noise coming from axle is usually heard when vehicle moves in neutral gear but is not loud.

• Ring gear damaged. • Differential box bolts loosened. • Ring gear teeth or pinion •

REPLACE. ADJUST. ADJUST.

ADJUST. REPLACE. OIL level. REPLACE. REPLACE. REPLACE or ADJUST (see above).

ADJUST. REPLACE bevel gear set. TIGHTEN to torque. REPLACE bevel gear set.

damaged.

• • • • •

REPLACE.

Differential thrust washers worn out.

•

REPLACE.

Half shaft spline worn out.

•

REPLACE.

Pinion spline worn out. Bent half shaft. Worn out differential gears. Worn out differential box or spider.

L11–05–8

REPLACE. REPLACE. REPLACE. REPLACE.

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE

BHL1105RA

Operation: Removing and Installing the Four-Wheel Drive Front Axle Suitable transmission jack

Job Code: 11 24 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Remove the hardnose / tool box. For additional information, refer to Section K10-01 HARDNOSE / TOOLBOX, PAGE K10–01–3 . 3. Raise the front loader to full height and install the safety stop. 4. Roll the loader bucket fully forward.

TV040056

5. Detach the front axle pivot pin grease point (1). Note: • Discard the locking nut. 6. Remove the front axle pivot pin retaining bolt (2).

1

2 TV040061

L11–05–9

FRONT AXLE AND STEER SYSTEM 7. Disconnect the power steering supply pipes.

TV040062

8. Loosen the propeller shaft locking ring.

TV040063

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

•

Warning: Secure the front axle to the transmission jack. Failure to follow this instruction may result in personal injury

Note: • Mark the axle pivot pin before removal to aid installation. 9. Using a suitable transmission jack (1), support the front axle. Note: • Secure the propeller shaft to one side when removing the front axle. Using a suitable slide hammer (2), remove the front axle pivot pin and remove the front axle.

2

1

TV040064

L11–05–10

FRONT AXLE AND STEER SYSTEM Installation Note: • Remove any dirt or burrs before installing the front axle pivot pin. Note: Make sure the propeller shaft is aligned with the front axle differential shaft when raising the axle into position.

•

1. To install, reverse the removal procedure. Note: • Install a new locking nut. 2. Tighten (2) to 98Nm (72 lb.ft).

1

2 TV040061

3. Check and adjust the hydraulic oil level as required. 4. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

L11–05–11

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–12

FRONT AXLE AND STEER SYSTEM REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP

BHL1105RC

Operation: Removing and Installing the Steering Cylinder Group

Job Code: 11 20 13 xx

Suitable lifting equipment

Standard tools

Removal Note: • Make a note of the position of any hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Disconnect the power steering supply pipes.

TV040062

3. Remove the union from the steering cylinder group.

TV040962

L11–05–13

FRONT AXLE AND STEER SYSTEM 4. Disconnect the inner track rod end from the steering cylinder group (both sides).

TV040964

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

5. Remove the steering cylinder group retaining bolts (1), and remove the steering cylinder group (2).

1

1

TV040965

Installation 1. To install, reverse the removal procedure. 2. Tighten (1) to 120Nm (89 lb.ft).

1

1

TV041131

L11–05–14

2

FRONT AXLE AND STEER SYSTEM 3. Tighten to 300Nm (221 lb.ft).

TV040964

4. Check and adjust the hydraulic oil level as required. 5. Operate the steering from full left-hand lock to full right-hand lock and check for correct operation.

L11–05–15

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–16

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP

BHL1105DA

Operation: Disassembly and Assembly of the Steering Cylinder Group None

Job Code: 11 20 17 xx Standard tools, Suitable piston ring compression tool

12

10

9 11

8 7 6 5 3 1

4 2 TV0400582

1

Wiper Seal

2

Sealing Ring

3

Flange

4

O-Ring

5

Piston Rod Assembly

6

Back-up Seal

7

Piston Sealing Ring

8

Back-up Seal

9

O-Ring

10

Cylinder

11

Sealing Ring

12

Wiper Seal

L11–05–17

FRONT AXLE AND STEER SYSTEM Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Clean the outside of the hydraulic cylinder.

•

Caution: Be careful to prevent damage to the cylinder.

2. Fasten the cylinder (10) in a soft jawed vice. 3. Remove the flange (3) from the steering cylinder group. 4. Remove the piston rod assembly (5) from the cylinder (10). 5. Remove the wiper seal (1), sealing ring (2) and the O-ring (4) from the flange (3). 6. Remove the back-up seal (6), piston sealing ring (7) and back-up seal (8) from the piston rod assembly (5). 7. Remove the O-ring (9), sealing ring (11) and the wiper seal (12) from the cylinder (10).

Assembly Note: • Install new O-ring seals, seals and rings. Note: lubricate the new O-ring seals, seals and rings with clean oil.

•

1. Install the wiper seal (12), sealing ring (11) and the O-ring (9) to the cylinder (10). 2. Install the back-up seal (8), piston sealing ring (7) and the back-up seal (6) to the piston rod assembly (5). 3. Install the O-ring (4), sealing ring (2) and the wiper seal (1) to the flange (3). 4. Lubricate the inside of the cylinder (10) and the piston rod assembly (5) with clean oil. Use a piston ring compression tool to hold the new back-up seals (6),(8) Piston Sealing Ring (7) in place.

•

Caution: Be careful not to damage the back-up seals and piston sealing ring.

5. Start the cylinder (10) onto the piston rod assembly (5). Push the cylinder onto the piston rod (5) assembly until the compression tool is pushed off the piston rod assembly. 6. Install the flange (3) onto the steering cylinder group.

L11–05–18

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP

BHL1105DB

Operation: Disassembly and Assembly of the Epicyclic Reduction Gear Group None

Job Code: xx xx xx xx Standard tools

6

7

8

5

4 3

10

2

1

1

Retaining Screw

2

Drain/Refill Plug

3

Epicyclic Reduction Gear Carrier

4

Pin

5

Needle Bearings

6

Planetary Gears

7

Needle Bearings

8

Washer

9

Cir-clip

10

O-ring seal

L11–05–19

9

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–3 . 2. Drain the hub oil. For additional information, refer to DRAINING AND FILLING THE HUB OIL, PAGE L11–05–69 in this section. 3. Remove the epicyclic reduction gear retaining screws and remove the epicyclic reduction gear.

Note: • On disassembly of the epicyclic reduction gear clean the contact surfaces of the epicyclic reduction gear and wheel hub and check it for excess wear. 4. Using suitable circlip pliers, remove the epicyclic reduction gear retaining circlips.

L11–05–20

FRONT AXLE AND STEER SYSTEM 5. Remove the epicyclic reduction gears (1). 6. Recover the needle roller bearings (2).

Assembly Note: • When installing new epicyclic reduction gears, install new needle bearings. 1. Install the epicyclic reduction gears (1). Note: • Use a suitable installation.

light

greese

to

aid

2. Install the needle roller bearings (2).

3. Install the epicyclic reduction gear retaining circlips.

L11–05–21

FRONT AXLE AND STEER SYSTEM 4. Clean and degrease the mating surfaces install a new o-ring seal.

5. Install the epicyclic reduction gear to the wheel hub. 6. Install the epicyclic reduction gear retaining screws (1). 7. Tighten to 30Nm (22 lb.ft).

8. Fill the hub with oil. For additional information, refer to DRAINING AND FILLING THE HUB OIL, PAGE L11–05–69 in this section. 9. Install the wheel. For additional information, refer to M12-01 FRONT WHEEL, PAGE M12–01–3 .

L11–05–22

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP Operation: Disassembly and Assembly of the Wheel Hub Group Suitable lifting equipment

BHL1105DC

Job Code: xx xx xx xx Standard tools, Ball joint separator, Ca715026, Ca715027, Ca119143

L11–05–23

FRONT AXLE AND STEER SYSTEM 1

Circlip

2

Washer

3

Washer

4

Epicylic Ring Gear

5

Retaining Bolt

6

Centering bushes

7

Wheel carrier

8

Lock ring

9

Taper Roller Bearing

10

Stud

11

Wheel Hub

12

Taper Roller Bearing

13

Oil Seal

14

Swivel Housing

15

Cone

16

Lower Kingpin

17

Retaining Bolt

18

Upper Kingpin

19

Retaining Bolt

20

Lock Nut

21

Steering Angle Adjustment Bolt

22

Bush

23

Oil seal

24

Universal-Joint Shaft End

25

Belleville washers

26

Axle

27

Belleville Washers

Disassembly Note: • Right-hand side shown, left-hand side similar. 1. Remove the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE L11–03–15 in this section. 2. Remove the circlip.

L11–05–24

FRONT AXLE AND STEER SYSTEM 3. Remove the washer (1) and the spacer (2).

4. Remove the wheel hub retaining bolts.

5. Using two hub retaining bolts, extract the epicyclic group.

L11–05–25

FRONT AXLE AND STEER SYSTEM 6. Remove the snap ring (1) and remove the epicyclic gear hub (2) from the epicyclic ring gear (3). 7. Using the special tool CA715027 — Driver for bush remove the wheel hub centering bushes.

1

2

3 TV040771

8. Using a suitable soft faced hammer, remove the front axle hub. Note: • Recover the outer taper roller bearing.

L11–05–26

FRONT AXLE AND STEER SYSTEM 9. Using a suitable lever, remove the hub seal (1). Note: • Discard the oil seal. 10. Recover the outer taper roller bearing. Using a suitable drift, remove the inner and outer taper roller bearing cones (2).

11. Using a suitable puller, remove the inner taper roller bearing.

TV040773

•

Caution: Leave the tie rod end nut on the tie rod end a few turns to prevent damage to the stud while using the ball joint separator.

12. Using a suitable ball joint separator, disconnect the tie rod assembly from the wheel hub.

TV040202

L11–05–27

FRONT AXLE AND STEER SYSTEM

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment, support the wheel hub assembly .

•

13. Remove the upper (1) and lower (2) kingpin retaining bolts and remove the kingpins. 14. Remove the swivel hub assembly.

1 1

2 TV040203

15. Remove the swivel thrust washers. orientation to aid installation.

Note the

TV040854

Note: • Position the swivel hub on a suitable flat surface. 16. Using a suitable lever, remove the oil seal. Note: • Discard the oil seal.

TV040851

L11–05–28

2

FRONT AXLE AND STEER SYSTEM 17. Using a suitable drift, remove the swivel housing bush.

TV040852

Assembly 1. Using the special tool CA119043 — Driver for bush , install the bush. 2. Using the special tool CA119117 — Driver for oil seal , install the oil seal.

TV040853

3. Install the swivel thrust washers.

TV040854

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Using suitable lifting equipment, support the swivel hub assembly .

•

4. Install the swivel hub assembly. Note: • Make sure the double universal-joint shaft is fully installed into the axle housing. 5. Install the upper (1) and lower (2) kingpins and kingpin retaining bolts.

L11–05–29

FRONT AXLE AND STEER SYSTEM 6. Tighten to 190Nm (140 lb.ft).

1 1

2 TV040203

7. Install the inner taper roller bearing.

TV040850

8. Using a suitable hydraulic press and the special tool CA715026 — Driver for bearing race , install the inner and outer taper roller bearing cones.

TV040925

Note: • Lubricate the oil seal with a light grease. 9. Using the special tool CA119143 — Driver for oil seal , install a new hub oil seal.

TV040926

L11–05–30

2

FRONT AXLE AND STEER SYSTEM 10. Install the front axle hub.

TV074058

11. Install the outer taper roller bearing.

TV040857

12. Install the epicyclic hub (2) to the epicyclic ring gear (3) and install the snap ring (1).

1

2

3 TV040771

Note: • Install two bushes slightly higher that the hub surface level to be used as dowel pins. 13. Using the special tool CA715027 — Driver for bush partially install the hub centering bushes.

TV040930

L11–05–31

FRONT AXLE AND STEER SYSTEM 14. Assemble the epicyclic group on the front wheel hub using the two protruding centering bushes as dowel pins.

TV040200

15. Using the special tool CA715027 — Driver for bush , install the remaining centering bushes.

TV040931

16. Install the epicyclic hub retaining bolts. 17. Tighten to 230Nm (170 lb.ft).

TV040846

18. Install the spacer (2) and the washer (1).

L11–05–32

FRONT AXLE AND STEER SYSTEM 19. Install the circlip.

20. Install the tie rod assembly onto the wheel hub. 21. Tighten to 250Nm (184lb.ft).

TV040937

22. Install the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE L11–03–15 in this section.

L11–05–33

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–34

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP

BHL1105DD

Operation: Disassembly and Assembly of the Axle Housing Group None

Job Code: 11 07 17 xx Standard tools, CA715034, CA715505, CA715163, CA715164, CA715701

Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE L11–05–23 in this section. 2. Drain the axle oil into a suitable container. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL, PAGE L11–05–67 in this section. 3. Remove the two double Universal-Joints from the axle housing (both sides).

TV040861

4. Remove the oil seal (2) from the axle housing (both sides). Note: • Discard the oil seal rings.

•

Caution: Be careful not to damage the bush housing.

5. Remove the bushes (1) from the axle housing (both sides). 6. Using a suitable extractor remove the upper king pin bush (3) and the ball bearing cup (4) from the king pin housings (both sides).

3

1

4 2 TV040862

L11–05–35

FRONT AXLE AND STEER SYSTEM 7. Remove the oil seals (1) and (3) from the axle housing. Note: • Discard the oil seals. 8.

Remove the bushes (2) and (4) from the axle housing.

•

Caution: Be careful not to damage the bush housing.

2

1 3

4 TV040863

9. Using a suitable lever, remove the cover from the differential support .

TV040864

10. Remove the oil seal (1) and the O-ring (2) from the cover (3). Note: • Discard the oil seals.

1 2 3 TV040865

L11–05–36

FRONT AXLE AND STEER SYSTEM Assembly Note: • Install new oil seals. 1. Using the special tool CA715034 , install the king pin bush (3) in the axle housing (both sides). 2. Using the special tool CA175034 — Driver , install the ball bearing cup (4) in the axle housing (both sides). 3. Using the special tool CA715505 — Driver , install the bush (1) and the oil seal (2).

3

1

4 2 TV040862

4. Install the bush (1) and the oil seal (2) as shown.

1

TV040866

5. Install the two double Universal-Joints into the axle housing (both sides).

TV040861

L11–05–37

2

FRONT AXLE AND STEER SYSTEM 6. Using the special tool CA715163 — Driver install the bushes (2) and (4) on the axle housing. Note: • Lubricate the oil seal with a light grease. Using the special tool CA715164 — Driver install the oil seals (2) and (3) on the axle housing.

2

1 3

4 TV040863

Note: • Lubricate the oil seal with a light grease. 7. Using the special tool CA715701 — Driver Install the oil seal (1) to the cover (8). 8. Install the O-ring seal (2) to the cover (3).

1 2 3 TV040865

•

Caution: Cover the pinion shaft spline to protect the oil seal from damage.

9. Install the cover to the axle housing. 10. Install the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE L11–05–23 in this section. 11. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL, PAGE L11–05–67 in this section.

L11–05–38

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP

BHL1105DE

Operation: Disassembly and Assembly of the Differential Support Group

Job Code: 11 03 13 xx

Suitable lifting equipment

Standard tools, CA119030, CA715116

13 12

9 11 10

8 7 6 2

5 4 1

3

TV040605

1

Differential Support

2

Retaining Bolt

3

Adjustment Nut

4

Taper Roller Bearing

5

Differential Assembly

6

Taper Roller Bearing

7

Adjustment Nut

8

Locking Tab

9

Retaining Bolt

10

Dowel

11

Differential Half-Collers

12

Retaining Bolt

13

Dowel

L11–05–39

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the axle housing group. For additional information, refer to AXLE HOUSING GROUP, PAGE L11–05–35 in this section.

•

Warning: Support the differential support. Failure to follow this instruction may result in personal injury.

2. Remove the differential support from the axle housing.

TV040867

3. Remove the locking tab retaining bolts (1) and remove the adjustment nut locking tabs (2).

1

1

2

2

TV040868

4. Mark the differential half-collers and the differential adjustment nuts to aid installation.

TV040869

L11–05–40

FRONT AXLE AND STEER SYSTEM 5. Using the special tool CA119030 — Wrench (1), Remove the differential adjustment nuts (2).

2 2

1

TV040870

6. Remove the half-collers retaining bolts.

TV040877

7. Remove the half–collers (1). Note: • Recover the half-coller dowels (2).

1

2

2 TV040871

L11–05–41

FRONT AXLE AND STEER SYSTEM

•

•

Caution: If the taper roller bearings are not to be replaced, make sure the taper roller bearing and cone remain a matched pair. Caution: Make a note of the differential position to aid installation.

8. Remove the differential assembly. Note: • Recover the taper roller bearing cones.

TV040872

L11–05–42

FRONT AXLE AND STEER SYSTEM Assembly 1. Install the pinion shaft. For further information refer to PINION GROUP, PAGE L11–05–55 in this section.

•

Caution: Make sure the taper roller bearing and cone remain a matched pair.

•

Caution: Make sure the differential is installed in the correct orientation.

2. Install the differential assembly.

TV040872

3. Install the half-coller dowels (2). 4. Install the half–collers (1).

1

2

2 TV040871

Note: • Do not tighten at this stage. 5. Install the half-collers retaining bolts.

TV040877

L11–05–43

FRONT AXLE AND STEER SYSTEM

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Only tighten the differential adjustment nut until the bearing backlash is removed and nominal pre-load is achieved.

•

6. Using the special tool CA119030 — Wrench (1), Install the differential adjustment nuts (2). Note: • Using a suitable soft-faced hammer, settle the differential taper roller bearings.

2 2

TV040870

7. Lock the pinion shaft. 8. Using a suitable measuring device, measure the pinion to crown wheel backlash. 9. Repeat the measurement in a further two positions 120° apart and compare the average of the three values. 10. The pinion to crown wheel backlash should be within the following range: 0.18mm — 0.23mm

TV040873

L11–05–44

1

FRONT AXLE AND STEER SYSTEM Note: • Make sure the differential adjustment nuts are adjusted equally to retain the nominal bearing pre-load and no free play. 11. Using the special tool CA119030 — Wrench , adjust the differential adjustment nuts until the correct pinion to crown wheel backlash is achieved. • Measured backlash is greater than the specified range — (A) , adjust the differential assembly closer to the pinion shaft by loosening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment nut equal amounts. • Measured backlash is less than the specified range — (B) , adjust the differential assembly away from the pinion shaft by tightening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment nut equal amounts.

A

A

B

B

TV040874

12. Once the correct pinion to crown wheel backlash is achieved, check that the differential taper roller bearings have no free play and no pre-load is evident. 13. Repeat steps 7 to 12 the whole sequence of the above mentioned operations until the indicated conditions are reached.

L11–05–45

FRONT AXLE AND STEER SYSTEM

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Using a suitable soft-faced hammer, settle the differential taper roller bearings.

•

Note: Rotate the differential assembly while tightening the adjustment nuts to seat the bearing rollers on their track.

•

14. Using a suitable measuring device with the cord wound round the pinion shaft spline, measure the total rotational torque.

TV040875

15. The total rotational torque should be within the following range excluding breakaway torque. (4.3 + P) to (6.45 + P) daN P = Measured pinion shaft rotational torque. For additional information refer to PINION GROUP, PAGE L11–05–55 in this section.

L11–05–46

FRONT AXLE AND STEER SYSTEM Note: • Make sure the differential adjustment nuts are adjusted equally to retain the set backlash. 16. Using the special tool CA119030 — Wrench , adjust the differential adjustment nuts until the correct differential taper roller bearing pre-load is achieved. • Total pre-load is less than the specified range — (A) , increase the differential taper roller bearing pre-load by tightening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment equal amounts. • Total pre-load is higher than the specified range — (B) , decrease the differential taper roller bearing pre-load by loosening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment equal amounts.

A

A

B

B

TV040876

L11–05–47

FRONT AXLE AND STEER SYSTEM Testing After Adjustment Note: • The marking test should always be carried out on both sides of the crown wheel teeth. 17. To test the marks of the crown wheel teeth, paint the ring gear with engineer’s blue.

TV040836

18. Check the contact pattern: OK = Correct contact — If the crown wheel is well adjusted, the mark on the teeth surfaces will be regular. Z = Excessive contact on the tooth tip — Adjust the pinion towards the crown wheel and then adjust the crown wheel away from the pinion in order to adjust the backlash. X = Excessive contact at the tooth base — Adjust the pinion away from the crown wheel and then adjust the crown wheel towards the pinion in order to adjust the backlash.

OK

Z

X

TV040837

Movements to correct 19. Adjust as required: 1 = move the pinion for type X contact adjustment. 2 = move the pinion for type Z contact adjustment.

2 1 TV040838

L11–05–48

FRONT AXLE AND STEER SYSTEM 20. Install the adjustment nut locking tabs (2) and install the locking tab retaining bolts (1). 21. Tighten to 13Nm (10 lb.ft).

1

1

2

2

TV040868

22. Tighten the half-collers retaining bolts to 266Nm (196 lb.ft).

TV040877

Note: • Make sure the two dowel pins are installed into the axle housing. 23. Thoroughly clean and de-grease the mating surfaces. Apply a bead of sealant following the pattern shown.

TV040878

24. Install the differential support onto the axle housing. 25. Tighten to 169Nm (125 lb.ft).

L11–05–49

FRONT AXLE AND STEER SYSTEM 26. Install the axle housing group. For additional information, refer to AXLE HOUSING GROUP, PAGE L11–05–35 in this section.

TV040867

L11–05–50

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP

BHL1105DF

Operation: Disassembly and Assembly of the Differential Group None

Job Code: 11 03 17 xx Standard tools, Suitable puller

7

8

9

10

6 5 4 3 2 1

12 6 7

TV0400879

1

Taper Roller Bearing

2

Housing

3

Thrust Plate

4

Sun Gear

5

Planetary Shaft

6

Planetary Gear

7

Thrust Washer

8

Sun Gear

9

Thrust Plate

10

Housing

11

Taper Roller Bearing

12

Locking Pin

L11–05–51

11

FRONT AXLE AND STEER SYSTEM Disassembly 1. Remove the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–05–39 in this section. 2. Position the differential in a suitable vice. 3. Remove the crown wheel retaining bolts (1) and remove the crown wheel (2).

1

2

TV040880

•

Caution: Make sure the internal differential components remain with the bottom housing.

Note: • Mark the differential carrier disassembly to aid installation.

prior

to

4. Remove the housing (1) from the housing (2). 5. Disassemble all of the internal differential components. 6. Check for wear of the components. Replace as necessary.

1 2

TV0400881

7. Using a suitable bearing puller remove the taper roller bearings from the housings.

TV040882

L11–05–52

FRONT AXLE AND STEER SYSTEM Assembly 1. Using the special tool CA119230 — Driver , install the taper roller bearings on the housings.

TV040882

2. Install the internal differential components into the bottom housing. 3. Install the housing (1) onto the housing (2).

1 2

TV0400881

Note: • Before installing the crown wheel retaining bolts, apply approved sealant (Loctite 270) to the bolts. 4. Install the crown wheel (2). 5. Tighten (1) to 95Nm (70 lb.ft). 6. Install the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–05–39 in this section.

1

2

TV040880

L11–05–53

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–54

FRONT AXLE AND STEER SYSTEM DISASSEMBLY AND ASSEMBLY — PINION GROUP

BHL1105DG

Operation: Disassembly and Assembly of the Pinion Group None

Job Code: 11 09 17 xx Standard tools, CA119099, CA715170, CA119225, CA715023, CA119182. CA119226, CA715179

10 9 8 7

4 6 5

3 2 1

TV040603

1

Pinion Shaft Retaining Nut

2

Retaining Lock Washer

3

Taper Roller Bearing

4

Differential Support

5

Washer

6

Collapsable Spacer

7

Washer

8

Taper Roller Bearing

9

Adjustment Shim

10

Pinion Shaft

Disassembly 1. Remove the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–05–39 in this section.

L11–05–55

FRONT AXLE AND STEER SYSTEM 2. Position the differential support group in a suitable vice. 3. Using the special tools CA119099 — Wrench (1) and CA715170 — Wrench (2) release the pinion shaft retaining nut.

1

2 TV040883

4. Remove and discard the pinion shaft retaining nut (1). 5. Remove the retaining lock washer (2).

2 1

TV040884

6. Using a suitable soft faced hammer, remove the pinion shaft (1). 7. Remove and discard the collapsable spacer (2). 8. Recover the washers (3) and taper roller bearing (4).

2 1

4

3 TV040885

9. Place the differential support on a suitable flat surface.

L11–05–56

FRONT AXLE AND STEER SYSTEM 10. Using a suitable drift, remove the taper roller bearing cones (1) and (2).

1

2 TV040886

11. Using a suitable bearing puller, remove the taper roller bearing (1). 12. Recover the adjustment shim (2).

1

2

TV40887

13. Check all pinion components for wear. Replace as necessary.

L11–05–57

FRONT AXLE AND STEER SYSTEM Assembly 1. Place the differential support on a suitable flat surface. 2. Using the special tool CA119225 — Driver , install the taper roller bearing cones (1) and (2).

1

2 TV040886

3. Install the special tool CA715023 — false pinion (1) with the pinion shaft taper roller bearings (2) and (3).

•

Caution: Do not over-tighten.

4. Install the pinion shaft retaining nut (4). 5. Tighten until the free play is eliminated.

1

4 2

3 TV040888

6. Install the special tools CA119182 — false differential bearings (1) and CA119226 — false differential shaft (2) into the differential support. 7. Secure the special tools into position with the differential half-collers (3).

3

2

TV040889

L11–05–58

1

FRONT AXLE AND STEER SYSTEM 8. Using a suitable depth gauge, measure through the false differential shaft (CA119226) This measurement is “X” . X = The distance between the axis of the differential taper roller bearings and the point at which the pinion head is supported, or base of the bearing.

X

TV040890

9. Determine the pinion shaft position adjustment shim “S” as follows: subtract the value “V” (requested conical distance) from the calculated value “X” . S=X—V Example: Shim thickness S = 109.9 – 107.00 = 2.9mm. Shim thickness “S” = 2.9mm.

107.00 00

V

TV040811

SHIM RANGE Thickness (mm)

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

3.3

3.4

10. Remove the differential half-collers (3). 11. Remove the special tools CA119182 — false differential bearings (1) and CA119226 — false differential shaft (2) from the differential support.

3

2

TV040889

12. Remove the pinion shaft retaining nut (4).

L11–05–59

1

FRONT AXLE AND STEER SYSTEM 13. Remove the special tool CA715023 — false pinion (1) with the pinion shaft taper roller bearings (2) and (3).

1

4 2

3 TV040888

14. Install the pinion shaft position adjustment shim (2) with chamfer against the gear. 15. Using a suitable hydraulic press and the special tool CA715179 — Driver install the rear taper roller bearing (1).

1

2

TV40887

•

Caution: Always install a new collapsable spacer.

16. Install the pinion shaft (1), new collapsable spacer (2) and the washers (3) into the differential support. 17. Using the special tool CA715179 — Driver , install the taper roller bearing (4).

2 1

4

3 TV040885

L11–05–60

FRONT AXLE AND STEER SYSTEM 18. Install a new retaining lock washer (2).

•

Caution: Always install a new pinion shaft retaining nut.

Note: Do not tighten at this stage.

•

19. Install a new pinion shaft retaining nut (1).

2 1

TV040884

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: • Using a suitable soft faced hammer, settle the pinion shaft bearings. Note: Rotate the pinion shaft several times to settle the pinion shaft bearings, before measuring the pinion shaft rotational torque.

•

20. Using a suitable measuring device with the cord wound round the pinion shaft spline, measure the pinion shaft rotational torque. 21. The rotational torque should be within the following range excluding breakaway torque. 9.2 to 13.7 daN

TV040891

L11–05–61

FRONT AXLE AND STEER SYSTEM

•

Caution: If the stated rotational torque range is exceeded the collapsable spacer must be replaced and the procedure repeated.

22. The adjustment is carried out by increasing the pinion shaft retaining nut torque setting gradually using the special tools CA119099 — Wrench (1) and CA715170 — Wrench (2), being careful not to exceed the stated range.

1

2 TV040883

23. Once the correct rotational torque is achieved, secure the pinion shaft retaining nut. Note: • Do not install a new pinion shaft oil seal at this stage. 24. Install the differential support group. For additional information, refer to DIFFERENTIAL SUPPORT GROUP, PAGE L11–05–39 in this section.

TV040892

L11–05–62

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — TOE-IN ADJUSTMENT

BHL1105GA

Operation: General Procedure Toe-in Adjustment None

Job Code: 11 13 01 xx Standard tools, Two one-metre-long bars

General Procedure The toe-in of the front wheels must be between 0 and 5mm toe-in as measured 500mm from the centre of the wheel hub. To check the exact value of the toe-in setting, proceed as follows. 1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • The bars must be fixed flat against the wheel hub flange and have an equal distance from the centre of the wheel hub. 2. Install two equal one-metre-long bars to the wheel side of the wheel hubs and lock in place with two wheel retaining nuts.

500mm

500mm

TV040979

3. Measure the distance (A) between the ends of the two bars. 4. Measure the distance (B) between the ends of the two bars. 5. The distance (A) must be 0 to 5mm less than distance (B).

A

B TV040980

L11–05–63

FRONT AXLE AND STEER SYSTEM Note: • Make sure the same number of threads are visible at the end of the left-hand and right-hand inner track rod end ball joints. 6. If it is necessary to correct the toe-in adjustment. Loosen the lock nut (1) on the left-hand and the right-hand side. Turn the inner track rod end ball joints (2) equally to achieve the specified toe-in adjustment. 7. Tighten (1) to 120Nm (89 lb.ft).

1

2

TV040981

L11–05–64

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT

BHL1105GB

General Procedure

1

50º 2 A

3 TV040966

1. Remove the front wheels. For additional information, refer to Section M12-01 FRONT WHEEL, PAGE M12–01–3 . Note: • Support the machine under the front chassis. 2. Turn the steering wheel until the front wheel hubs are on full left-hand lock. 3. Place a straight edge (3) against the axle input flange or against the machine hardnose. Make sure the straight edge is parallel with the axle centre-line. 4. Place a second straight edge (2) against the wheel hub flange (1).

•

Caution: Make sure the steering angle does not exceed 52 degrees. Failure to follow this instruction may result in excessive wear to the drive shaft universal joints.

5. Measure the angle (A) at which both straight edges intersect. Subtract angle A from 90 degrees to give the steering lock. Angle A = 40 Steering angle 90 – 40 = 50 degrees. 6. Adjust the left-hand stop for maximum left steering lock and right-hand stop for maximum right steering lock. 7. Loosen the lock nut (1) and adjust the steering stop adjuster bolt (2) until the bolt head touches the steering stop. Tighten the lock nut (1) to 150Nm.

L11–05–65

FRONT AXLE AND STEER SYSTEM 8. Turn the steering wheel until the front wheel hubs are on full right-hand lock and repeat the procedure for the right-hand side.

1 2

TV040967

L11–05–66

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL Operation: Draining and Filling the Front Axle Housing Oil None

BHL1105GC

Job Code: 11 07 09 xx Standard tools

Draining 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Loosen the refill plug (1) to release any pressure. 3. Remove the drain plug (2) and drain the oil into a suitable container.

Filling 1. Install the drain plug (2) and tighten to 60Nm (44 lb.ft). 2. Fill with oil until the refill hole (1) level is reached. 3. Install the refill plug (1) and tighten to 60Nm (44 lb.ft).

1

2 TV040946

L11–05–67

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–68

FRONT AXLE AND STEER SYSTEM GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL

BHL1105GD

Draining 1. Position the hub until the drain/refill plug is positioned at the top. Loosen the drain plug to release any pressure. 2. Position the hub until the drain/refill plug is positioned at the bottom. Remove the drain/refill plug and drain the hub oil into a suitable container.

TV040197

Filling 1. Position the hub until the drain/refill plug is at the 3 o’clock position. Fill with oil until the drain/refill hole level is reached. 2. Install the drain/refill plug and tighten to 60Nm (44 lb.ft).

TV040934

L11–05–69

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–70

FRONT AXLE AND STEER SYSTEM SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE

BHL1105SA

Special Tools Tool No.

Description

CA119030

Wrench

CA119033

Interchangeable Handle

CA119043

Driver

CA119099

Wrench for Lock Nut

CA715026

Driver for Bearing Race

CA715027

Driver for Bush

CA119117

Driver

CA119143

Driver

CA119182

False Differential Box

CA119225

Driver

CA119226

False Differential Box

CA119230

Driver

CA715023

False Pinion

CA715034

Driver

CA715035

Driver

CA715163

Driver

CA715164

Driver

CA715170

Wrench

CA715179

Driver

CA715505

Driver

CA715506

Driver

CA715701

Driver

L11–05–71

FRONT AXLE AND STEER SYSTEM Torque Values Description

Nm

Lb.ft

Epicyclic Reduction Hub

80

59

Wheel Hub

230

170

Axle Drain/Fill Plugs

60

44

Wheel Studs

70

52

King Pin

190

140

Crown Wheel

95

70

Grease Nipple

8

6

Differential Adjustment Nut Locking Tabs

13

10

Differential Housing

169

125

Differential Half Collers

266

196

Breather

10

7

Blanking Plug

25

18

Steering Cylinder

120

89

Swivel Joint

300

221

Tie-Rod Locking Nut

250

184

Tie-Rod End

220

162

Steering Angle Adjustment Locking Nut

150

111

General Specifications Description

Value

Crown Wheel Gear Ratio

2.133/1

Epicyclic Reduction Gear Ratio

6.00/1

Total Ratio

12.80/1

Dry Weight

303 Kg

Input Rotation

Clockwise (C.W.)

Steering Angle

55° 0–2mm

Toe-in

0–5mm

Crown Wheel / Pinion Backlash

0.18 – 0.23mm

Pinion Shaft Bearing Pre-Load “P”

“P” = 9.2 – 13.7 daN

Total Pinion/Differential Bearing Pre-load

(4.3 + P) — (6.45 + P) daN

Axle Housing Oil Capacity

6.5 Litres

Epicyclic Reduction Hub Oil Capacity

1.0 Litre

Oil Type (Use recommended oil enriched in Additives)

API GL5 (for possible alternatives see – GENERAL INFORMATION – FLUIDS AND LUBRICANTS at the start of this manual).

Grease Type

TECNOLUBE SEAL PLOYMER 400/L (DIN = KHER1R ISO-I-XMR-XM2) AGIP MU/EP2 (King pin only)

Sealant

Silastic 732

L11–05–72

FRONT AXLE AND STEER SYSTEM

Note: This page intentionally left blank.

L11–05–73

WHEELS AND TYRES

M12 SECTION

SAFETY PRECAUTIONS — WHEELS AND TYRES.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–1 REMOVAL AND INSTALLATION — FRONT WHEEL. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–3 REMOVAL AND INSTALLATION — REAR WHEEL .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–5 REMOVAL AND INSTALLATION — INNER TUBE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–7 REMOVAL AND INSTALLATION — TYRE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–11 SPECIFICATIONS — WHEELS AND TYRES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . M12–01–13

WHEELS AND TYRES SAFETY PRECAUTIONS — WHEELS AND TYRES

BHM1201IA

Wheels and Tyres

PREPARATION

•

Before mounting a tyre on a used rim, ensure the flange area (particularly the bead seat area) is clean and smooth. Remove any build-up of rust, corrosion or old rubber with a chisel or wire brush. Thoroughly inspect the inside of the casing for damage or foreign material. Ensure that both tyre and tube are completely dry, as moisture deteriorates the cord fabric of the tyre and may result in eventual failure of the tyre. Lubricate both beads with a thin solution of vegetable oil soap in water, or equivalent rubber lubricant recommended for this requirement. (NEVER use petroleum-based solutions or silicones).

• • • • • • •

• • • • • • • • •

NEVER re-inflate a tyre that has been run flat or seriously underinflated without removing and checking for tyre, tube or rim damage. NEVER rework, weld, heat or braze rims. NEVER install tubes that are buckled or creased. NEVER use a tube in a casing larger or smaller than that for which the tube was designed by the manufacturer. NEVER hit the tyre or rim with a hammer. NEVER mount a tyre on a rim where any parts show cracks, damage, or have been repaired by welding or brazing. ALWAYS use specialised tools, as recommended by tyre suppliers, for mounting and demounting of tyres. ALWAYS inspect inside of tyres for loose cords, cuts, penetrating objects, or other carcass damage. Repairable damage should be repaired before installing the tube. Tyres with irreparable damage must be discarded. ALWAYS clean and inspect rims. ALWAYS check rim diameter to ensure it exactly matches the rim diameter moulded on the tyre. ALWAYS inspect the inside of the tyre for dirt, liquids, or foreign material and remove before installing the tube. ALWAYS use new tubes in new tyres. ALWAYS check to ensure the tube is clean before installing in the tyre. ALWAYS lubricate with approved tyre mounting lubricant. Never use anti-freeze, silicones or petroleum-based lubricants. ALWAYS use an extension hose with a gauge and a clip-on chuck so that the operator may stand aside during inflation. ALWAYS inspect valve cores and sealing cap for proper air retention. Replace damaged or leaky cores or caps. ALWAYS inflate tyre to the tyre manufacturer’s recommended cold operating pressure.

Wheel Nuts If a wheel is removed and replaced for puncture repair or any other reason, the wheel nuts must be tightened to the torques given in the Specifications Section of this manual and checked daily until stabilised.

•

M12–01–1

Warning: Many machines use special wheel nuts and washers, which must never be substituted by a standard wheel nut. When fitted, always use the special washers under the rear wheel nuts. If either the nut or washers are lost they must only be replaced with genuine Aftercare parts.

WHEELS AND TYRES

Note: This page intentionally left blank.

M12–01–2

WHEELS AND TYRES REMOVAL AND INSTALLATION — FRONT WHEEL

BHM1201RA

Operation: Removing and Installing the Front Wheel Suitable axle stands Suitable lifting equipment

Job Code: 12 04 13 xx Standard tools

Removal 1. Park the machine on firm level ground. 2. Loosen the front wheel retaining nuts. 3. Use the loader to raise the front wheels of the ground.

•

Warning: Use suitable axle stands to support the machine. Failure to follow this instruction may result in personal injury.

4. Support the machine under the front chassis. 5. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Remove the front wheel retaining nuts.

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

7. Using suitable lifting equipment, remove the front wheel.

TV040065

Installation

•

Caution: If the wheel retaining nuts or washers are lost they must only be replaced with genuine Aftercare parts. When a wheel is installed the wheel nuts must be tightened to the correct torque value and checked daily until stabilized.

1. To install, reverse the removal procedure. 2. Tighten to 300 Nm (222 lb.ft).

M12–01–3

WHEELS AND TYRES 3. For 970 / 980 machines, tighten to 600 Nm (444 lb.ft).

TV040065

M12–01–4

WHEELS AND TYRES REMOVAL AND INSTALLATION — REAR WHEEL

BHM1201RB

Operation: Removing and Installing the Rear Wheel Suitable axle stands Suitable lifting equipment

Job Code: 12 05 13 xx Standard tools

Removal 1. Park the machine on firm level ground. 2. Loosen the rear wheel retaining nuts. 3. Use the stabiliser leg to raise the rear wheel of the ground.

•

Warning: Use suitable axle stands to support the machine. Failure to follow this instruction may result in personal injury.

4. Support the machine under the rear chassis. 5. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 6. Remove the rear wheel retaining nuts.

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

7. Using suitable lifting equipment, remove the rear wheel.

TV040066

Installation

•

Caution: If the wheel retaining nuts or washers are lost they must only be replaced with genuine Aftercare parts. When a wheel is installed the wheel nuts must be tightened to the correct torque value and checked daily until stabilised.

1. To install, reverse the removal procedure.

M12–01–5

WHEELS AND TYRES 2. Tighten to 600 Nm (444 lb.ft).

TV040066

M12–01–6

WHEELS AND TYRES REMOVAL AND INSTALLATION — INNER TUBE

BHM1201RC

Operation: Removing and Installing the Inner Tube

Job Code: N/A

None

Bead unseating tool, Tyre lever, Standard tools

Removal

•

Warning: Refer to SAFETY PRECAUTIONS – WHEELS AND TYRES in this section.

1. Remove the wheel. For additional information, refer to FRONT WHEEL, PAGE M12–01–3 or REAR WHEEL, PAGE M12–01–5 in this section. 2. Lay the wheel on the ground with the valve uppermost. 3. Deflate the tyre by removing the valve core. 4. Remove the valve retaining nut.

•

Caution: Take care not to damage the rim or tyre.

5. Drive the bead unseating tool between the tyre and the rim and release the bead from the rim.

TV040752

6. Turn the wheel over and lay flat on the ground.

•

Caution: Take care not to damage the rim or tyre.

7. Drive the bead unseating tool between the tyre and the rim and release the bead from the rim. 8. Using a suitable solution of soap and water or an approved lubricant, lubricate the rim, tyre and base of the tube.

TV040752

M12–01–7

WHEELS AND TYRES Note: • Begin at the valve location. 9. Using suitable tyre levers, pry the tyre from the rim using small bites of the tyre levers, ensuring the bead on the opposite side is fully located in the rim well.

TV040753

10. Position the wheel in the vertical position and remove the inner tube.

Installation

•

Caution: Examine the bead seating area of the rim. Remove any build-up of rust, corrosion or old rubber. Inspect inside the tyre casing for debris or damage.

1. To install, reverse the removal procedure, but note the following: Note: • When the inner tube is installed, adding a small amount of air will assist in preventing the tyre from pinching the inner tube. 2. Install the inner tube until it is correctly aligned in the tyre. Place the tube in the tyre with the valve located through the valve hole in the rim. Refit the valve retaining nut, finger tight. Note: A solution of soap and water, or similar rubber lubricant, brushed on to the rim and bead will help fitment.

•

3. Install the tyre, starting opposite the valve location taking small bites with long tyre levers and keeping the fixed part of the bead fully located in the well.

TV040760

M12–01–8

WHEELS AND TYRES

•

•

•

Warning: Never stand over the assembly when inflating, remote control inflation equipment should be used. Failure to follow this instruction may result in personal injury. Caution: Care must be taken not to pinch the tube when fitting. Warning: If the beads fail to seat correctly at the recommended pressure, the tube may be pinched. Do not increase the pressure but remove the valve core and release the tyre from the rim. Lubricate the tyre, bead and rim then re-inflate at the recommended pressure. Repeat process until both beads are properly seated. When seating beads, inflation beyond the recommended pressure may break the bead or rim with explosive force, sufficient to cause serious physical injury or death. Inspect both sides of the tyre to ensure both beads are evenly seated. If not, completely deflate the tyre and repeat the complete remounting procedure. Failure to follow these instructions may result in personal injury.

4. Centre the tyre on the rim and inflate. 5. Remove the valve core and completely deflate the tyre. 6. Refit the valve core and inflate to recommended pressure.

M12–01–9

WHEELS AND TYRES

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M12–01–10

WHEELS AND TYRES REMOVAL AND INSTALLATION — TYRE

BHM1201RD

Operation: Removing and Installing the Tyre None

Job Code: N/A Bead unseating tool, Tyre lever, Standard tools

Removal

•

Warning: Refer to SAFETY PRECAUTIONS – WHEELS AND TYRES in this section.

1. Remove the wheel. For additional information, refer to FRONT WHEEL, PAGE M12–01–3 or REAR WHEEL, PAGE M12–01–5 in this section. 2. Remove the inner tube. For additional information, refer to INNER TUBE, PAGE M12–01–7 in this section.

•

Caution: Take care not to damage the rim or tyre.

Note: A solution of soap and water, or similar rubber lubricant, brushed on to the rim and bead will help removal.

•

3. Position the wheel in a vertical position and using suitable tyre levers, pry the tyre off the rim using small bites of the tyre levers.

TV040761

Installation

•

Caution: Examine the bead seating area of the rim. Remove any build-up of rust, corrosion or old rubber. Inspect inside the tyre casing for debris or damage.

1. To install, reverse the removal procedure, but note the following: 2. Place the rim on the ground, lubricate the bead and rim and place the tyre on the rim.

M12–01–11

WHEELS AND TYRES 3. Using long tyre levers, refit the tyre.

TV040762

•

•

•

Warning: Never stand over the assembly when inflating, remote control inflation equipment should be used. Failure to follow this instruction may result in personal injury. Caution: Care must be taken not to pinch the tube when fitting. Warning: If the beads fail to seat correctly at the recommended pressure, the tube may be pinched. Do not increase the pressure but remove the valve core and release the tyre from the rim. Lubricate the tyre, bead and rim then re-inflate at the recommended pressure. Repeat process until both beads are properly seated. When seating beads, inflation beyond the recommended pressure may break the bead or rim with explosive force, sufficient to cause serious physical injury or death. Inspect both sides of the tyre to ensure both beads are evenly seated. If not, completely deflate the tyre and repeat the complete remounting procedure. Failure to follow these instructions may result in personal injury.

4. Inflate the tyre to the recommended pressure.

M12–01–12

WHEELS AND TYRES SPECIFICATIONS — WHEELS AND TYRES

BHM1201SA

Torque Values Description

Nm

Lb.ft

Front Wheel Retaining Nut

300

221

Rear wheel Retaining Nut

600

442

Front and Rear wheel Retaining Nut 970 / 980 machines

600

442

M12–01–13

DRIVETRAIN AND BRAKES

N13 SECTION

DESCRIPTION AND OPERATION — POWERSHIFT TRANSMISSION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–01–1 DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–01–19 DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION PRESSURE TESTING.. .. .. .. .. ..N13–01–35 REMOVAL AND INSTALLATION — POWERSHIFT TRANSMISSION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–01–45 DISASSEMBLY AND ASSEMBLY — POWERSHIFT TRANSMISSION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–01–53 DISASSEMBLY AND ASSEMBLY — FORWARD LOW CLUTCH. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–01–77 DISASSEMBLY AND ASSEMBLY — 1ST CLUTCH .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–01–89 DISASSEMBLY AND ASSEMBLY — REVERSE CLUTCH. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–101 DISASSEMBLY AND ASSEMBLY — 2ND CLUTCH .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–113 DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–125 DISASSEMBLY AND ASSEMBLY — DISCONNECT SHAFT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–135 DISASSEMBLY AND ASSEMBLY — CHARGING PUMP DRIVE SHAFT.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–139 DISASSEMBLY AND ASSEMBLY — INPUT SHAFT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–143 DISASSEMBLY AND ASSEMBLY — TRANSMISSION CONTROL VALVE.. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–149 GENERAL PROCEDURE — CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR . .. N13–01–151 GENERAL PROCEDURE — POWERSHIFT TRANSMISSION CLUTCH CALIBRATION .. .. .. .. .. .. N13–01–153 SPECIFICATIONS — POWERSHIFT TRANSMISSION. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–01–157 DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION — TURNER . .. .. .. .. .. . N13–02–1 DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–02–9 DIAGNOSING AND TESTING — SYNCHROSHIFT TRANSMISSION PRESSURE TESTING .. .. .. ..N13–02–13 REMOVAL AND INSTALLATION — SYNCHROSHIFT TRANSMISSION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–15 DISASSEMBLY AND ASSEMBLY — SYNCROSHIFT TRANSMISSION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–23 DISASSEMBLY AND ASSEMBLY — INPUT SHAFT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–47 DISASSEMBLY AND ASSEMBLY — COUNTERSHAFT . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–65 DISASSEMBLY AND ASSEMBLY — REVERSE IDLER SHAFT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–67 DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–69 DISASSEMBLY AND ASSEMBLY — HYDRAULIC MULTIPLATE CLUTCH FOUR-WHEEL DRIVE SHAFT. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–77 DISASSEMBLY AND ASSEMBLY — DIRECTION CONTROL VALVE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–89 DISASSEMBLY AND ASSEMBLY — GEAR LEVER HOUSING. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–93 SPECIFICATIONS — SYNCHROSHIFT TRANSMISSION . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–02–95 DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–03–1 DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM SAFIM . .. .. .. .. .. .. .. .. .. .. .. . N13–03–3 REMOVAL AND INSTALLATION — MASTER CYLINDER (POWER BRAKES) .. .. .. .. .. .. .. .. .. .. .. .. . N13–03–5 REMOVAL AND INSTALLATION — MASTER CYLINDER (SAFIM BRAKES) .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–03–7 REMOVAL AND INSTALLATION — BRAKE FLUID RESERVOIR (SAFIM BRAKES) . .. .. .. .. .. .. .. ..N13–03–11 REMOVAL AND INSTALLATION — PARKING BRAKE CALIPER.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–13 REMOVAL AND INSTALLATION — PARKING BRAKE DISC . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–15 REMOVAL AND INSTALLATION — DIFFERENTIAL LOCK SOLENOID VALVE . .. .. .. .. .. .. .. .. .. .. ..N13–03–17 GENERAL PROCEDURE — BRAKE BLEEDING POWER BRAKES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–19 GENERAL PROCEDURE — BRAKE BLEEDING SAFIM BRAKES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–21 SPECIFICATIONS — POWER BRAKES . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–23 SPECIFICATIONS — BRAKES — SAFIM.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–03–25 DESCRIPTION AND OPERATION — TWO-WHEEL STEER REAR AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–04–1 DIAGNOSING AND TESTING — TWO-WHEEL STEER REAR AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–04–3 REMOVAL AND INSTALLATION — TWO WHEEL STEER REAR AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–04–9 DISASSEMBLY AND ASSEMBLY — BRAKE CALIPER . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–13 DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP . .. .. .. .. .. .. .. .. .. .. ..N13–04–15 DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–19 DISASSEMBLY AND ASSEMBLY — HALF SHAFT AND BRAKE GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–25 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–33 DISASSEMBLY AND ASSEMBLY — PINION GROUP . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–41 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL HOUSING GROUP .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–51

GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL .. .. .. .. .. ..N13–04–67 SPECIFICATIONS — TWO-WHEEL STEER REAR AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–04–69 DESCRIPTION AND OPERATION — FOUR-WHEEL STEER REAR AXLE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–05–1 DIAGNOSING AND TESTING — FOUR-WHEEL STEER REAR AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–05–3 REMOVAL AND INSTALLATION — FOUR-WHEEL STEER REAR AXLE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . N13–05–9 REMOVAL AND INSTALLATION — STEERING CYLINDER (FOUR-WHEEL STEER) .. .. .. .. .. .. .. ..N13–05–13 DISASSEMBLY AND ASSEMBLY — PARKING BRAKE CALIPER (FOUR-WHEEL STEER) .. .. .. ..N13–05–15 DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR WHEEL-STEER) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–05–17 DISASSEMBLY AND ASSEMBLY — REAR WHEEL HUB GROUP (FOUR-WHEEL STEER) .. .. .. ..N13–05–23 DISASSEMBLY AND ASSEMBLY — AXLE BEAM TRUMPETS AND BRAKE GROUP (FOUR-WHEEL STEER) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–05–31 DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER) . .. .. .. .. .. ..N13–05–41 DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER) . .. .. .. .. .. .. .. .. .. .. ..N13–05–49 GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) . .. .. .. .. .. .. .. .. .. .. .. ..N13–05–59 GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL (FOUR-WHEEL STEER) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–05–61 GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER). .. ..N13–05–63 SPECIFICATIONS — FOUR-WHEEL STEER REAR AXLE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–05–65 DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION – CARRARO.. .. .. .. .. . N13–06–1 DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO . .. .. .. .. .. .. ..N13–06–11 DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO PRESSURE TESTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–15 REMOVAL AND INSTALLATION — SYNCHROSHUTTLE TRANSMISSION — CARRARO .. .. .. .. ..N13–06–19 DISASSEMBLY AND ASSEMBLY — PLUGS AND FILTERS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–31 DISASSEMBLY AND ASSEMBLY — TRANSMISSION OIL PUMP .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–39 DISASSEMBLY AND ASSEMBLY — HYDRAULIC CONTROL VALVE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–43 DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SOLENOID VALVE. .. .. .. .. .. .. .. .. .. .. ..N13–06–61 DISASSEMBLY AND ASSEMBLY — TRANSMISSION HOUSING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–65 DISASSEMBLY AND ASSEMBLY — INPUT SHAFT AND IDLER SHAFT. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–06–83 DISASSEMBLY AND ASSEMBLY — SHAFTS C AND B. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–06–105 DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SHAFT (E) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–06–129 DISASSEMBLY AND ASSEMBLY — SPEED CONTROLS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–06–139 SPECIFICATIONS — SYNCHROSHUTTLE TRANSMISSION — CARRARO . .. .. .. .. .. .. .. .. .. .. .. .. N13–06–145 DESCRIPTION AND OPERATION — CARRARO POWERSHIFT TRANSMISSION.. .. .. .. .. .. .. .. .. .. . N13–07–1 DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION. .. .. .. .. .. .. .. .. .. .. .. ..N13–07–19 DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION PRESSURE TESTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–07–29 REMOVAL AND INSTALLATION — CARRARO POWERSHIFT TRANSMISSION . .. .. .. .. .. .. .. .. .. ..N13–07–33 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION .. .. .. .. .. .. .. .. .. ..N13–07–43 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT FORWARD AND REVERSE CLUTCHES . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–07–49 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 2ND SPEED CLUTCH.. .. .. .. .. .. ..N13–07–67 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 1ST CLUTCH .. .. .. .. .. .. .. .. .. .. .. ..N13–07–79 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 3RD AND 4TH SPEED CLUTCHES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..N13–07–85 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 4WD CLUTCH. .. .. .. .. .. .. .. .. .. .. N13–07–103 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT HYDRAULIC PUMP DRIVE SHAFT. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–07–113 DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION CONTROL VALVE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–07–117 GENERAL PROCEDURE — CARRARO POWERSHIFT CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–07–121 SPECIFICATIONS — CARRARO POWERSHIFT TRANSMISSION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. N13–07–123

Note: This page intentionally left blank.

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — POWERSHIFT TRANSMISSION

BHN1301OA

Identification Of The Unit

• •

Model and type of the unit Unit serial number

TV040541

Schematic View Powershift Transmission 1

2

3

4

5

6

7

8

9

10

11 12 13 14 15

16 17 18

19

20

TV041060

24

23

22

N13–01–1

21

DRIVETRAIN AND BRAKES 1

Charging Pump / Input Drive Shaft

2

Torque Converter

3

Charge Pump

4

Input Shaft

5

Forward Driven Gear

6

Forward Low Gear

7

Forward Low Clutch

8

Forward High Cluth

9

Forward High Clutch Gear

10

Forward High Drive Gear

11

Reverse Driven Gear

12

Forward Low Clutch Gear

13

Reverse Clutch

14

1st Clutch

15

1st Clutch Gear

16

2nd Clutch Gear

17

2nd Clutch

18

Lower Output Drive Gear

19

Upper Output Gear

20

Rear Output Flange

21

Lower Output Flange

22

Axle Disconnect (Four-Wheel Drive) Clutch

23

Disconnect Shaft

24

Front Output Flange

N13–01–2

DRIVETRAIN AND BRAKES Transmission Hydraulic Circuit

21

20

27

10

44

28

29

12

22

1

24

13

25

11

2

26

23

3

31

4

30

14

5

32

15

33

6

34

16

35

36

7

37

8

38

17

39

40

9

18

41

19

42

43

Neutral and 2nd Clutch Engaged

TV040542

1

Pressure Test Port — Torque Converter In

2

Torque Converter

3

Temperature Test Port — Torque Converter Out To Oil Cooler

4

Pressure Test Port — Torque Converter Out To Oil Cooler

5

Torque Converter By-Pass Valve — Pressure Difference 4 Bar (58 PSI)

6

Transmission Oil Cooler

7

Temperature Test Port — Oil Cooler Out To Lubrication

8

Pressure Test Port — From Oil Cooler (Lubrication Pressure)

9

Transmission Lubrication

10

Safety Valve — 10 Bar (145 PSI) Cracking Pressure

11

Solenoid Pressure — 5 Bar (73 PSI)

12

Pressure Regulating Valve — 20 Bar (290 PSI)

13

Pressure Reducer to 5.5 Bar (80 PSI)

14

Neutral/Forward Solenoid

15

Neutral/Reverse Solenoid

16

High/Low Solenoid

17

2nd/1st Solenoid

18

Range Modulation Solenoid

19

Axle Disconnect (Four-Wheel Drive) Solenoid

20

Pressure Test Port — Regulated Pressure

N13–01–3

DRIVETRAIN AND BRAKES 21

Oil Filter By-Pass Valve — Pressure Difference 4.3 Bar (62 PSI)

22

Oil Filter

23

Electronic Controlled Modulation Valve — (5.5 to 0 Bar (80 to 0 PSI)

24

Pressure Test Port — Pressure Before the Oil Filter

25

Pressure Booster — 0–5.5 to 0–20 Bar (0–80 to 0–290 PSI)

26

Accumulator

27

Air Breather

28

Suction Oil Strainer

29

Charging Pump

30

Clutch Pressure — 20 Bar (290 PSI)

31

Modulated Pressure — 0 to 20 Bar (290 PSI)

32

Reverse Clutch

33

Pressure Test Port — Reverse Clutch

34

Forward Low Clutch

35

Pressure Test Port — Forward Low Clutch

36

Forward High Clutch

37

Pressure Test Port — Forward High Clutch

38

2nd Clutch

39

Pressure Test Port — 2nd Clutch

40

1st Clutch

41

Pressure Test Port — 1st Clutch

42

Axle Disconnect (Four-Wheel Drive) Clutch

43

Pressure Test Port — Axle Disconnect (Four-Wheel Drive) Clutch

44

Transmission Sump

N13–01–4

DRIVETRAIN AND BRAKES The transmission and torque converter function together through a common hydraulic system. The charging pump (29) draws oil through the suction oil strainer (28) and directs it to the oil filter (22). Protecting the filter from system pressure in excess of 4.3 Bar (62 PSI) is a by-pass valve (21). A pressure regulating valve (12) maintains the pressure for the control valve and clutches at 20 bar (290 PSI) and excess oil is returned to the torque converter circuit.

The torque converter is protected from pressures over 10 bar (145 PSI) by a safety valve (10). After leaving the torque converter, the oil flows through the oil cooler (6) then on to lubricate and cool the transmission bearings and clutches. The oil drains back to the transmission sump (44) under gravity. A torque converter by-pass valve (5) will open if the pressure difference across the torque converter and oil cooler is greater than 4 bar (58 PSI), assisting start up from cold and protecting from high RPM).

N13–01–5

DRIVETRAIN AND BRAKES Gear and Clutch Layout 1

2

3 7

6

4

5 TV040558

1

Forward Low Clutch

2

Forward High Clutch

3

1st Clutch

4

2nd Clutch

5

Axle Disconnect (Four-Wheel Drive) Clutch

6

Input Drive Shaft

7

Reverse Clutch

N13–01–6

DRIVETRAIN AND BRAKES The transmission assemblies.

1

is

composed

of

five

main

2

2

3

4

5

5

TV0400543

N13–01–7

DRIVETRAIN AND BRAKES 1

The torque converter and charging pump drive section

2

The input or directional clutches

3

The range clutches

4

The output section

5

The transmission controls

N13–01–8

DRIVETRAIN AND BRAKES Transmission Assembly and Controls 1. The Torque Converter and Charging Pump Drive Section

1

TV040547

Engine power is transmitted from the engine flywheel to the impeller through the impeller cover. This element is the charging pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at its centre and discharges at its outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft or directional clutch shaft. This element receives fluid at its outer diameter and discharges at its centre. The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and changes its direction to allow correct entry for recirculation into the impeller element. This recirculation will make the converter multiply torque.

The torque multiplication in function of the balding (impeller, turbine and reaction member) and the torque converter output speed (turbine speed). The torque converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. In the impeller cover a splined shaft is installed which runs inside and through the turbine shaft to drive a hydraulic pump which is fitted at the back of the transmission. Since the shaft is connected to the centre of the impeller cover, the hydraulic pump speed will be the same as engine speed. The rear side of the impeller cover has a tanged drive which drives the transmission charging pump located in the converter housing. The transmission charging pump speed is also the same as the engine speed.

N13–01–9

DRIVETRAIN AND BRAKES 2. Input or Directional Clutches

2

TV040548

The turbine shaft driven from the turbine transmits power to the forward or reverse clutches. These clutches consist of a drum with splines and a bore to receive a hydraulic actuated piston. The piston is oil tight by the use of sealing rings. A steel disc with internal splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the outer diameter is inserted. Discs are alternated until the required total is achieved. A backing plate is then inserted and secured with a snap ring. A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the control valve which is fitted on the side of the transmission will direct oil under pressure through tubes and passages to the selected clutch shafts. Oil sealings are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft to the desired clutch.

Pressure of the oil forces the piston and discs against the backing plate. The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil will drain back via the control valve into the transmission sump. The powershift transmission has one reverse clutch and two forward clutches (forward Low and forward High). This, in combination with the two range clutches, results in the transmission having 4 forward speeds and 2 reverse speeds. The engagement of the directional clutches is modulated; which means that clutch pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving and will allow smooth engagement of drive. The modulation is controlled electronically in the control valve.

N13–01–10

DRIVETRAIN AND BRAKES 3. The Range Clutches

3

TV040549

Once a directional clutch is engaged power is transmitted to the range clutches (1st or 2nd). Operation and actuation of the range clutches is similar to the directional clutches. The engagement of the range clutches is also modulated to enable a smooth engagement.

The modulation for these clutches is achieved by means of a restrictor valve fitted in the control valve which is controlled electronically and which limits oil flow to the clutch during shifts. In the clutch itself the plate before the end plates is dished to build up the clamping force of the clutch gradually.

N13–01–11

DRIVETRAIN AND BRAKES 4. The Output Section

4

TV040550

With a range clutch engaged power is finally transmitted to the output shafts. The powershift transmission can have an upper output or lower output at the rear side of the unit, and a lower output at the front side. Output rotation of the rear upper output is opposite the engine rotation when the forward clutch is engaged, while output rotation of the lower rear output and the front output is the same as the engine rotation with the forward clutch engaged.

The lower front output has an axle disconnect clutch to enable four-wheel drive. The clutch is similar to the other clutches except that it has no modulation. The disconnect clutch is controlled electronically. The clutch is engaged with an electrical signal.

N13–01–12

DRIVETRAIN AND BRAKES 5. The Transmission Controls

5

5

TV040551

Operation of the valve is as follows: (Refer to transmission hydraulic circuit) The control valve has 6 solenoids, 6 shift spools, a pressure reducer, an electronic controlled modulation valve, an accumulator, a pressure booster and a speed sensor. Regulated pressure 20 bar (290 PSI) is directed to the shift spools, pressure booster (25) and pressure reducer (13). In the pressure reducer (13), regulated pressure is reduced to 5.5 bar (80 PSI). This reduced pressure is used as supply for the solenoids (11) and electronic controlled modulation valve (23). When activated, the electronic controlled modulation valve (23) will give an output pressure curve from 0 to 5,5 bar (0 to 80 PSI). This pressure curve is multiplied in the pressure booster (25) so that a curve from 0 to 20 bar (0 to 290 PSI) is available for the directional clutches. Between the electronic controlled modulation valve (23) and the pressure booster (25) is an accumulator (26) to dampen any hydraulic vibration. When forward is selected the electronic controlled modulation valve (23) and the neutral/forward solenoid (14) are activated. The pilot pressure of the neutral/forward solenoid will move the shift spool so that the forward clutch (34) or (36) can be fed with modulated pressure. If the High/Low solenoid (16) is not activated, the forward high clutch (36) is engaged. If it is activated, the Forward Low clutch (34) is engaged. When reverse is selected the electronic controlled modulation valve (23) and the neutral/reverse

solenoid (15) are activated, the pilot pressure of the neutral/reverse solenoid will move the shift spool so that the reverse clutch (32) can be fed with modulated pressure. The shift spools from forward and reverse are located against each other with a return spring in between; this is to ensure that only one direction can be selected. Range is selected as follows: If the range 2nd/1st solenoid (17) is not activated, regulated pressure is fed through the modulation shift spool and through the 2nd/1st shift spool to the 2nd clutch (38). If the range 2nd/1st solenoid (17) is activated, the pilot pressure will move the shift spool so that 1st clutch (40) is engaged. The range clutches also have modulation which operates as follows: When the range is changed, oil will flow through the modulation shift spool to the chosen range clutch momentary until the friction discs are closed against the dished plate. At that moment the range modulation solenoid (18) is activated. The pilot pressure will move the modulation shift spool so that the oil supply is fed through a restrictor which is in by-pass of the valve. The controlled volume of oil is used to push in the dished outer plate gradually until the clutch is fully closed. This will give a smooth build up of torque. At that moment the range modulation solenoid (18) is released, so that the modulation shift spool returns to its rest position and allows full oil flow to the clutch.

N13–01–13

DRIVETRAIN AND BRAKES The control valve also controls the front lower output disconnect (four-wheel drive) clutch (42). If the disconnect solenoid (19) is activated, the pilot pressure of the disconnect solenoid (19) will move the shift spool so that the disconnect (four-wheel drive) clutch (42) can be fed with full pressure The control valve also has a speed sensor. This sensor will pick up upper output gear speed. This information is used in the electronic gear selector to determine shift logic. Since the sensor picks up upper output gear speed, the signal will be in direct relation to the turbine speed if any directional clutch is engaged. Control Valve Solenoid Activation Activated Solenoids Transmission Gear

Direction Solenoids N/F

N/R

Range Solenoids 2/1

High/Low

Range Modulation

Disconnect (Four-Wheel Drive)

Engaged Clutches

F1

Forward Low, 1st

F2

Forward Low, 2nd

F3

Forward High, 1st

F4

Forward High, 2nd

N1

1st

N2

2nd

R1

Reverse, 1st

R2

Reverse, 2nd

Four-Wheel Drive

Disconnect (Four-Wheel Drive) = Active Solenoid

Note: • The High/Low solenoid is activated when in reverse in preparation for a direction change to forward. Range modulation solenoid is activated for 0.5 seconds every time the 1st / 2nd solenoid is energized. When four-wheel drive is selected the disconnect (four-wheel drive) clutch is pressurised.

N13–01–14

DRIVETRAIN AND BRAKES The transmission is controlled by an electronic gear selector (EGS or TCT16). This unit has a microprocessor which receives certain inputs (gear selector position, speed sensor etc.) which are processed and will give output signals to the control valve. Three types of transmission controller (1) are available. These can be identified by the colour of the decal (2).

1

TV041045

Coloured Decal

Number of Forward Speeds

Transmission Type

Red

4

Automatic

Blue

4

Manual

Green

3

Manual

Power Flows Forward 1st Gear — Forward Low and 1st clutch engaged.

TV040552

N13–01–15

2

DRIVETRAIN AND BRAKES Forward 2nd Gear — Forward Low and 2nd clutch engaged.

TV040553

Forward 3rd Gear — Forward High and 1st clutch engaged.

TV040554

N13–01–16

DRIVETRAIN AND BRAKES Forward 4th Gear — Forward High and 2nd clutch engaged.

TV040555

Reverse 1st Gear — Reverse and 1st clutch engaged.

TV040556

N13–01–17

DRIVETRAIN AND BRAKES Reverse 2nd Gear — Reverse and 2nd clutch engaged.

TV040557

N13–01–18

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION

BHN1301TA

The following information is presented as an aid to isolate and determine the specific problem area in a transmission that is not functioning correctly. When diagnosing a transmission problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connection lines, and controls, including the engine as a complete system. By analysing the description and operation together with the information in this and the pressure testing section, it should be possible to identify and correct any malfunction which may occur in the system.

Diagnosing Procedures In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is the “life blood” of the transmission. It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and lubricate the working components. Faults fall into three general categories: mechanical, hydraulic and electrical. Stall Test Use a stall test to identify whether the transmission, torque converter, or the engine is the malfunctioning component when a complaint of poor performance is made. Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure may also be measured.

Mechanical And Electrical Checks Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical checks should be made: • Check the parking brake for correct adjustment. • Ensure all lever linkages are properly connected and adjusted in each segment and at all connecting points. • The controls are actuated electrically. Check the wiring and electrical components. • Ensure that all components of the cooling system are in good condition and operating correctly. • The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary. • The engine must be operating correctly. Ensure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications. Hydraulic Check Note: • The transmission fluid must be at the operating temperatures of 82° to 93°C (180° to 200° F) to achieve correct fluid level and pressure readings.

•

Caution: Do not attempt to make these checks with cold oil.

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check: The Check the oil level in the transmission. transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with torque converter at “stall”. (Refer to torque converter stall procedure).

N13–01–19

DRIVETRAIN AND BRAKES Torque Converter Stall Procedure

•

•

•

Caution: If the operating pressures at idle are too low, do not carry out this test. Caution: Do not operate the torque converter at stall condition longer than 30 seconds at one time, shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature 120°C (250°F) maximum will cause damage to transmission clutches, fluid, torque converter, and oil seals. Caution: If the engine RPM recorded by the tachometer exceeds the maximum specified RPM, reduce the engine RPM to idle immediately. Clutch slippage is indicated.

Permitted Torque Converter Stall Speeds Models 820

860 SX

860 Elite

970

Maximum no-load engine RPM

2325 — 2375

2325 — 2375

2325 — 2375

2325 — 2375

Stall speed RPM

2125 — 2175

1975 — 2225

1975 — 2225

1975 — 2225

Note: • Transmission fluid level and engine coolant level must be correct. Both fluids must be at normal operating temperature Note: The transmission fluid must be at the operating temperature of 82° to 93°C (180° to 200° F) to achieve the correct readings.

•

Note: • Check the engine is capable of obtaining the specified maximum no-load engine RPM before stall testing.

•

Caution: Be careful that the vehicle does not move unexpectedly when operating the engine and torque converter at stall RPM.

1. Put the vehicle against a solid barrier, such as a wall, apply the parking brake, service brakes and block the wheels. 2. Start the engine. 3. Put the directional control lever in FORWARD (or REVERSE, as applicable). 4. Select the highest gear and increase the engine speed to the maximum RPM until the tachometer reading stabilizes. 5. Read of the stall speed RPM on the tachometer.

N13–01–20

DRIVETRAIN AND BRAKES Problem Stall speed too high

•

Low oil level

Low clutch pressure(s).

Stall speed too low

• • • •

Internal damage within the torque converter.

Problem Low clutch pressure

Low charging pump output

Overheating

Noisy torque converter

Lack of power

Action

Possible Cause

•

• Slipping clutch(es). • Engine maximum no-load RPM • speed too low.

•

Possible Cause

• •

Low oil level.

• •

Faulty charging pump.

• •

Low oil level.

• • • • •

Defective charging pump.

• • •

Worn charging pump.

• •

CHECK the oil level (should always be checked prior to stall testing). CHECK clutch pressure(s). CHECK clutch(es). CHECK engine controls and performance. REPAIR/REPLACE the torque converter. Action

• •

FILL to proper level.

• •

REPLACE charging pump.

• •

FILL to correct oil level.

• • • • •

REPLACE charging pump.

• • •

REPLACE.

Low engine RPM at torque converter stall.

•

TURN engine check governor.

See “Overheating” and make same checks.

•

MAKE corrections as explained in “Overheating”.

Clutch pressure regulating valve stuck open. Broken or worn clutch shaft or piston sealing rings. Suction screen blocked.

Dirty oil cooler. Restriction in cooler lines. Low oil level. Worn oil sealing rings.

Worn charging pump. Worn or damaged bearings.

N13–01–21

CLEAN valve spool and housing. REPLACE sealing rings.

CLEAN suction screen and charging pump. CLEAN oil cooler. CHANGE cooler lines. FILL to correct oil level. REMOVE, DISASSEMBLE and REBUILD torque converter assembly. REPLACE. A complete DISASSEMBLY will be necessary to determine which bearing is faulty.

DRIVETRAIN AND BRAKES Fault Codes The Powershift transmission controller (1) has an inbuilt diagnostic facility. This facility utilises the digital display (2) at the front of the controller to indicate, in coded format, malfunctions in the transmission electrical and electronic circuitry.

2

1

TV040985

If the controller recognises a fault, the yellow “T” Light Emitting Diode (LED) (3) will start to flash. If the controller is in the reset condition, the red “F” LED (2) will be illuminated. To display the fault code, depress and hold the mode button “M” (1) for 2 seconds. The fault code will be displayed in the digital display (4). The digital display will alternate between a first set of digits that represent the fault area and a second set of digits that represents the fault type. If several faults occur at the same time, the controller will only display the most severe fault code on the digital display. Note: • Releasing the mode button “M” will clear the memory. If an intermittent fault occurs, the controller will store the last fault code in memory. To view the stored fault code, depress and hold the mode button “M” (1) for 2 seconds. Releasing the mode button “M” will clear the fault code from the memory. If the mode button “M” is depressed again, the digital display will alternate between — — and — — to indicate the memory has been cleared.

1

M TF 4 TV040986

N13–01–22

3

2

DRIVETRAIN AND BRAKES Fault Code List Fault Area

Fault Type

Fault

Description

Direction outputs — shutdown (latched)

In severe dangerous conditions, all outputs will be shutdown. Turn the starting key to the OFF position to reset the controller and leave the shutdown mode.

Direction outputs — forced to a positive voltage or open circuit

One of the direction outputs (Forward solenoid, C214, Pin 6 or Reverse solenoid, C214, Pin 7) is forced to a positive voltage or has an open circuit.

Limp home mode

An internal fault with the EEPROM parameters is detected at power up. The transmission can be operated in F1, F2, R1 and R2. There are no downshift and direction change protections and no modulation for speed changes.

Direction modulator output — open circuit or short to ground.

Direction modulation solenoid output (C214, Pin 3) is shorted to ground or has an open circuit.

Direction modulator output — short circuit

Direction modulation solenoid output (C214, Pin 3) is shorted to a positive voltage.

Digital output — short circuit

One of the digital outputs (1/2 solenoid, C214, Pin 4 or Forward Low/High solenoid, C214, Pin 5 or Axle Disconnect solenoid, C214, pin 9) is shorted to ground.

Digital output — other fault

One of the digital outputs (1/2 solenoid, C214, Pin 4 or Forward Low/High solenoid, C214, Pin 5 or Axle Disconnect solenoid, C214, pin 9) is shorted to a positive voltage or has an open circuit.

Speed sensor failure — open circuit

Speed sensor failure — short circuit

N13–01–23

The speed sensor (C214, Pin 21) has an open circuit.

The speed sensor (C214, Pin 11 or 21) is shorted to ground.

DRIVETRAIN AND BRAKES Fault Area

Fault Type

Fault

Description

Battery — voltage high

If the battery voltage is greater than 16.5 Volts, there will be no speed readings. Speed changes above 2nd gear are not possible. If the battery voltage is greater than 24 Volts, the direction and range modulator outputs (C214, Pins 3 and 13) will not function correctly. A 24 Volt jump-start (less than 5 minutes) is allowed.

Forward/Reverse input error

The direction lever Forward request input (C214, Pin 12) and Reverse request input (C214, Pin 19) are activated at the same time.

Temperature sensor failure — open circuit

The temperature sensor (C214, Pin 18) has an open circuit. This fault will also occur if the temperature is greater than 150 degrees Celsius. Temperature sensor resistance — –50 ºC = 1.030 K Ohms and 150 ºC = 4.280 K Ohms.

Temperature sensor failure — short circuit

The temperature sensor (C214, Pin 18 or 11) is shorted to ground. The fault will also occur if the temperature is less than –50 degrees Celsius.

Redundant shutdown path error (latched)

The controller uses a relay to cut off the power to the output circuits in case of severe danger. The relay is checked at power up and if a problem is detected, this error will be displayed. Turn the starting key to the OFF position to reset the controller and leave the shutdown mode. This fault is also displayed if at power up an external power source is connected to an output circuit.

General Information Display Modes The general information display modes are to provide information on speed, shift lever position and gear position. After turning the key start switch ON, the controller defaults to the gear position display. Depress the mode button “M” (1) to navigate through the available information display modes in order. When the mode button “M” is released, the digital display (2) will show the values for the selected menu.

1

M TF 2 TV041036

N13–01–24

DRIVETRAIN AND BRAKES General Information Display Modes Available Mode

Value

Description Gear Position This mode displays the engaged direction and range. If either or both differ from the shift lever, the corresponding decimal point will flash. The example shows Neutral 1st. Speed (km/h) This mode displays the vehicle speed in km/h. For speeds below 10 km/h, the speed is displayed in 0.1 km/h increments. The example shows 4.2 km/h. Speed (mph) This mode displays the vehicle speed in mph. For speeds below 10 mph, the speed is displayed in 0.1 mph increments. The example shows 4.2 mph. Shift Lever Position This mode displays the current shift lever position. Only the positions actually available on the transmission are displayed. If different from the transmission, the corresponding decimal point will flash. The example shows Forward 3rd.

On-Board Diagnostic Modes The on-board diagnostic modes are part of the transmission controller, providing diagnostic support through the resources available on the system. To access the diagnostic modes, depress and hold the mode button “M” (1) while turning the key start switch ON. At key ON the digital display (3) will show the first menu on the list and the yellow “T” LED (2) will be illuminated to indicate the diagnostic menu has been activated. Depress the mode button “M” (1) to navigate through the available diagnostic modes in order. When the mode button “M” is released, the digital display (3) will show the values for the selected menu.

1

M TF 3 TV040988

N13–01–25

2

DRIVETRAIN AND BRAKES On-Board Diagnostic Modes Available Diagnostic Screen

Mode (Digital Display)

Description Turbine speed (“rP” rotations per minute).

1 Supply voltage (“bA” battery voltage). 2 Input test (“It” input test). 3 Output test (“ot” output test). 4

5

Temperature displayed in Celsius (“tc” temperature Celsius).

6

Temperature displayed in Fahrenheit (“tF” temperature Fahrenheit).

7

Direction modulator — Direction modulation solenoid (“An” analogue output 00).

8

Range modulator — Range modulation solenoid valve (“An” analogue output 01).

N13–01–26

DRIVETRAIN AND BRAKES Diagnostic Screen 1 — Turbine Speed This mode displays the turbine speed. After releasing the mode button, the digital display shows the turbine speed in Revolutions Per Minute (RPM). From 0 to 999 RPM the digital display shows the value x10. The value in the example is 630 RPM.

From 1000 RPM, the digital display shows the value x1000. The value in the example is 1400 RPM.

Diagnostic Screen 2 — Supply Voltage This mode displays the supply voltage from the battery into the controller. After releasing the mode button, the digital display shows the supply voltage in Volts.

Voltage range: 13.0 to 13.4 Volts.

Values with a fractional part of 0.5 Volts or higher have the right decimal point on. Voltage range 13.5 to 13.9 Volts.

N13–01–27

DRIVETRAIN AND BRAKES Diagnostic Screen 3 — Input Test Note: • The vehicle can be driven in this mode. This mode is used to verify operation of the direction change lever (Forward / Reverse) and other inputs. After releasing the mode button, the digital display shows the inputs that are active. ON if an input at C214, Pin 12 (Forward) is detected.

ON if an input at C214, Pin 19 (Reverse) is detected.

ON if an input at C214, Pin 14 (Shift lever Forward Low/High selection) is detected.

ON if an input at C214, Pin 15 (Shift lever 2/1 selection) is detected.

ON if an input at C214, Pin 16 (Four-Wheel Drive request) is detected.

ON if an input at C214, Pin 17 (De-clutch request) is detected.

ON if an input at C214, Pin 26 (Kickdown request) is detected.

ON if an input at C214, Pin 27 (Not Used) is detected.

N13–01–28

DRIVETRAIN AND BRAKES Diagnostic Screen 4 — Output Test Note: • This mode can only be selected when stationary. When depressing the mode button while driving or if a speed sensor fault is present, this mode will be skipped. After operating in this mode, the transmission is locked in neutral until the shift lever is cycled through the neutral position. This mode is used to supply information on the status of the outputs. The possible states are G (Good) S (Short circuit to ground) and O (Open circuit or a short circuit to battery voltage). The controller tests each output sequentially, the left side of the digital display shows a number representing the output being tested, the right side shows the status of the tested output. After releasing the mode button, the digital display shows the status of the outputs. Example 1 Output 1 is Good.

Example 2 Output 2 has a short circuit to ground.

Example 3 Output 3 has an open circuit or has a short circuit to battery voltage.

N13–01–29

DRIVETRAIN AND BRAKES Note: • Each output corresponds to a specific pin on the transmission controller connector 214. Output (First Number Displayed on the digital display)

Function

Connector 214 Pin Number

1

Forward solenoid

6

2

Reverse solenoid

7

3

1/2 selection solenoid

4

4

Forward Low/High selection solenoid

5

5

Four-Wheel Drive/Rear Wheel Drive solenoid

9

8

Direction and range modulation solenoid valve supplys

22

Diagnostic Screen 5 — Temperature Displayed in Celsius This mode is used to diagnose if there is a fault with the temperature sensor. After releasing the mode button, the digital display shows the transmission temperature in ºC.

Temperature of 83 ºC

Temperature of 99 ºC or higher have both decimal points flashing. Temperature of 99 ºC

Temperature of 0ºC or less have both decimal points flashing. Temperature of 0 ºC

N13–01–30

DRIVETRAIN AND BRAKES Diagnostic Screen 6 — Temperature Displayed in Fahrenheit This mode is used to diagnose if there is a fault with the temperature sensor. After releasing the mode button, the digital display shows the transmission temperature in ºF.

Temperature of 83 ºF (28 ºC)

If the right decimal point is on, the temperature must be increased by 100 ºF 183 ºF (84 ºC)

If the left decimal point is on, the temperature must be increased by 200 ºF 283 ºF (140 ºC)

Temperature of 299 ºF or higher have both decimal points flashing. 299 ºF (148 ºC)

Temperature of 0 ºF or less have both decimal points flashing. 0 ºF

Diagnostic Screen 7 — Direction modulation solenoid valve (Analogue Output 00) This mode is used to supply information on the status of the direction modulator solenoid valve (C214, Pin 3). The possible states are Gd (Good) oc (open circuit or a short circuit to ground) and Sc (Short circuit to a positive voltage). After releasing the mode button, the digital display shows the status of the analogue output.

Output is good.

Output has an open circuit or a short circuit to ground.

Output has a short circuit to a positive voltage.

N13–01–31

DRIVETRAIN AND BRAKES Diagnostic Screen 8 — Range modulation solenoid valve (Analogue Output 01) This mode is used to supply information on the status of the range modulator solenoid valve (C214, Pin 13). The possible states are Gd (Good) oc (open circuit or a short circuit to ground) and Sc (Short circuit to a positive voltage). After releasing the mode button, the digital display shows the status of the analogue output.

Output is good.

Output has an open circuit or a short circuit to ground.

Output has a short circuit to a positive voltage.

N13–01–32

DRIVETRAIN AND BRAKES Component Testing

•

• •

Solenoid (forward reverse, high/low, 2nd/1st, modulation, disconnect). coil resistance: 28 Ohms (± 2 Ohms) at 20°C (68°F). Electronic controlled modulation valve: coil resistance: 3.55 Ohms (± 0.25 Ohm) at 20°C (68°F). Speed sensor: — frequency: 0 — 25000 Hz. — sensing distance: 0 — 2.5 mm. — Wire identification: Speed Signal = Red Temperature Signal = Green Sensor Ground = Blue

Temperature sensor (in speed sensor) resistance versus temperature Temperature °C — — — — — —

55 50 40 30 20 10 0 10 20 25 30 40

Resistance Ω

Temperature °C

Resistance Ω

980 1030 1135 1247 1367 1496 1630 1772 1922 2000 2080 2245

50 60 70 80 90 100 110 120 125 130 140 150

2417 2597 2785 2980 3182 3392 3607 3817 3915 4008 4166 4280

N13–01–33

DRIVETRAIN AND BRAKES

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N13–01–34

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — POWERSHIFT TRANSMISSION PRESSURE TESTING

BHN1301TB

Transmission Hydraulic Circuit

21

20

27

10

44

28

29

12

22

1

24

13

25

11

2

26

23

3

31

4

30

14

5

32

15

33

6

34

16

35

36

7

37

8

38

17

39

40

9

18

41

19

42

43

Neutral and 2nd Clutch Engaged

TV040542

1

Pressure Test Port — Torque Converter In

2

Torque Converter

3

Temperature Test Port — Torque Converter Out To Oil Cooler

4

Pressure Test Port — Torque Converter Out To Oil Cooler

5

Torque Converter By-Pass Valve — Pressure Difference 4 Bar (58 PSI)

6

Transmission Oil Cooler

7

Temperature Test Port — Oil Cooler Out To Lubrication

8

Pressure Test Port — From Oil Cooler (Lubrication Pressure)

9

Transmission Lubrication

10

Safety Valve — 10 Bar (145 PSI) Cracking Pressure

11

Solenoid Pressure — 5 Bar (73 PSI)

12

Pressure Regulating Valve — 20 Bar (290 PSI)

13

Pressure Reducer to 5.5 Bar (80 PSI)

14

Neutral/Forward Solenoid

15

Neutral/Reverse Solenoid

16

High/Low Solenoid

17

2nd/1st Solenoid

18

Range Modulation Solenoid

N13–01–35

DRIVETRAIN AND BRAKES 19

Axle Disconnect (Four-Wheel Drive) Solenoid

20

Pressure Test Port — Regulated Pressure

21

Oil Filter By-Pass Valve — Pressure Difference 4.3 Bar (62 PSI)

22

Oil Filter

23

Electronic Controlled Modulation Valve — (5.5 to 0 Bar (80 to 0 PSI)

24

Pressure Test Port — Pressure Before the Oil Filter

25

Pressure Booster — 0–5.5 to 0–20 Bar (0–80 to 0–290 PSI)

26

Accumulator

27

Air Breather

28

Suction Oil Strainer

29

Hydraulic Charge Pump

30

Clutch Pressure — 20 Bar (290 PSI)

31

Modulated Pressure — 0 to 20 Bar (290 PSI)

32

Reverse Clutch

33

Pressure Test Port — Reverse Clutch

34

Forward Low Clutch

35

Pressure Test Port — Forward Low Clutch

36

Forward High Clutch

37

Pressure Test Port — Forward High Clutch

38

2nd Clutch

39

Pressure Test Port — 2nd Clutch

40

1st Clutch

41

Pressure Test Port — 1st Clutch

42

Axle Disconnect (Four-Wheel Drive) Clutch

43

Pressure Test Port — Axle Disconnect (Four-Wheel Drive) Clutch

44

Transmission Sump

•

Warning: Do not work on or around hydraulic systems without wearing safety glasses. Failure to follow this instruction, may result in personal injury.

Note: • All pressures and flows to be measured with the transmission oil temperature between 82°C and 93°C (180–200°F). Note: All temperature and pressure test ports have M10 x 1 THD O-ring port ISO 6149–1.

•

1. Temperature test port (3) — Torque converter out to oil cooler Transmission Bottom View • Normal operating temperature should be 70 – 120°C (158 – 248°F). Maximum allowed N13–01–36 temperature 120°C (248°F).

DRIVETRAIN AND BRAKES 2. Pressure test port (20) — Transmission regulated pressure Transmission Top View — Select Neutral 2nd • Pressure should be 16.5 bar (239 PSI) at 600 Engine RPM • Pressure should be 19.6 — 23.1 bar (284 — 335 PSI) at 2200 Engine RPM

20

TV041068

N13–01–37

DRIVETRAIN AND BRAKES 3. Pressure test ports (33), (35), (37) and (41) — Clutch pressures Transmission Rear View — 1st clutch (41) — Clutch engaged when Forward 1st/3rd or Reverse 1st is selected — Forward High clutch (37) — Clutch engaged when Forward 3rd or 4th is selected — Forward Low clutch (35) — Clutch engaged when Forward 1st or 2nd is selected — Reverse clutch (33) — Clutch engaged when Reverse 1st or 2nd is selected • Pressure should be 18.1 — 21.5 bar (263 — 312 PSI) with clutch engaged at 2200 Engine RPM • Pressure should be 0 — 0.2 bar (0 — 3 PSI) with clutch disengaged at 2200 Engine RPM

37

35

33 41

TV041069

N13–01–38

DRIVETRAIN AND BRAKES 4. Pressure test ports (39) and (43) — Clutch pressures Transmission Left Side View — 2nd clutch (39) — Clutch engaged when Forward 2nd/4th or Reverse 2nd is selected — Disconnect clutch (four-wheel drive) (43) — Clutch engaged when four-wheel drive is selected • Pressure should be 18.1 — 21.5 bar (263 — 312 PSI) with clutch engaged at 2200 Engine RPM • Pressure should be 0 — 0.2 bar (0 — 3 PSI) with clutch disengaged at 2200 Engine RPM

39

43

TV041070

5. Pressure test ports (20) and (24) — Oil filter by-pass valve A — Transmission Right Side View, B — Transmission Top View • Pressure should not exceed 4.1 – 5 bar (59 – 73 PSI)

N13–01–39

DRIVETRAIN AND BRAKES

24

20

A

B

TV041063

6. Pressure test port (5) — Lubrication oil Transmission Rear View • Pressure should be 0.3 — 0.5 bar at 47 l/min (12.4 GPM) pump flow (+/- 1800 Engine RPM)

5

TV041071

N13–01–40

DRIVETRAIN AND BRAKES 7. Pressure test port (1) — Safety valve Transmission Left Side View • Pressure should not exceed 9.5 — 10.5 bar (138 — 152 PSI)

1

TV041072

N13–01–41

DRIVETRAIN AND BRAKES 8. Pressure test port (4) — Pressure to oil cooler (torque converter out) Transmission Bottom View • Pressure should be a minimum of 2 bar (29 PSI) at 2000 Engine RPM • Pressure should be a maximum of 5 bar (73 PSI) at 2375 Engine RPM

4

TV041073

9. Pressure test ports (1) and (8) — Torque converter by-pass valve A — Transmission Left Side View, B — Transmission Rear View • Pressure should not exceed 5 – 7 bar (73 – 102 PSI)

N13–01–42

DRIVETRAIN AND BRAKES

8

1

A

B

TV041064

N13–01–43

DRIVETRAIN AND BRAKES

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N13–01–44

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — POWERSHIFT TRANSMISSION

BHN1301RA

Operation: Removing and Installing the Powershift Transmission Suitable lifting equipment, Suitable transmission jack

Job Code: 13 24 13 xx Standard tools

Removal

1. Position 150mm blocks under each stabiliser and fully lower. Raise the front of the machine to the same level. 2. Remove the right-hand rear wheel. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 . 3. Support the machine. Note: • Ensure there is at least 915mm clearance between the ground and the chassis .

915mm TV051247

4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 5. Drain the transmission fluid into a suitable container. 6. Install the transmission drain plug and a new O-ring. 7. Tighten to 44Nm (32 lb.ft). 8. Remove the parking brake caliper. For additional information, refer to Section N13-03 PARKING BRAKE CALIPER, PAGE N13–03–13 .

N13–01–45

DRIVETRAIN AND BRAKES

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Remove and discard the retaining bolts.

•

9. Detach the rear propeller shaft from the rear differential and secure it to one side.

TV040057

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: • Remove and discard the retaining bolts. 10. Remove the rear propeller shaft from the transmission.

TV040086

11. Remove the cabin heater air ducting. For additional information, refer to Section H08-01 CABIN HEATER AIR DUCTING, PAGE H08–01–13 . 12. Disconnect the differential lock solenoid electrical connector (1), supply hose (2) and steering supply hose (3).

TV040087

N13–01–46

DRIVETRAIN AND BRAKES 13. Disconnect the transmission harness electrical connector.

TV040088

14. Remove the hydraulic oil pump upper retaining bolts.

TV040359

15. Remove the hydraulic oil pump lower retaining bolts and secure the hydraulic pump to one side.

TV040360

16. Disconnect the transmission oil cooler inlet pipe (1) and the transmission oil cooler outlet pipe (2).

TV040089

N13–01–47

DRIVETRAIN AND BRAKES

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Discard the propeller shaft retaining bolts.

•

17. Remove the front propeller shaft retaining bolts (1) and detach the front propeller shaft. Remove the bell housing cover (2). Disconnect the transmission filler tube and steering return pipe (3).

TV040090

18. Using the access hole, remove the torque converter retaining bolts.

TV040166

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

19. Using suitable lifting equipment, support the engine. 20. Reposition the transmission oil cooler pipes and wiring harness to one side, to gain access to the upper transmission retaining bolts.

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

21. Using a suitable transmission jack, support the transmission.

N13–01–48

DRIVETRAIN AND BRAKES

•

Caution: Ensure the torque converter is removed with the transmission.

22. Remove the transmission retaining bolts and remove the transmission.

TV040361

23. Remove the transmission from the right-hand side of the machine.

Installation 1. To install, reverse the removal procedure. 2. Tighten to 71 Nm (52 lb.ft).

TV040361

3. Tighten to 41 Nm (30 lb.ft).

TV040362

N13–01–49

DRIVETRAIN AND BRAKES Note: • Install new propeller shaft retaining bolts. 4. Tighten 1 to 47 Nm (35 lb.ft).

TV040090

5. Tighten to 98Nm (72 lb.ft).

TV040360

6. Tighten to 98Nm. (72 lb.ft).

TV040359

Note: • Install new retaining bolts. 7. Tighten to 47 Nm (35 lb.ft).

TV040086

N13–01–50

DRIVETRAIN AND BRAKES

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

8. Tighten to 47Nm (35 lb.ft).

TV040057

N13–01–51

DRIVETRAIN AND BRAKES

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N13–01–52

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — POWERSHIFT TRANSMISSION

BHN1301DA

Operation: Disassembly and Assembly of the Powershift Transmission

Job Code: 13 24 17 xx

Suitable lifting equipment

Standard tools, Locally fabricated transmission housing lifting tool, Suitable puller, Bearing heater

Disassembly 1. Remove the drive plates and backing ring.

2. Remove the torque converter.

3. Remove and discard the transmission oil filter.

TV040256

N13–01–53

DRIVETRAIN AND BRAKES 4. Remove the transmission oil filter adapter. Note: • Remove and discard the O-ring seal.

TV040255

5. Remove the charging pump retaining bolts.

TV040257

6. Using a suitable puller, remove the charging pump. 7. Remove and discard the oil seal. Note: • Remove and discard the O-ring seal.

TV040260

8. Remove the four-wheel drive flange retaining nut.

N13–01–54

DRIVETRAIN AND BRAKES 9. Recover the washer, O-ring seal and remove the four-wheel drive flange. Note: • Discard the O-ring seal.

TV040261

10. Remove the output flange retaining nut. 11. Recover the washer, O-ring seal and remove the output flange. Note: • Discard the O-ring seal.

TV040225

12. Remove the breather.

TV040226

N13–01–55

DRIVETRAIN AND BRAKES 13. Remove the wiring harness electrical connector mounting nut.

TV040227

14. Remove the control valve protection cover. Note: Remove and discard the gasket.

•

TV040228

15. Remove the transmission control valve Note: Recover the bypass valve spool and spring.

•

TV040229

N13–01–56

DRIVETRAIN AND BRAKES 16. Using suitable circlip pliers, remove the charging pump drive shaft bearing retaining circlip.

TV040231

17. Using a suitable soft faced hammer, knock the shaft through the torque converter housing. 18. Remove the charging pump drive shaft assembly.

TV040232

19. Remove the transmission housing plug.

TV040230

N13–01–57

DRIVETRAIN AND BRAKES Note: • Make a note of the position of the bolts prior to removal, to aid installation. 20. Remove the converter housing to transmission housing retaining bolts.

TV040233

21. Install the locally fabricated transmission housing lifting tool. For additional information refer to SPECIFICATIONS, PAGE N13–01–157 in this section. 22. Using internal snap ring pliers, expand the output shaft rear bearing retaining snap ring. 23. Holding the snap ring open, tap on output shaft and transmission housing to separate the two parts of the housing. Note: • Remove the bearing spacer.

TV040234

N13–01–58

DRIVETRAIN AND BRAKES

•

Caution: Make sure all clutchpacks and shafts remain in the torque converter housing.

24. Using suitable lifting equipment, remove the transmission housing from the torque converter housing. Note: Remove and discard the gasket.

•

TV040235

25. Remove and discard the output shaft sealing rings (1). 26. Using suitable circlip pliers, remove the output shaft bearing circlip (2).

1

2

TV040236

27. Using suitable circlip pliers, remove the output shaft bearing retaining ring. 28. Using a suitable puller, remove the output shaft bearing.

TV040237

N13–01–59

DRIVETRAIN AND BRAKES 29. Using a suitable puller, remove the 2nd shaft bearing.

TV040238

30. Using a suitable puller, remove the input shaft bearing.

TV040239

31. Remove and discard the reverse/1st shaft sealing rings.

TV040240

32. Using a suitable puller, remove the reverse/1st shaft bearing.

TV040241

N13–01–60

DRIVETRAIN AND BRAKES 33. Remove and discard the forward low/high shaft sealing rings.

TV040242

34. Using a suitable puller, remove the forward low/high shaft bearing.

TV040243

35. Using a suitable puller, remove the forward high gear from the input shaft.

TV040244

36. Remove the upper output gear from the 2nd shaft.

TV040245

N13–01–61

DRIVETRAIN AND BRAKES 37. Remove the suction tube. Note: • Remove and discard the O-ring seal.

TV040246

38. Remove the oil baffle.

TV040247

39. Remove the gear from the 2nd shaft.

TV040248

40. Remove the output shaft.

TV040249

N13–01–62

DRIVETRAIN AND BRAKES 41. Remove the 2nd shaft.

TV040250

42. Using suitable circlip pliers, expand the circlip and remove the disconnect shaft assembly.

TV040265

43. Remove the forward high/low shaft assembly.

44. Remove the input shaft and reverse/1st shaft together.

N13–01–63

DRIVETRAIN AND BRAKES 45. Remove and discard the output shaft oil seal

TV040262

46. Remove the bypass plug, spring and ball (1). 47. Remove the safety valve plug, spring and ball (2).

N13–01–64

DRIVETRAIN AND BRAKES Assembly 1. Install the safety valve ball, spring and plug (2). 2. Install the bypass plug, spring and ball (1).

Note: • Lubricate the oil seal with a light grease. 3. Install a new output shaft oil seal

TV040262

•

Caution: Take care not to damage the sealing rings.

4. Install the input shaft and the reverse/1st shaft together.

N13–01–65

DRIVETRAIN AND BRAKES

•

Caution: Take care not to damage the sealing rings.

5. Install the forward low/high shaft.

6. Using suitable circlip pliers, expand the circlip and install the disconnect shaft into the housing. Note: • Make sure the circlip is correctly located into the groove.

TV040265

•

Caution: Take care not to damage the sealing rings.

7. Install the 2nd shaft assembly.

TV040250

N13–01–66

DRIVETRAIN AND BRAKES

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

8. Install the output shaft assembly.

TV040249

9. Install the lower output gear to the 2nd shaft.

TV040248

10. Install the oil baffle. 11. Apply Loctite 243 to the threads of the retaining bolts.

TV040247

Note: • Install a new O-ring seal. 12. Install the suction tube.

N13–01–67

DRIVETRAIN AND BRAKES 13. Apply Loctite 243 to the threads of the retaining bolts.

TV040246

14. Install the upper output gear to the 2nd shaft.

TV040245

15. Using a suitable bearing heater, heat the forward high gear to 150°C (302°F). 16. Install the forward high gear.

TV020268

17. Using a suitable bearing heater, heat the input shaft bearing to 120°C (248°F). 18. Install the input shaft bearing.

TV020269

19. Using a suitable bearing heater, heat the reverse/1st shaft bearing to 120°C (248°F).

N13–01–68

DRIVETRAIN AND BRAKES 20. Install the reverse/1st shaft bearing.

TV040270

21. Using a suitable bearing heater, heat the reverse/high shaft bearing to 120°C (248°F). 22. Install the reverse/high shaft bearing.

TV040271

23. Using a suitable bearing heater, heat the upper output shaft bearing to 120°C (248°F). 24. Install the upper output shaft bearing.

TV040272

25. Using a suitable bearing heater, heat the lower output shaft bearing to 120°C (248°F). 26. Install the lower output shaft bearing with the groove facing down.

TV040273

N13–01–69

DRIVETRAIN AND BRAKES 27. Install the output shaft bearing retaining circlip (2). 28. Install the output shaft sealing rings (1).

1

2

TV040236

29. Install a new gasket and clutch pressure O-ring seals into the O-ring grooves. 30. Tap the dowel pins in transmission case and torque converter housing. 31. Using internal snap ring pliers, expand the output shaft bearing retaining snap ring.

TV040234

32. Using the locally fabricated transmission housing lifting tool and suitable lifting equipment. Install the transmission housing on to the torque converter housing. Note: Make sure the snap ring is fully in located in the groove.

•

Note: Install the bearing spacer.

•

TV040235

N13–01–70

DRIVETRAIN AND BRAKES 33. Tighten the torque converter housing to transmission housing retaining bolts to 45Nm (33 lb.ft).

TV040233

Note: • Lubricate the oil seal with a light grease. 34. Install the lower output shaft oil seal.

TV040274

35. Install the upper output bore plug. 36. Install the output flange (1) O-ring seal (2) and washers (3).

2 3

1 TV040275

N13–01–71

DRIVETRAIN AND BRAKES 37. Install a new output flange retaining nut. 38. Tighten to 380Nm.

TV040276

Note: • Install a new O-ring seal. 39. Install the transmission housing plug. 40. Tighten to 17Nm (13 lb.ft)

TV040230

41. Install the charging pump drive shaft assembly into the housing.

TV040232

42. Using suitable circlip pliers, install the charging pump drive shaft rear bearing circlip.

TV040231

N13–01–72

DRIVETRAIN AND BRAKES 43. Install the four-wheel drive flange (1), O-ring seal (2) and washer (3).

2 3

1

TV041066

44. Install a new four-wheel drive flange retaining nut. 45. Tighten to 380Nm (280 lb.ft).

TV040261

Note: • Install a new O-ring seal and doughty washers. 46. Install the charging pump into the converter housing. 47. Tighten to 23Nm (17 lb.ft).

TV040257

48. Install the torque converter.

N13–01–73

DRIVETRAIN AND BRAKES 49. Install the drive plates and backing ring. 50. Tighten to 37Nm (27 lb.ft).

Note: • Install a new 0–ring seal. 51. Install the transmission oil filter adaptor. 52. Tighten to 23Nm (17 lb.ft).

TV040255

53. Install a new transmission oil filter. 54. Tighten to 34Nm (25 lb.ft).

TV040256

Note: • Install the bypass valve spool into the solenoid housing and the spring into the transmission case. 55. Install the transmission control valve.

N13–01–74

DRIVETRAIN AND BRAKES 56. Tighten to 22Nm (16 lb.ft).

TV040229

Note: • Position the wiring harness electrical connector in the transmission control valve protection cover. Note: Install a new gasket.

•

57. Install the control valve protection cover. 58. Tighten to 6Nm (4 lb.ft).

TV040228

59. Install the wiring harness electrical connector mounting nut. 60. Tighten to 7Nm (5 lb.ft).

TV040227

61. Install the breather.

N13–01–75

DRIVETRAIN AND BRAKES 62. Tighten to 38Nm (28 lb.ft).

TV040226

N13–01–76

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — FORWARD LOW CLUTCH

BHN1301DC

Operation: Disassembly and Assembly of the Forward Low Clutch

Job Code: 13 42 17 xx

None

Standard tools, Clutch piston spring compressor

9

20 10

21

11

22 23 24 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8

TV040571

N13–01–77

DRIVETRAIN AND BRAKES 1

Low/High Clutch Shaft

2

Clutch Piston Inner Seal

3

Clutch Piston Outer Seal

4

Clutch Piston

5

Piston Wear Washer

6

Piston Return Spring

7

Spring Retainer

8

Circlip

9

Clutch Outer Half Friction Disc

10

Clutch Inner Friction Disc (x8)

11

Clutch Outer Steel Disc (x7)

12

Clutch Outer Half Friction Disc

13

Backing Plate

14

Backing Plate Seal

15

Backing Plate Retaining Snap Ring

16

Circlip

17

Clutch Gear Bearing

18

Circlip

19

Low Clutch Gear

20

Circlip

21

Clutch Gear Bearing

22

Circlip

23

Reverse Driven Gear

24

Low/High Clutch Shaft Bearing

N13–01–78

DRIVETRAIN AND BRAKES Disassembly 1. Using a suitable puller, remove the low/high clutch shaft bearing (1) and reverse driven gear (2).

1 2

TV040319

2. Using suitable circlip pliers, remove the clutch gear circlip.

TV040320

3. Using a suitable puller, remove the clutch gear and clutch gear outer bearing.

TV040321

4. Remove the backing plate retaining snap ring.

TV040322

N13–01–79

DRIVETRAIN AND BRAKES 5. Remove the clutch disc backing plate (1). Note: • Remove and discard the sealing ring (2).

1 2

TV040323

6. Remove the outer half friction disc.

TV040324

7. Remove the eight clutch inner steel discs and seven clutch outer friction discs.

TV040325

8. Remove the outer half friction disc.

TV040326

N13–01–80

DRIVETRAIN AND BRAKES 9. Using a suitable puller, remove the clutch gear inner bearing.

TV040327

10. Using suitable circlip pliers, remove the clutch gear inner bearing locating circlip.

TV040328

11. Using a suitable hydraulic press, compress the piston return spring. 12. Using suitable circlip pliers, release the piston return spring retaining circlip.

TV040284

13. Remove the circlip (1), spring retainer (2) and piston return spring (3).

1

2 3 TV040285

N13–01–81

DRIVETRAIN AND BRAKES 14. Remove the clutch piston wear washer.

TV040286

15. Remove the clutch piston assembly.

TV040287

16. Remove and discard the clutch piston inner seal (1) and outer seal (2).

1

2 TV040288

N13–01–82

DRIVETRAIN AND BRAKES Assembly Note: • Install new sealing rings. 1. Install clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

1

2 TV040288

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

TV040287

3. Install the clutch piston wear washer.

TV040286

N13–01–83

DRIVETRAIN AND BRAKES 4. Install the piston return spring (3), spring retainer (2) and the circlip (1).

1

2 3 TV040285

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable circlip pliers, install the circlip. Note: • Make sure the circlip is correctly located in the groove.

TV040284

7. Using suitable circlip pliers, install the clutch gear inner bearing locating circlip.

TV040328

N13–01–84

DRIVETRAIN AND BRAKES 8. Using a suitable hydraulic press, install the clutch gear inner bearing.

TV040329

Note: • Soak new friction discs in transmission oil before assembly. Note: Install the outer half friction disc with the friction side of the disc away from the piston.

•

9. Install the outer half friction disc.

TV040326

Note: • Soak new friction discs in transmission oil before assembly. Note: Alternate the friction and steel discs until the correct amount of discs are installed. The first and last discs are steel.

•

10. Install the eight clutch inner steel discs and seven clutch outer friction discs.

TV040325

N13–01–85

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc towards the piston. 11. Install the outer half friction disc.

TV040324

Note: • Install a new sealing ring (2). 12. Install the clutch disc backing plate (1).

1 2

TV040323

13. Install the backing plate retaining snap ring.

TV040322

N13–01–86

DRIVETRAIN AND BRAKES

•

•

•

Caution: Take care not to damage the sealing ring. Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

14. Install the low clutch gear assembly.

TV040330

Note: • Make sure that the bearing shield is on the outside. 15. Using a suitable hydraulic press, install the clutch gear outer bearing.

TV040331

N13–01–87

DRIVETRAIN AND BRAKES 16. Using suitable circlip pliers, install the outer bearing circlip.

TV040320

17. Using a suitable hydraulic press, install the reverse driven gear.

TV040332

18. Using a suitable hydraulic press, install the clutch shaft bearing.

TV040333

N13–01–88

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — 1ST CLUTCH

BHN1301DD

Operation: Disassembly and Assembly of the 1st Clutch None

Job Code: 13 43 17 xx Standard tools

7

6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

10 9 8 TV041044

N13–01–89

DRIVETRAIN AND BRAKES 1

Reverse/1st Clutch Shaft

2

Clutch Piston Inner Seal

3

Clutch Piston Outer Seal

4

Clutch Piston

5

Clutch Piston Wear Spacer

6

Belleville Washers (x11)

7

Circlip

8

Clutch Outer Half Friction Disc

9

Clutch Inner Steel Disc (x8)

10

Clutch Outer Friction Disc (x7)

11

Clutch Outer Half Friction Disc

12

Modulation Spring

13

Backing Plate

14

Backing Plate Retaining Snap Ring

15

Clutch Gear Bearing

16

Circlip

17

1st Clutch Gear

18

Circlip

19

Clutch Gear Bearing

20

Snap Ring

N13–01–90

DRIVETRAIN AND BRAKES Disassembly 1. Using suitable circlip pliers, remove the 1st clutch gear bearing circlip.

TV040297

2. Using a suitable puller, remove the 1st clutch gear and clutch gear bearing.

TV040298

3. Remove the backing plate retaining snap ring.

TV040299

4. Remove the backing plate.

TV040300

N13–01–91

DRIVETRAIN AND BRAKES 5. Remove the modulation spring.

TV040301

6. Remove the outer half friction disc.

TV040302

7. Remove the eight inner steel discs and seven outer friction discs.

TV040303

8. Remove the outer half friction disc.

TV040304

N13–01–92

DRIVETRAIN AND BRAKES 9. Using a suitable puller, remove the 1st clutch gear inner bearing.

TV040305

10. Using a suitable hydraulic press, compress the clutch piston belleville washers. 11. Using suitable circlip pliers, release the circlip.

TV040306

12. Remove the circlip (1). 13. Remove the eleven belleville washers (2).

1

2 TV040307

14. Remove the clutch piston wear spacer.

TV040308

N13–01–93

DRIVETRAIN AND BRAKES 15. Remove the clutch piston assembly.

TV040287

16. Remove and discard the clutch piston inner seal (1) and outer seal (2).

1

2 TV040288

N13–01–94

DRIVETRAIN AND BRAKES Assembly Note: • Install new sealing rings. 1. Install clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

1

2 TV040288

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

TV040287

3. Install the clutch piston wear spacer.

TV040308

N13–01–95

DRIVETRAIN AND BRAKES 4. Install the eleven clutch piston belleville washers (2). Note: • Install the first belleville washer with the large diameter of bevel towards the wear spacer. Alternate the ten remaining belleville washers. 5. Install the circlip (1) on to the reverse/1st clutch shaft.

1

2 TV040307

6. Using a suitable hydraulic press, compress the clutch piston belleville washers. 7. Using suitable circlip pliers, install the circlip. Note: • Make sure the circlip is correctly located in the groove.

TV040306

8. Using a suitable hydraulic press, install the 1st clutch gear inner bearing.

TV040309

N13–01–96

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc away from the piston. 9. Install the outer half friction disc.

TV040304

Note: • Soak new friction discs in transmission oil before assembly. Note: • Alternate the friction and steel discs until the correct amount of discs are installed. The first and last discs are steel. 10. Install the eight clutch inner steel discs and seven clutch outer friction discs.

TV040303

N13–01–97

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc towards the piston. 11. Install the outer half friction disc.

TV040302

Note: • Install the modulation spring with the large diameter of the bevel away from the piston. 12. Install the modulation spring.

TV040301

13. Install the backing plate.

TV040300

N13–01–98

DRIVETRAIN AND BRAKES 14. Install the backing plate retaining snap ring.

TV040299

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

15. Install the 1st clutch gear assembly.

TV040310

Note: • Make sure that the bearing shield is on the outside. 16. Using a suitable hydraulic press, install the clutch gear outer bearing.

TV040311

N13–01–99

DRIVETRAIN AND BRAKES 17. Using suitable circlip pliers, install the outer bearing retaining circlip.

TV040297

N13–01–100

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — REVERSE CLUTCH

BHN1301DE

Operation: Disassembly and Assembly of the Reverse Clutch

Job Code: 13 45 17 xx

None

Standard tools, Bearing heater

17 18 19 20 21 22 23 9 24

10 11

12 13 14 15 16

1 2 3 4 5 6 7 8

TV040572

N13–01–101

DRIVETRAIN AND BRAKES 1

Reverse/1st Clutch Shaft

2

Clutch Piston Inner Seal

3

Clutch Piston Outer Seal

4

Clutch Piston

5

Clutch Piston Wear Washer

6

Piston Return Spring

7

Spring Retainer

8

Circlip

9

Clutch Outer Half Friction Disc

10

Clutch Inner Steel Disc (x8)

11

Clutch Outer Friction Disc (x7)

12

Clutch Outer Half Friction Disc

13

Backing Plate

14

Backing Plate Seal

15

Backing Plate Retaining Snap Ring

16

Circlip

17

Clutch Gear Bearing

18

Circlip

19

Reverse Clutch Gear

20

Circlip

21

Clutch Gear Bearing

22

Circlip

23

Reverse Driven Gear

24

Reverse/1st Shaft Bearing

N13–01–102

DRIVETRAIN AND BRAKES Disassembly 1. Using a suitable puller, remove the reverse driven gear and reverse/1st shaft bearing.

TV040338

2. Using suitable circlip pliers, remove the clutch gear bearing circlip.

TV040320

3. Using a suitable puller, remove the reverse clutch gear and clutch gear outer bearing.

TV040339

4. Remove the backing plate retaining snap ring.

TV040322

N13–01–103

DRIVETRAIN AND BRAKES 5. Remove the clutch disc backing plate (1). Note: • Remove and discard the sealing ring (2).

1 2

TV040323

6. Remove the outer half friction disc.

TV040324

7. Remove the eight clutch inner steel discs and seven clutch outer friction discs.

TV040325

8. Remove the outer half friction disc.

TV040326

N13–01–104

DRIVETRAIN AND BRAKES 9. Using a suitable puller, remove the clutch gear inner bearing.

TV040340

10. Using suitable circlip pliers, remove the clutch gear inner bearing locating circlip.

TV040328

11. Using a suitable hydraulic press, compress the piston return spring. 12. Using suitable circlip pliers, release the piston return spring retaining circlip.

TV040284

13. Remove the circlip (1), spring retainer (2) and piston return spring (3).

1

2 3 TV040285

N13–01–105

DRIVETRAIN AND BRAKES 14. Remove the clutch piston wear washer.

TV040286

15. Remove the clutch piston assembly.

TV040287

16. Remove and discard the clutch piston inner seal (1) and outer seal (2).

1

2 TV040288

N13–01–106

DRIVETRAIN AND BRAKES Assembly Note: • Install new sealing rings. 1. Install clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

1

2 TV040288

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

TV040287

3. Install the clutch piston wear washer.

TV040286

N13–01–107

DRIVETRAIN AND BRAKES 4. Install the piston return spring (3), spring retainer (2) and the circlip (1).

1

2 3 TV040285

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable circlip pliers, install the circlip. Note: • Make sure the circlip is correctly positioned in the groove.

TV040284

7. Using suitable circlip pliers, install the clutch gear inner bearing locating circlip.

TV040328

N13–01–108

DRIVETRAIN AND BRAKES 8. Using a suitable hydraulic press, install the clutch gear inner bearing.

TV040329

Note: • Soak new friction discs in transmission oil before assembly. Note: Install the outer half friction disc with the friction side of the disc away from the piston.

•

9. Install the outer half friction disc.

TV040326

Note: • Soak new friction discs in transmission oil before assembly. Note: Alternate the friction and steel discs until the correct amount of discs are installed. The first and last discs are steel.

•

10. Install the eight clutch inner steel discs and seven clutch outer friction discs.

TV040325

N13–01–109

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc towards the piston. 11. Install the outer half friction disc.

TV040324

Note: • Install a new sealing ring (2). 12. Install the clutch disc backing plate (1).

1 2

TV040323

13. Install the backing plate retaining snap ring.

TV040322

N13–01–110

DRIVETRAIN AND BRAKES

•

•

•

Caution: Take care not to damage the sealing ring. Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

14. Install the reverse clutch gear assembly.

TV040330

Note: • Make sure that the bearing shield is on the outside. 15. Using a suitable hydraulic press, install the clutch gear outer bearing.

TV040331

N13–01–111

DRIVETRAIN AND BRAKES 16. Using suitable circlip pliers, install the outer bearing circlip.

TV040320

17. Using a suitable hydraulic press, install the reverse driven gear.

TV040341

18. Using a suitable hydraulic press, install the clutch shaft bearing.

TV040342

N13–01–112

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — 2ND CLUTCH

BHN1301DF

Operation: Disassembly and Assembly of the 2nd Clutch

Job Code: 13 44 17 xx

None

Standard tools, Suitable puller

18 19 20

17

21 22 23

9 10 11

12 13 14 15 1 16

2 3 4 5

7

6

8 TV040574

N13–01–113

DRIVETRAIN AND BRAKES 1

2nd Shaft Assembly

2

Clutch Piston Inner Seal

3

Clutch Piston Outer Seal

4

Clutch Piston Assembly

5

Clutch Piston Wear Washer

6

Piston Return Spring

7

Spring Retainer

8

Circlip

9

Clutch Outer Half Friction Disc

10

Clutch Inner Steel Disc (x9)

11

Clutch Outer Friction Disc (x8)

12

Clutch Outer Half Friction Disc

13

Modulation Spring

14

Backing Plate

15

Backing Plate Retaining Snap Ring

16

Clutch Gear Bearing

17

Circlip

18

2nd Clutch Gear

19

Circlip

20

Clutch Gear Bearing

21

Bearing Support Washer

22

2nd Clutch Shaft Bearing

23

Clutch Shaft Sealing Ring (x2)

N13–01–114

DRIVETRAIN AND BRAKES Disassembly 1. Remove and discard the clutch shaft sealing rings.

TV040312

2. Using a suitable bearing puller remove the 2nd clutch shaft bearing (1), the bearing support washer (2) and the 2nd clutch gear (3). 3. Using suiable circlip pliers, remove the bearing locating circlips from the clutch gear.

1 2

TV040313

4. Remove the backing plate retaining snap ring.

TV040299

5. Remove the backing plate.

TV040300

N13–01–115

3

DRIVETRAIN AND BRAKES 6. Remove the modulation spring.

TV040301

7. Remove the outer half friction disc.

TV040302

8. Remove the eight inner steel discs and seven outer friction discs.

TV040303

9. Remove the outer half friction disc.

TV040304

N13–01–116

DRIVETRAIN AND BRAKES 10. Using a suitable bearing puller, remove the clutch gear inner bearing.

TV040314

11. Using a suitable hydraulic press, compress the piston return spring. 12. Using suitable circlip pliers, release the piston return spring retaining circlip.

TV040284

13. Remove the circlip (1), spring retainer (2) and piston return spring (3).

1

2 3 TV040285

14. Remove the clutch piston wear washer.

TV040286

N13–01–117

DRIVETRAIN AND BRAKES 15. Remove the clutch piston assembly.

TV040287

16. Remove and discard the clutch piston inner seal (1) and outer seal (2).

1

2 TV040288

N13–01–118

DRIVETRAIN AND BRAKES Assembly Note: • Install new sealing rings. 1. Install clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size untill the new seal is flush with the outer diameter of the piston.

1

2 TV040288

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

TV040287

3. Install the clutch piston wear washer.

TV040286

N13–01–119

DRIVETRAIN AND BRAKES 4. Install the piston return spring (3), spring retainer (2) and the circlip (1).

1

2 3 TV040285

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable circlip pliers, install the circlip. Note: • Make sure the circlip is correctly located in the groove.

TV040284

7. Using a suitable hydraulic press, install the clutch gear inner bearing.

TV040309

N13–01–120

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the half friction disc with the friction side of the disc away from the piston. 8. Install the outer half friction disc.

TV040296

Note: • Soak new friction discs in transmission oil before assembly. Note: Alternate the friction and steel discs until the correct amount of discs are installed. The first and last discs are steel.

•

9. Install the eight clutch outer steel discs and seven clutch inner friction discs.

TV040295

N13–01–121

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc towards the piston. 10. Install the outer half friction disc.

TV040294

Note: • Install the modulation spring with the large diameter of the bevel away from the piston. 11. Install the modulation spring.

TV040301

12. Install the backing plate.

TV040300

N13–01–122

DRIVETRAIN AND BRAKES 13. Install the backing plate retaining snap ring.

TV040292

14. Using suiable circlip pliers, install the bearing locating circlips.

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

15. Install the 2nd clutch gear assembly.

TV041074

Note: • Make sure the bearing shield is on the outside. 16. Using a suitable hydraulic press, install the outer bearing.

TV040316

N13–01–123

DRIVETRAIN AND BRAKES 17. Install the bearing spacer.

TV040317

18. Using a suitable hydraulic press, install the 2nd shaft bearing.

TV040318

19. Install the 2nd clutch shaft sealing rings.

TV040312

N13–01–124

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT

BHN1301DG

Operation: Disassembly and Assembly of the Output Shaft None

Job Code: 13 46 17 xx Standard tools

20 21

11 12 13 14 15

19 16 17 18

1 2 3 4 5 6

10

7

8

9

N13–01–125

DRIVETRAIN AND BRAKES 1

Sealing Ring (x3)

2

Circlip

3

Output Shaft Bearing

4

Circlip

5

Circlip

6

Output Gear

7

Circlip

8

Output Shaft

9

Clutch Piston Inner Seal

10

Clutch Piston Outer Seal

11

Clutch Piston

12

Clutch Piston Wear Washer

13

Piston Return Spring

14

Spring Retainer

15

Circlip

16

Clutch Outer Half Friction Disc

17

Clutch Inner Steel Disc (x12)

18

Clutch Outer Friction Disc (x11)

19

Clutch Outer Half Friction Disc

20

Backing Plate

21

Backing Plate Retaining Snap Ring

N13–01–126

DRIVETRAIN AND BRAKES Disassembly 1. Using suitable circlip pliers, remove the output shaft bearing locating circlip.

TV040277

2. Using suitable circlip pliers, remove the output gear circlip (1). 3. Remove the output gear (2).

1

2

TV040278

Note: • Rotate the shaft 180°. 4. Remove the backing plate retaining snap ring.

TV040279

5. Remove the backing plate.

TV040280

N13–01–127

DRIVETRAIN AND BRAKES 6. Remove the outer half friction disc.

TV040281

7. Remove the twelve clutch inner steel discs and eleven clutch outer friction discs.

TV040282

8. Remove the outer half friction disc.

TV040283

9. Using a suitable hydraulic press, compress the piston return spring. 10. Using suitable circlip pliers, release the piston return spring retaining circlip.

TV040284

N13–01–128

DRIVETRAIN AND BRAKES 11. Remove the circlip (1), spring retainer (2) and piston return spring (3).

1

2 3 TV040285

12. Remove the clutch piston wear washer.

TV040286

13. Remove the clutch piston assembly.

TV040287

14. Remove and discard the clutch piston inner seal (1) and outer seal (2).

1

2 TV040288

N13–01–129

DRIVETRAIN AND BRAKES Assembly Note: • Install new sealing rings. 1. Install clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

1

2 TV040288

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

TV040287

3. Install the clutch piston wear washer.

TV040286

N13–01–130

DRIVETRAIN AND BRAKES 4. Install the piston return spring (3), spring retainer (2) and the circlip (1).

1

2 3 TV040285

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable circlip pliers, install the circlip. Note: • Make sure the circlip is correctly located in the groove.

TV040284

Note: • Soak new friction discs in transmission oil before assembly. Note: Install the half friction disc with the friction side of the disc away from the piston.

•

7. Install the outer half friction disc.

TV040283

N13–01–131

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Alternate the friction and steel discs until the correct amount of discs are installed. The first and last discs are steel. 8. Install the twelve clutch outer steel discs and eleven clutch inner friction discs.

TV040282

Note: • Soak new friction discs in transmission oil before assembly. Note: • Install the outer half friction disc with the friction side of the disc towards the piston. 9. Install the outer half friction disc.

TV040281

10. Install the clutch disc backing plate.

TV040280

N13–01–132

DRIVETRAIN AND BRAKES 11. Install the backing plate retaining snap ring.

TV040279

Note: • Rotate the shaft 180°. 12. Install the output gear (2). 13. Using suitable circlip pliers, install the output gear circlip (1).

1

2

TV040278

14. Using suitable circlip pliers, install the output shaft bearing locating circlip.

TV040277

N13–01–133

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–134

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — DISCONNECT SHAFT

BHN1301DH

Operation: Disassembly and Assembly of the Disconnect Shaft

Job Code: 13 47 17 xx

None

Standard tools. Suitable puller

6

5 4 3

2 1 TV041061

1

Bearing

2

Circlip

3

Clutch Hub

4

Circlip

5

Clutch Disconnect Shaft

6

Bushing (x2)

N13–01–135

DRIVETRAIN AND BRAKES Disassembly 1. Using a suitable puller, remove the disconnect shaft front bearing (1). 2. Recover the circlip (2).

1 2

TV040334

3. Remove the clutch hub (1) from the disconnect shaft (2).

1

TV040335

4. Using suitable circlip pliers, remove the clutch hub circlip from the disconnect shaft. Note: • Remove the bushings if required.

TV040336

N13–01–136

2

DRIVETRAIN AND BRAKES Assembly Note: • Install new bushings (if required). 1. Using suitable circlip pliers, install the clutch hub circlip.

TV040336

2. Install the clutch hub (1) on to the disconnect shaft (2).

1

2

TV040335

3. Install the circlip (1). 4. Install the bearing (2).

1

TV040337

N13–01–137

2

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–138

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CHARGING PUMP DRIVE SHAFT

BHN1301DJ

Operation: Disassembly and Assembly of the Charging Pump Drive Shaft

Job Code: 13 38 17 xx

None

Standard tools, Suitable puller

4 3 2

1

TV040569

1

Charging Pump drive shaft

2

Sealing ring

3

Charging Pump drive shaft bearing

4

Charging Pump drive shaft bearing circlip

Disassembly 1. Using suitable circlip pliers, remove the charging pump drive shaft bearing circlip.

TV040343

N13–01–139

DRIVETRAIN AND BRAKES 2. Using a suitable puller, remove the charging pump drive shaft bearing.

TV040344

3. Remove the sealing ring from the charging pump drive shaft.

TV040345

N13–01–140

DRIVETRAIN AND BRAKES Assembly 1. Install the sealing ring on the charging pump drive shaft.

TV040345

2. Using a suitable press, install the charging pump drive shaft bearing.

TV040346

3. Using suitable circlip pliers, install the charging pump drive shaft bearing circlip.

TV040343

N13–01–141

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–142

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — INPUT SHAFT

BHN1301DK

Operation: Disassembly and Assembly of the Input Shaft

Job Code: 13 47 17 xx

None

Standard tools, Suitable puller

9 8

7 1 6 5

4 3 2 TV040570

1

Sealing Ring

2

Input Shaft Bearing

3

Circlip

4

Circlip

5

Forward Low Gear

6

Circlip

7

Input Shaft

8

Circlip

9

Sealing Ring

N13–01–143

DRIVETRAIN AND BRAKES Disassembly 1. Remove the input shaft sealing ring.

TV040347

2. Using suitable circlip pliers, remove the forward high gear circlip.

TV040348

3. Using suitable circlip pliers, remove the forward low gear circlip.

TV040349

4. Rotate the input shaft 180°. 5. Remove the input shaft sealing ring.

TV040350

N13–01–144

DRIVETRAIN AND BRAKES 6. Using a suitable puller, remove the input shaft bearing.

TV040351

7. Using suitable circlip pliers, remove the input shaft bearing locating circlip.

TV040352

8. Using suitable circlip pliers, remove the input shaft forward low gear circlip.

TV040353

9. Using a suitable hydraulic press, remove the forward low gear from the input shaft.

TV040354

N13–01–145

DRIVETRAIN AND BRAKES Assembly 1. Using suitable circlip pliers, install the forward lower gear circlip.

TV040349

2. Using a suitable bearing heater, heat the forward low gear to 150° C (302° F). 3. Install the forward low gear.

TV040355

4. Using suitable circlip pliers, install the forward low gear circlip.

TV040353

5. Using suitable circlip pliers, install the input shaft bearing locating circlip.

TV040352

N13–01–146

DRIVETRAIN AND BRAKES 6. Using a suitable bearing heater, heat the input shaft bearing to 150° C (302° F). 7. Install the input shaft bearing.

TV040356

8. Install the input shaft sealing ring.

TV040350

9. Rotate the input shaft 180°. 10. Using suitable circlip pliers, install the input shaft forward high gear circlip.

TV040348

11. Install the input shaft sealing ring.

TV040347

N13–01–147

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–148

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — TRANSMISSION CONTROL VALVE

BHN1301DL

28 6 16

37

27

15 38

14

39

26 5

13

25

12

40

11

36

4

18 24 23

10

9 3

35

22 17

8

34 19

2

21

31 33

7

32 20 1

29

41 42

43

30

44 46 45 47 48

TV040578

1

Valve Body

8

Disconnect Spool

2

Pressure Reducer Spool

9

Spool

3

Pressure Reducer Spring

10

Separator Plate

4

Separator Plate

11

1st/2nd Spool

5

Pressure Regulator Spring

12

Pilot Spool Spring

6

Pressure Regulator Spool

13

Stop Spool

7

Pilot Spool Spring

14

Separator Plate

N13–01–149

DRIVETRAIN AND BRAKES 15

Range Modulation Spool

16

Pilot Spool Spring

17

Accumulator Spring

18

Accumulator Spool

19

Booster Spool

20

Reverse Spool

21

Pilot Spool Spring

22

Forward Spool

23

Stop Spool

24

Separator Plate

25

Forward Low/Forward High Spool

26

Pilot Spool Spring

27

Spool Cover

28

Spool Cover Retaining Bolt

29

Check Port Plug

30

Retaining Bolt

31

Spacer Plate

32

Bypass Valve Spool

33

Bypass Valve Spring

34

Solenoid Plate

35

Plug

36

Solenoid

37

Electronic Controlled Modulation Valve

38

Solenoid Retaining Clamp

39

Solenoid Retaining Clamp Retaining Bolt

40

Wiring Strap

41

Speed Sensor

42

O-ring

43

O-ring

44

Retaining Nut

45

Wiring Harness

46

Wiring Harness Clamp

47

Lock Washer

48

Clamp Screw

N13–01–150

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR After the repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed. The following are considered the minimum steps to be taken: 1. Drain the entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from the machine for cleaning. 3. Replace oil filter elements cleaning out filter cases thoroughly. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow

BHN1301GB

will not adequately clean the cooler. If necessary, the cooler assembly should be removed from the machine for cleaning, using oil, compressed air, and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes. 5. Reassemble all components and use only the specified type of oil. Fill the transmission through the filler opening until fluid comes up to the oil level check port. Run the engine for 2 minutes at low RPM to prime the torque converter and hydraulic lines. Check the transmission oil with the engine running at idle RPM and add oil as necessary. Check the transmission oil level when the transmission is at the operating temperature 82 — 93°C (180 — 200°F). 6. Check all drain plugs, lines, connections, etc. for leaks and tighten where necessary.

N13–01–151

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–152

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — POWERSHIFT TRANSMISSION CLUTCH CALIBRATION

BHN1301GA

The powershift controller can be used to determine the optimal clutch fill parameters. The calibration process creates the ideal start situation for clutch engagement. The clutch fill times can be calibrated in two ways. • Using the Microsoft Windows based T16000 Diagnostic Monitor. The transmission • Stand-alone calibration. controller automatically calibrates the transmission after guiding the user through a set-up procedure. Note: The transmission fluid must be at the normal operating temperature 70 — 120°C (158 — 248°F) to achieve the correct calibration.

•

•

Caution: Make sure four-wheel drive is disengaged.

1. Raise the rear of the machine (wheels off the ground) using the stabiliser legs. 2. Set the engine speed to approximately 1500 RPM. Note: • Make sure the transmission output has sufficient resistance to be stalled in neutral, while allowed to spin in either forward or reverse. 3. Lightly apply the parking brake. Note: • During the stand-alone calibration, only the forward and reverse clutches are calibrated. The transmission controller (1) will show the clutch currently being tested and the result of the calibration on the digital display (2). The left side of the display shows the clutch currently being tested. • L for Forward Low • H for Forward High • R for Reverse

2

1

TV040985

The right side of the display shows the result of the calibration. If the fill time is too short, only the lowest segment is illuminated. If it is too short, but within twice

the tolerance, the middle and lower segments are illuminated.

N13–01–153

DRIVETRAIN AND BRAKES Display Examples (Display)

Description Fill time for the Forward Low clutch is too high.

Fill time for the Forward High clutch is too high, but within twice the tolerance.

Fill time for the reverse clutch was successful and within tolerance. The middle segment is illuminated for 1 second, indicating the successful calibration.

Fill time for the Forward Low clutch is too short, but within twice the tolerance.

Fill time for the Forward Low clutch is too short. Fill time for the Forward Low clutch failed. Three segments of the LCD will be illuminated for 0.5 seconds indicating a problem. The transmissions output was prevented from rotating. This can be caused by braking too hard during the calibration process or a fill time that is excessively high. If the fill time is too high, the calibration system will attempt to reduce the fill time by adapting the fill parameters. The Forward Low clutch calibration phase failed. If the calibration for a specific clutch failed, the original fill time values will be used. This failure can be caused by braking too hard during the calibration process .

N13–01–154

DRIVETRAIN AND BRAKES Stand-Alone Calibration To start the calibration, depress and hold the mode button “M” (1) for 10 seconds (this can be done during or after the key start switch is turned ON). The digital display (2) will show “cA” to indicate the controller has entered the calibration menu.

1

Note: • Make sure the transmission output has sufficient resistance to be stalled in neutral, while allowed to spin in either forward or reverse.

M

When the initial conditions have been carried out, i.e. temperature within range, output speed is zero and the shift lever is in neutral, the transmission controller digital display will alternate between “Go” and “F”(Go to Forward) to indicate Forward has to be selected.

TF 2 TV041062

If the transmission temperature is outside the range for calibration, the temperature will be displayed. The example below shows 85 ºC Temperatures less than 0 ºC are shown as “0.0.” and temperatures greater than 99 ºC are shown as “9.9.” .

When the transmission temperature is within the range for calibration, the transmission controller digital display will alternate between Go and n(GO to Neutral) to indicate Neutral has to be selected.

Note: • To exit the calibration process at any time, move the shift lever to the opposite direction. All original calibration values will be restored. When forward is selected, the transmission calibration starts and completes automatically. Note: • Make sure the transmission controllers power supply is not interrupted during, and 3 seconds after the calibration process has completed. If the power supply is interrupted, re-calibrate the transmission again.

When neutral has been selected, the transmission controller digital display will alternate between “St” and “oP”(STOP) to indicate the parking brake or service brake needs to be lightly applied.

The transmission calibration values are automatically stored in permanent memory after the calibration process has completed. If the calibration of a clutch fails, the controller will default to the factory presets for the clutch.

N13–01–155

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–01–156

DRIVETRAIN AND BRAKES SPECIFICATIONS — POWERSHIFT TRANSMISSION

BHN1301SA

Special Tools Transmission Housing Lifting Tool (P.N: TG 1500-676)

10

10

45º

Ø190

Ø126 255

57,2

±0,1

2 Holes Ø13

Ø 10

2 x 30º 57,2

1

±0,1

57,2

±0,1

7 15

2

15

3

95

+5

R 15 -0

TV041080

1

Mounting Plate

2

Box Section

3

Lifting Eye

Note: • Material: ST37

N13–01–157

DRIVETRAIN AND BRAKES General Information Transmission

Power Shift

Make

Dana

Model

121-4FT 16000-22 6108875M91

Fermec P/N

2.60:1

Torque Converter Stall Ratio Pump Pressure

20.5 – 23.5bar

Clutch Pressure

20.5 – 23.0bar 4.9 – 5.0bar

Torque Converter Working Pressure Torque Converter Safety Valve Pressure

9.0bar

Solenoid Pressure

9.5bar

860 Transmission Control Unit

4503428

970 Transmission Control Unit

4503427

Lubrication Pressure

0.4 – 0.5bar

Capacity System Powershift Transmission

Temperatures ALL

Viscocity 10W

Specification ATF

Temperature Specifications

• •

Normal operating temperature 70 — 120°C (158 — 248°F). Maximum allowed transmission temperature 120°C (248°F).

N13–01–158

Capacity 23 (Total System)

Notes Check oil level with engine running at idle. Approved oils: ATF Elfmatic G3 Esso D (21611)

DRIVETRAIN AND BRAKES Torque Values Note: • All threads assembly.

must

be

lubricated

before

Description

Nm

Lb.ft

Transmission Bell Housing

71

52

Torque Converter

41

30

Propeller Shaft

47

35

Hydraulic Pump

98

72

Transmission/Converter Housing

45

33

Output Flange

380

280

Transmission Housing Plug

17

13

Four-wheel Drive Flange

380

280

Charging Pump

23

17

Torque Converter Drive Plates

37

27

Transmission Oil Filter Adapter

23

17

Transmission Oil Filter

34

25

Transmission Control Valve

22

16

Transmission Control Valve Cover

6

4

Wiring Harness Connector Mounting Nut

7

5

Transmission Air Breather

38

28

N13–01–159

DRIVETRAIN AND BRAKES Torque Chart (Bolts) Note: • (Based in VDI 2230, µ = 0,14 and CCI standard) Metric

Inch Torque

Class 8,8 M5 x 0,8 M8 x 1,25 M10 x 1,5

Torque

Grade 5

Nm

lbft

5 — 6 20 — 25 40 — 50

3,7 — 4,4 14,7 — 18,4 29,5 — 36,8

0,5000

Nm

lbft

87 — 95

64,1 — 70,0

Torque Chart (O-Ring Port Plugs) Metric

Inch Torque

Size M10 x 1 M22 x 1,5 M33 x 2

Torque

Size

Nm

lbft

8 — 10 48 — 60 112 — 140

5,9 — 7,4 35,4 — 44,2 82,5 — 103,2

1,3125 — UN

Nm

lbft

112 — 140

82,5 — 103,2

Torque Chart (Pipe Plugs) Metric

Inch Torque

Size M22 x 1,5 UNI 7707

Torque

Size

Nm

lbft

48 — 60

35,4 — 44,2

0,1250 — 27 NPTF

N13–01–160

Nm

lbft

9 — 13

6,6 — 9,6

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION — TURNER

BHN1302OA

Schematic View Synchroshuttle Transmission

1

2

3

4

5

6

7

8 19

9

18

17

10 16 11

15

14

13 TV040913

N13–02–1

12

DRIVETRAIN AND BRAKES 1

Torque Converter

2

Transmission Oil Pump

3

Reverse Idler Shaft

4

Forward Clutch

5

Reverse Clutch

6

Reverse Primary Gear

7

Countershaft

8

Four-wheel Drive Gear Drive

9

Output Shaft Flange

10

1st Gear

11

Four-wheel Drive Gear Driven

12

Four-wheel Drive Hydraulic Multiplate Clutch

13

Four-wheel Drive Output Shaft Flange

14

1st / 2nd Synchroniser

15

2nd Gear

16

3rd Gear

17

3rd / 4th Synchroniser

18

4th Gear

19

Forward Primary Gear

N13–02–2

DRIVETRAIN AND BRAKES

16

15

14

13

12

11

TV040912

N13–02–3

21

22

23

1

2

3

20

4

19

5

6

18

7

8

17

9

10

Transmission Hydraulic Circuit

DRIVETRAIN AND BRAKES 1

Torque Converter Relief Valve

2

Pressure Regulator Valve

3

Forward Clutch

4

Forward Clutch Oil Pressure Test Port

5

Forward / Reverse Control Valve

6

Reverse Clutch Oil Pressure Test Port

7

Reverse Clutch

8

Four-wheel Drive Clutch

9

Four-wheel Drive Solenoid Valve

10

Transmission Oil Pump Pressure Test Port

11

Transmission Full Flow Oil Filter

12

Torque Converter

13

Cold Start Relief Valve

14

Lubrication Oil Pressure Test Port

15

Oil Cooler Inlet

16

Oil Cooler Outlet

17

Transmission Oil Pump

18

Sump

19

Suction Strainer

20

Oil Cooler

21

Transmission Temperature Sender

22

Lubrication Oil Pressure Test Port

23

Torque Converter Oil Pressure Test Port

N13–02–4

DRIVETRAIN AND BRAKES The Clutch Circuit Oil from the transmission sump (18) is drawn up through the suction strainer (19) by the transmission oil pump (17). It is forced, under pressure from the transmission oil pump (17), through the transmission full flow oil filter (11) into the clutch circuit. To protect the transmission full flow oil filter (11) during cold start the cold start relief valve (13), dumps oil back to the sump (18) should it exceed 26 bar pressure. From the transmission full flow oil filter (11) the oil flows through the pressure regulator valve (2). This maintains the clutch system pressure at 14 bar. From this valve, oil also enters the torque converter circuit. The solenoid actuated forward / reverse control valve (5), when operated, sends oil from the clutch circuit to the forward or reverse clutch piston which then applies the appropriate clutch. When in neutral the valve closes and oil from the clutch pistons is returned to the sump (18). On four-wheel drive models an additional solenoid valve (9), when engaged, sends oil from the clutch circuit to the four-wheel drive clutch piston which then

applies the clutch. When disengaged the valve (9) closes and oil from the clutch piston is returned to the sump (18).

The Torque Converter Circuit Oil enters the torque converter circuit from the pressure regulator valve (2). It flows through passages in the transmission oil pump housing (17) and into the torque converter (12). Pressure is controlled by the torque converter relief valve (1) which prevents the pressure within the torque converter from exceeding the design limits. Any excess is returned to the sump (18).

The Cooling and Lubrication Circuit Hot oil flows from the torque converter (12) via the inside of the transmission oil pump (17) stator tube, through the centre of the transmission oil pump (17) , and out of the transmission via connecting hoses (15) and (16). It is then passed through an external oil cooler (20) before being returned to the transmission where it is used to cool the clutches and lubricate the input shaft bearings before being returned to the sump (18).

N13–02–5

DRIVETRAIN AND BRAKES Component Location Torque Converter Relief Valve (1) — 10.5 bar

TV040404

Pressure Regulator Valve (2) — 14 bar

TV040405

Forward / Reverse Control Valve (5) 1 – Reverse solenoid 2 – Forward solenoid

1

TV040921

Four-wheel Drive Solenoid Valve (9)

TV040439

N13–02–6

2

DRIVETRAIN AND BRAKES Transmission Full Flow Oil Filter (11)

TV040436

Cold Start Valve (13) — 26 bar

TV040922

Transmission Temperature Sender (21)

TV040407

N13–02–7

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–8

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION

BHN1302TA

If a malfunction of the transmission is indicated a systematic pressure checking procedure should be followed. These checks should be carried out while the transmission is still in the vehicle so that true operating conditions are created. Pressure checks are essential since a failure in the transmission hydraulic system may not be easily traceable when the transmission is stripped down on a bench. All pressure checks should be carried out with the transmission gear lever in the neutral position, the oil

temperature at 80 to 85 degrees celcius. and the engine speed maintained at 2000 to 2500 RPM. As a safety precaution the vehicles parking brake should be applied. All pressure test ports have a 9/16 ins. UNF thread. A pressure gauge is required that will measure up to 20 bar ( 290 lb / in2. ). For test port locations refer to PRESSURE TEST PORTS in this section.

N13–02–9

DRIVETRAIN AND BRAKES Fault Diagnosis Hydraulic System Problem Transmission fails to drive in either direction

Transmission drives in one direction only

Delay in taking up drive

No drive from Four-wheel drive

Transmission overheating

Possible Cause

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Low or no transmission oil pump pressure. Low or no oil in the transmission. Mechanical failure in the transmission. Worn or broken input shaft sealing rings. Pressure regulator valve faulty. Direction control valve not operating. Blockage in oil ports restricting flow. Low oil pressure on one clutch pack due to leaks. Clutch piston seals worn or damaged. Clutch pack excessively worn. Direction valve or coil faulty. Mechanical failure in the transmission. Blockage in oil ports restricting flow. Worn or damaged input shaft sealing ring. Low torque converter pressure. Low or no oil in the transmission. Low clutch pressure. Faulty modulation in direction control valve. Blockage in direction valve. Blockage in oil ports restricting flow. Four-wheel drive solenoid valve or coil not operating. Mechanical failure in the transmission. Low four-wheel drive clutch pack pressure. Four-wheel drive clutch pack worn. Oil level too high or low. Restriction in the oil cooler flow. Low oil pressure. Clutch packs slipping due to oil low pressure or wear. Mechanical failure in the transmission. Excessive stall operation.

N13–02–10

DRIVETRAIN AND BRAKES Problem

Possible Cause

• • • • • Vehicle moves with direction • Difficult gear selection

Forward or reverse clutch pack pressurised when not selected. Direction valve faulty. Input shaft sealing rings leaking. Mechanical failure in the transmission. Forward and reverse clutch pack not releasing due to mechanical failure. See “Difficult gear selection”.

valve in neutral position High stall speed

Low stall speed

Low transmission oil pump pressure

High pump pressure Low forward or reverse clutch pack pressure

High forward / reverse clutch pack pressure Torque converter pressure low

Torque converter pressure high

• • • • • • • • • • • • • • • • • • • • •

Low or no oil in the transmission.

• • • • • •

Torque converter relief valve faulty.

Air in oil. Clutch plates slipping due to low oil pressure or wear. Torque converter faulty. Torque converter relief valve faulty. Incorrect torque converter fitted. Poor engine performance. Torque converter defective. Incorrect torque converter fitted. Worn or broken transmission oil pump. Leaking transmission oil pump sealing ring. Blocked oil strainer or filter. Blockage in oil ports between transmission sump and oil pump. Pressure regulator valve stuck open. Cold start valve stuck open. Pressure regulator valve faulty. Very low transmission oil temperature. Faulty direction control valve. Piston seal or O-ring leaking. Input shaft sealing ring leaking. Pressure regulator valve faulty.

Leak in torque converter, oil cooler or connecting hoses. Very high transmission oil temperature. Converter relief valve faulty. Blockage or restriction in oil cooler. Very low transmission oil temperature.

N13–02–11

DRIVETRAIN AND BRAKES Problem

Possible Cause

• • • • • High four-wheel drive clutch • Low four-wheel drive clutch pack pressure

Four-wheel drive piston seals leaking. Four-wheel drive shaft sealing ring leaking. Leak from four-wheel drive clutch supply pipe. Faulty Four-wheel drive solenoid. Blockage or restriction in four-wheel drive clutch supply pipe. Pressure regulator valve faulty.

pack pressure

Low lubrication pressure

• • •

Blockage or restriction in oil cooler. Input shaft front sealing ring leaking. Very high transmission oil temperature.

Fault Diagnosis Mechanical System Problem Noise

Difficult gear selection

Jumping out of gear

Possible Cause

•

Vehicle driveline problem:Axles, prop shaft, engine, engine mounts.

• • • • • • • • • • • • • • • • • • • • •

Mis-alignment of transmission / engine.

•

Excess end float on output shaft assembly or gears.

Bearings worn or damaged. Gear teeth damaged or broken. Excessive end float of shafts or gears. Clutch plate failure forward, reverse or four-wheel drive. Incorrect grade of oil in the transmission. Low or no oil in the transmission. Gear or thrust washer beginning to seize. Shift rods worn or bent. Shift forks worn, loose or twisted. Synchroniser assemblies worn or damaged. Clutch pack not releasing due to mechanical fault. Clutch pack not releasing due to hydraulic fault. Gear shift stub lever worn or damaged. Incorrect grade of oil in the transmission. Low or no oil in the transmission. Detent springs worn or broken. Synchroniser or gear dog teeth worn or damaged. Synchroniser assembies worn or damaged. Shift forks worn, loose or twisted. Restriction or wear in gear linkage or stub lever assembly not allowing gears to be fully selected.

N13–02–12

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — SYNCHROSHIFT TRANSMISSION PRESSURE TESTING Note: • Forward, reverse and four-wheel drive clutch pack pressures should not be more than 1 bar lower than the transmission oil pump pressure. Note: • The transmission oil, should be at an approximate temperature of 80 Degrees Celsius during pressure tests. Note: • All test ports have a 9/16” UNF thread. 1. Transmission oil pump — Pressure should be 13.5 to 15.5 bar at maximum engine speed. (2350 RPM).

TV040914

2. Reverse clutch — Pressure should be 12.5 to 15.5 bar at maximum engine speed. (2350 RPM).

TV040916

3. Forward clutch — Pressure should be 12.5 to 15.5 bar at maximum engine speed. (2350 RPM).

TV040915

N13–02–13

BHN1302TB

DRIVETRAIN AND BRAKES 4. Four-wheel drive — Pressure should be 12.5 to 15.5 bar at maximum engine speed. (2350 RPM).

TV040917

5. Torque Converter relief valve — Pressure should not exceed 10.5 bar at maximum engine speed. (2350 RPM).

TV040918

6. Lubrication oil — Pressure should be 0.5 to 2.5 bar at maximum engine speed. (2350 RPM).

TV040919

N13–02–14

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — SYNCHROSHIFT TRANSMISSION

BHN1302RA

Operation: Removing and Installing the Synchroshift Transmission Suitable lifting equipment, Suitable transmission jack

Job Code: 13 26 13 xx Standard tools

Removal

1. Position 150mm blocks under each stabilizer and fully lower. 2. Remove the right-hand rear wheel. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 . 3. Support the machine as shown using suitable supports. Note: • Ensure there is at least 915mm clearance between the ground and the lower chassis.

915mm TV051247

4. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 5. Drain the transmission fluid into a suitable container. 6. Install the transmission drain plug and a new O-ring. 7. Tighten to 44Nm. 8. Remove the parking brake caliper. For additional information, refer to Section N13-03 PARKING BRAKE CALIPER, PAGE N13–03–13 .

N13–02–15

DRIVETRAIN AND BRAKES

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Remove and discard the retaining bolts.

•

9. Detach the rear propeller shaft from the rear differential and secure it to one side.

TV040057

10. Remove the rear propeller shaft from the transmission.

TV040132

11. Detach the front propeller shaft from transmission and secure it to one side.

the

TV040358

For 12. Remove the cabin heater air ducting. refer to Section additional information, H08-01 CABIN HEATER AIR DUCTING, PAGE H08–01–13 .

N13–02–16

DRIVETRAIN AND BRAKES 13. Disconnect the transmission oil cooler pipe.

TV040920

Note: • Make a note of the position of the transmission wiring harness electrical connectors to aid installation. 14. Disconnect the transmission wiring harness electrical connectors and position it to one side.

TV040133

15. Disconnect the differential lock/steering supply hose (1). 16. Detach the differential lock control valve (2) and position it to one side.

1 2

TV040134

17. Remove the gearshift selector lever return spring (1), retaining bolt (2) and the gearshift selector lever (3).

N13–02–17

DRIVETRAIN AND BRAKES 18. Disconnect the gearshift selector lever electrical connector (4).

TV040135

19. Detach the hydraulic oil pump and secure to it one side.

TV040136

20. Disconnect the transmission oil cooler inlet pipe (1), steering return hose (2) and transmission oil filler tube (3).

1

2

3 TV040137

21. Using the access hole remove the torque converter retaining bolts.

TV040166

N13–02–18

DRIVETRAIN AND BRAKES

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

22. Using suitable lifting equipment, support the engine. 23. Cut the cable ties and position the wiring harness to one side.

TV040138

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

24. Using a suitable transmission jack, support the transmission.

•

Caution: Ensure the torque converter is removed with the transmission.

25. Remove the transmission retaining bolts and remove the transmission.

TV040361

N13–02–19

DRIVETRAIN AND BRAKES Installation 1. To install, reverse the removal procedure. 2. Tighten to 71Nm (52 lb.ft).

TV040361

3. Tighten to 41Nm (30 lb.ft).

TV040362

4. Tighten to 98Nm (72 lb.ft).

TV040136

5. Tighten (2) to 58Nm (42 lb.ft).

TV040135

N13–02–20

DRIVETRAIN AND BRAKES 6. Tighten (2) to 12Nm (9 lb.ft).

1 2

TV040134

Note: • Install new retaining bolts. 7. Tighten to 47Nm (35 lb.ft).

TV040358

Note: • Install new retaining bolts. 8. Tighten to 47Nm (35 lb.ft).

TV040132

N13–02–21

DRIVETRAIN AND BRAKES

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

9. Tighten to 47Nm (35 lb.ft).

TV040057

N13–02–22

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — SYNCROSHIFT TRANSMISSION

BHN1302DA

Operation: Disassembly and Assembly of the Syncroshift Transmission

Job Code: 13 26 17 xx

Suitable lifting equipment

Standard tools, FER.011 (KM3524), Dial test indicator (D.T.I) gauge

Disassembly 1. Remove the torque converter adapter plate.

TV040400

2. Remove the torque converter.

TV040401

3. Rotate the transmission 90 degrees and place on a suitable bench. Note: • For convenience the bench top should have a hole in it to accommodate the input shaft and pump. 4. Remove the gear shift lever assembly.

TV040402

5. Remove the protective plastic caps.

N13–02–23

DRIVETRAIN AND BRAKES 6. Remove the direction control valve.

TV040403

7. Remove the torque converter relief valve.

TV040404

8. Remove the pressure regulator valve.

TV040405

9. Remove the cold start plug (1), plunger (2) and ball (3).

TV040406

N13–02–24

DRIVETRAIN AND BRAKES 10. Remove the temperature sender.

TV040407

11. Remove the output shaft flange. Note: Remove and discard the O-ring oil seal.

•

TV040408

12. Remove the four-wheel drive output shaft flange. (If equipped). Note: • Remove and discard the O-ring oil seal. 13. Recover the spacer.

TV040409

N13–02–25

DRIVETRAIN AND BRAKES 14. Remove the four-wheel drive clutch supply pipe (If equipped).

TV040907

Note: • Lever slots are provided to assist removal. Note: The bearing cones and shims may fall from the rear case during removal.

•

15. Remove 18 retaining bolts. 16. Using suitable lifting equipment remove the rear transmission case.

TV040410

17. Remove the four-wheel drive shaft assembly. (If equipped).

TV040411

N13–02–26

DRIVETRAIN AND BRAKES Note: • To aid removal, tilt the countershaft (1) and reverse idler shaft (2). 18. Remove the input shaft assembly (3).

1

2

3

TV040412

19. Remove the reverse idler shaft assembly.

TV040413

20. Remove the outer detent plug (1), spring (2) and ball (3).

TV040414

N13–02–27

DRIVETRAIN AND BRAKES Note: • Ensure both synchronisers are in the neutral position. 21. Remove the 1st / 2nd shift fork grub screw.

TV040415

22. Remove the 1st / 2nd shift rod from the housing. Note: • Recover the interlock ball from the detent bore.

TV040416

•

Warning: Before attempting to remove the 3rd / 4th shift rail, replace the detent plug as the ball and spring may shoot out. Failure to follow this instruction may result in personal injury.

23. Remove the 3rd / 4th shift fork grub screw.

TV040417

N13–02–28

DRIVETRAIN AND BRAKES 24. Turn the 3rd / 4th shift rod through 90 degrees and withdraw from the housing.

TV040418

25. Remove the detent plug (1), inner detent ball (2) and spring (3).

TV040419

26. Remove the counter shaft assembly.

TV040423

27. Remove the 1st / 2nd and 3rd / 4th shift forks.

TV040424

N13–02–29

DRIVETRAIN AND BRAKES 28. Remove the output shaft assembly.

TV040426

29. Remove the transmission oil strainer cover (1), O-ring (2), spacer (3) and transmission oil strainer (4).

4 2 1 3 TV040435

30. Remove and discard the oil filter.

TV040436

31. Remove the oil filter housing. Note: • Remove and discard the gasket.

TV040437

N13–02–30

DRIVETRAIN AND BRAKES 32. Remove the four-wheel drive solenoid coil. equipped).

(If

TV040439

33. Remove the four-wheel drive solenoid spool. (If equipped).

TV040440

34. Remove and discard the expansion plug from the shimming access hole.

TV040442

N13–02–31

DRIVETRAIN AND BRAKES 35. Rotate the case 90 degrees. transmission oil pump assembly.

Remove the

Note: • Remove and discard the sealing ring and cooper washers.

TV040445

N13–02–32

DRIVETRAIN AND BRAKES Assembly Note: • All shafts and bearings should be lubricated with transmission fluid prior to assembly. Note: To prevent possible contamination of hydraulic parts, lint or cotton rags should not be used.

•

Note: • Lubricate the oil seal with a light grease. 1. Position the front case as shown and using a suitably sized tube, fit a new four-wheel drive output shaft oil seal to a depth of 6mm below the housing face. (If equipped).

TV040583

Note: • Install new copper washers and sealing ring. 2. Install the transmission oil pump assembly and sealing ring. 3. Tighten to 18Nm. 4. Check for free rotation of the transmission oil pump rotor.

TV040445

N13–02–33

DRIVETRAIN AND BRAKES Note: • Use a light grease to hold the bearing cups into the case. 5. Install the bearing cups (if previously removed).

TV040585

6. Using a suitable tool, push the inner detent spring and ball into the case (1) and secure in place with a dummy plug (2).

1

2

TV040586

7. Install the countershaft (1) and reverse idler shaft (2) assemblies.

1

TV040587

8. Slide the 1st / 2nd fork onto the 3rd / 4th rail. Install the 3rd / 4th shift fork. 9. Tighten to 21 Nm.

N13–02–34

2

DRIVETRAIN AND BRAKES 10. Hold the forks and rail in place on the output shaft then install the complete assembly into the case. Note: • The shift rail should displace the dummy plug as it enters the bore.

•

Caution: Check that the inner detent spring and ball have not become displaced and remove the loose dummy plug from the case sump.

TV040417

11. Install the interlock ball into the detent bore.

TV040903

12. Install the 1st / 2nd shift rod. 13. Tighten the 1st / 2nd shift fork retaining screw to 21Nm. Note: Check that the interlock ball is correctly positioned in between the two rails.

•

TV040416

14. Install the outer detent ball (3), spring (2) and plug (1).

N13–02–35

DRIVETRAIN AND BRAKES 15. Tighten to 47Nm (35 lb.ft).

TV040414

Note: • Lubricate the oil seal with a light grease. 16. Install the four-wheel drive shaft assembly. equipped).

(If

TV040413

Note: • Lubricate the oil seal with a light grease. Note: To aid installation, tilt the countershaft (1) and reverse idler shaft (2).

•

17. Install the input shaft assembly (3).

1

2

3

TV040412

N13–02–36

DRIVETRAIN AND BRAKES Note: • Lubricate the oil seal with a light grease. 18. Position the rear case as shown and using a suitably sized tube, fit a new output shaft oil seal to a depth of 6mm below the housing face.

TV040588

Note: • Use a light grease to hold the bearing cups into the case. 19. Rotate the case 180 degrees and replace the shim packs and bearing cups. The 2mm thick spacer shim should be fitted into the case first, then fit the remaining shims followed by the bearing cup.

TV040594

•

Caution: When fitting the rear case be careful to avoid damaging the input shaft sealing rings.

20. Install the rear case, (without sealant at this stage), and secure with at least 6 equally spaced bolts. 21. Tighten to 55Nm.

TV040410

N13–02–37

DRIVETRAIN AND BRAKES Note: • All shaft assemblies should be rotated several times to seat the bearings prior to measuring the end float. 22. Position a Dial Test Indicator (D.T.I) Gauge on the end of the input shaft as shown, and using a suitable pry bar through the side access hole, measure and note the shaft end float.

TV040589

23. Install special tool FER.011 (KM3524) (12mm thread), to the end of the reverse idler shaft. Position a D.T.I. gauge as shown, and using a pry bar lift the shaft, then measure and note the end float.

TV040590

24. Install special tool FER.011 (KM3524) (12mm thread), to the end of the countershaft. Position a D.T.I. gauge as shown, and using a pry bar lift the shaft, then measure and note the end float.

TV040591

N13–02–38

DRIVETRAIN AND BRAKES 25. Install special tool FER.011 (KM3524) (12mm thread), to the end of the output shaft. Position a D.T.I. gauge as shown, and using a pry bar lift the shaft, then measure and note the end float.

TV040592

26. Install special tool FER.011 (KM3524) (12mm thread), to the end of the four-wheel drive shaft. (If equipped). Position a D.T.I. gauge as shown, and using a pry bar lift the shaft, then measure and note the end float.

TV040593

27. Remove the rear case and add or remove shims as necessary to give 0.0254 to 0.0762 (0.001” to 0.003”) end float on all shafts. 28. Repeat steps 18 to 26 until all shaft end floats are correct. 29. Replace the O-rings in the front case. Note: • The input shaft and four-wheel drive shaft sealing rings should now be fitted. 30. Using an approved liquid gasket (Loctite 5203), install the rear case taking care not to damage the input shaft or four-wheel drive shaft sealing rings. 31. Tighten the 18 bolts to 55Nm.

TV040410

32. Replace the shaft end plug and O-ring assemblies.

N13–02–39

DRIVETRAIN AND BRAKES 33. Tighten to 47Nm (35 lb.ft).

TV040906

34. Install the four-wheel drive clutch supply pipe (If equipped). 35. Apply sealant (Loctite 542) to threads. Tighten to 5Nm.

TV040907

36. Using an approved sealant (Loctite 649), fit a new expansion plug to the shimming access hole.

TV040656

37. Install the output shaft flange, O-ring, washer and bolt. 38. Tighten to 78Nm (56 lb.ft).

TV040408

N13–02–40

DRIVETRAIN AND BRAKES 39. Install the spacer (1), four-wheel drive output shaft flange (2), O-ring (3), washer (4) and bolt (5). 40. Tighten to 78Nm (56 lb.ft).

TV040659

41. Install the cold start ball (3), plunger (2) and plug (1). 42. Tighten to 53Nm.

TV040406

Note: • Lubricate the oil seals with transmission fluid. 43. Install the pressure regulator valve. 44. Tighten to 53Nm (39 lb.ft).

TV040405

Note: • Lubricate the oil seals with transmission fluid. 45. Install the torque converter regulator valve.

N13–02–41

DRIVETRAIN AND BRAKES 46. Tighten to 27Nm (20 lb.ft).

TV040404

47. Install the temperature sender. 48. Tighten to 24Nm (18 lb.ft).

TV040407

Note: • Install new O-ring oil seals. 49. Install the transmission control valve. Note: The valve can only be fitted one way round as it is located by a small dowel pin.

•

50. Tighten to 7Nm (5 lb.ft). 51. Install new protective plastic caps.

TV040403

52. Install the transmission oil strainer (1), spacer (2), O-ring (3) and transmission oil strainer cover (4).

N13–02–42

DRIVETRAIN AND BRAKES 53. Tighten (1) to 25Nm (18 lb.ft).

4 2 1 3 TV040435

54. Apply a bead of an approved sealant (Loctite 5900), to the gear case as shown.

TV040661

55. Install the gear lever assembly. 56. Tighten to 20Nm (15 lb.ft).

TV040402

Note: • Do not use sealant on this gasket it is graphite coated. 57. Install the filter housing and gasket. 58. Tighten to 55Nm (41 lb.ft).

TV040437

N13–02–43

DRIVETRAIN AND BRAKES Note: • Lubricate the oil seal with a light grease. 59. Install a new oil filter. 60. Tighten to 9Nm (7 lb.ft).

TV040436

Note: • Lubricate the oil seals with a light grease. 61. Install the four-wheel drive solenoid spool. equipped). 62. Tighten to 25Nm (18 lb.ft).

(If

TV040440

63. Install the four-wheel drive solenoid coil and nut. (If equipped). 64. Tighten to 6Nm (4 lb.ft).

TV040439

65. Install the pump drive shaft. 66. Rotate the transmission 90 degrees.

N13–02–44

DRIVETRAIN AND BRAKES 67. Install the torque converter.

TV040401

68. Install the torque converter adaptor plate. 69. Tighten to 37Nm (27 lb.ft).

TV040400

N13–02–45

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–46

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — INPUT SHAFT Operation: Disassembly and Assembly of the Input Shaft None

BHN1302DB

Job Code: 13 48 17 xx Standard tools, FER.001 (KM3003), (KM3519), FER.009 (KM3523), FER.004 (KM3516).

N13–02–47

DRIVETRAIN AND BRAKES 1

Bearing

23

Piston Sealing Rings

2

Support Washer

24

O-ring

3

Thrust Bearing

25

Piston Sealing Ring

4

Needle Roller Bearings

26

O-ring

5

Needle Roller Bearings Spacer

27

Clutch Piston

6

Forward Primary Gear

28

Clutch Plate — Steel

7

Thrust Washer

29

Clutch Plate — Friction

8

Circlip

30

Clutch Pack Retaining Plate

9

Spring Retainer

31

Clutch Pack Retaining Ring

10

Piston Return Spring

32

Piston Return Spring

11

Clutch Pack Retaining Ring

33

Spring Retainer

12

Clutch Pack Retaining Plate

34

Circlip

13

Clutch Plate — Friction

35

Thrust Washer

14

Clutch Plate — Steel

36

Reverse Primary Gear

15

Piston Sealing Ring

37

Needle Roller Bearing

16

O-ring

38

Needle Roller Bearing Spacer

17

Clutch Piston

39

Thrust Bearing

18

O-ring

40

Thrust Washer

19

Piston Sealing Ring

41

Circlip

20

Sealing Ring

42

Bearing

21

Input Shaft Assembly Co-axial

43

Shims

22

Sealing Rings

44

Bearing Spacer

N13–02–48

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–49

DRIVETRAIN AND BRAKES Disassembly (Reverse Clutch) 1. Position the shaft assembly in a soft jawed vice.

TV040421

2. Remove and discard the sealing rings.

TV040420

3. Using the appropriate bearing puller FER.001 (KM3003) with the removable collet KM3519 , remove the rear bearing.

TV040422

4. Remove the circlip (1), thrust washer (2) and needle roller bearing (3).

TV040425

N13–02–50

DRIVETRAIN AND BRAKES 5. Remove the reverse primary gear.

TV040427

6. Remove the needle roller bearing (1), spacer (2), needle roller bearing (3) and thrust washer (4).

1 2 3 4

TV040428

7. Remove the clutch pack retaining ring.

TV040429

8. Remove the clutch pack retaining plate.

TV040430

N13–02–51

DRIVETRAIN AND BRAKES 9. Remove the clutch pack. Note: • Six plain clutch plates (externally splined) and six friction clutch plates (internally splined).

TV040434

10. Using the appropriate tool FER.009 (KM3523) , compress the piston spring and release the circlip.

TV040438

11. Remove the circlip (1), retainer (2) and spring (3).

TV040441

12. Remove the clutch piston.

N13–02–52

DRIVETRAIN AND BRAKES 13. Remove and discard the piston sealing rings and O-rings.

TV040443

N13–02–53

DRIVETRAIN AND BRAKES Assembly (Reverse Clutch) 1. Renew the piston sealing rings and O-rings. To assist assembly bend the inner sealing ring into a heart shape. 2. Using transmission fluid to lubricate the seals, push the clutch piston into the clutch housing.

TV040443

3. Install the spring (3), retainer (2) and circlip (1).

TV040441

4. Using the appropriate tool FER.009 (KM3523) , compress the spring and locate the circlip into its groove.

TV040438

N13–02–54

DRIVETRAIN AND BRAKES 5. Install six plain clutch plates (externally splined) and six friction clutch plates (internally splined) alternately.

TV040434

6. Install the clutch pack retaining plate.

TV040430

7. Install the clutch pack retaining ring.

TV040429

8. Install the thrust washer (4), needle roller bearing (3), spacer (2) and needle roller bearing (1).

1 2 3 4

TV040428

N13–02–55

DRIVETRAIN AND BRAKES 9. Install the reverse primary gear.

TV040427

10. Install the needle roller bearing (3), thrust washer (2) and circlip (1). Note: The needle roller bearing should be fitted with the closed side of its cage against the gear.

•

TV040425

11. Using an appropriately sized tube, install the rear bearing.

TV040454

Note: • To avoid damage, the sealing rings should be left off until all shimming operations have been completed. 12. Install new sealing rings.

N13–02–56

DRIVETRAIN AND BRAKES 13. There is a pump drive shaft bush fitted in the end of the shaft which may be replaced if worn.

TV040420

N13–02–57

DRIVETRAIN AND BRAKES Disassembly (Forward Clutch) 1. Turn the shaft over and secure in a soft jawec vice. 2. Remove and discard the sealing ring.

TV040444

3. Using the appropriate bearing puller FER.001 (KM3003) with the removable collet FER.004 (KM3516) , remove the front bearing.

TV040422

4. Remove the thrust washer (1) needle roller bearing (2).

1

2

TV040446

5. Remove the forward primary gear.

TV040443

N13–02–58

DRIVETRAIN AND BRAKES 6. Remove needle roller bearing (1), spacer (2), needle roller bearing (3) and the thrust washer (4).

1 2 3 4

TV040428

7. Remove the clutch pack retaining ring.

TV040429

8. Remove the clutch pack retaining plate.

TV040430

9. Remove the clutch pack. Note: • Six plain clutch plates (externally splined) and six friction clutch plates (internally splined).

TV040434

N13–02–59

DRIVETRAIN AND BRAKES 10. Using the appropriate tool FER.009 (KM3523) , compress the piston spring and release the circlip.

TV040438

11. Remove the circlip (1), retainer (2) and spring (3).

TV040441

12. Remove the clutch piston. 13. Remove and discard the piston sealing rings and O-rings.

TV040443

N13–02–60

DRIVETRAIN AND BRAKES Assembly (Forward Clutch) 1. Renew the piston sealing rings and O-rings. To assist assembly bend the inner sealing ring into a heart shape. 2. Using transmission fluid to lubricate the seals, push the piston into the clutch housing.

TV040443

3. Install the spring (3), retainer (2) and circlip (1).

TV040441

4. Using the appropriate tool FER.009 (KM3523) , compress the spring and locate the circlip into its groove.

TV040438

N13–02–61

DRIVETRAIN AND BRAKES 5. Install six plain clutch plates (externally splined) and six friction clutch plates (internally splined) alternately.

TV040434

6. Install the clutch pack retaining plate.

TV040430

7. Install the thrust washer (4), needle roller bearing (3), spacer (2) and needle roller bearing (1).

1 2 3 4

TV040428

8. Install the forward primary gear.

TV040443

N13–02–62

DRIVETRAIN AND BRAKES 9. Install the needle roller bearing (2) and thrust washer (1).

1

2

TV040446

10. Using an appropriately sized tube, Install the bearing as shown.

TV040454

11. Install a new sealing ring

TV040444

N13–02–63

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–64

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — COUNTERSHAFT

BHN1302DC

Operation: Disassembly and Assembly of the Countershaft None

Job Code: 13 49 17 xx Standard tools, FER.001 (KM3003), FER.006 (KM3518)

1

Bearing

2

Countershaft

3

Bearing

4

Shims

5

Bearing Spacer

Disassembly

1. Position the shaft assembly in a suitable soft jawed vice.

N13–02–65

DRIVETRAIN AND BRAKES 2. Using the appropriate bearing puller FER.001 (KM3003) and removable collets FER.007 (KM3522) and FER.006 (KM3518) , remove the front and rear bearings.

TV040910

Assembly 1. Using an appropriately sized tube, install the front and rear bearings.

TV040911

N13–02–66

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — REVERSE IDLER SHAFT

BHN1302DD

Operation: Disassembly and Assembly of the Reverse Idler Shaft None

Job Code: 13 50 17 xx Standard tools, FER.001 (KM3003), FER.002 (KM3509)

1

Bearing

2

Reverse Idler Shaft

3

Bearing

4

Shims

5

Bearing Spacer

Disassembly

1. Position the shaft assembly in a suitable soft jawed vice. 2. Using the appropriate bearing puller FER.001 (KM3003) and removable collet FER.002 (KM3509) , remove the front and rear bearings.

TV040908

N13–02–67

DRIVETRAIN AND BRAKES Assembly 1. Using an appropriately sized tube, install the front and rear bearings.

TV040909

N13–02–68

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — OUTPUT SHAFT Operation: Disassembly and Assembly of the Output Shaft None

BHN1302DE

Job Code: 13 46 17 xx Standard tools, FER.001 (KM3003), FER.005 (KM3517), FER.006 (KM3518),

TV040672

N13–02–69

DRIVETRAIN AND BRAKES 1

Sealing cap

2

Bearing

3

Thrust Washer

4

4th Gear

5

Circlip

6

Synchroniser Hub

7

3rd / 4th Synchroniser Assembly

8

3rd / 4th Shift Fork

9

1st / 2nd Shift Fork

10

3rd gear

11

Plug Assembly

12

Detent Spring

13

Detent Ball

14

Detent Balls

15

Detent Spring

16

1st / 2nd Shift Rod

17

3rd / 4th Shift Rod

18

Output Shaft

19

2nd Gear

20

Synchroniser Hub

21

1st / 2nd Synchroniser Assembly

22

1st Gear

23

1st Gear Output Shaft Needle Roller Bearings

24

Bearing Spacer

25

Bearing Sleeve

26

Four-Wheel Drive Gear

27

Bearing

28

Shims

29

Bearing Spacer

30

Oil Seal

31

Output Shaft Flange

32

O-ring Seal

33

Washer

34

Retaining Bolt

N13–02–70

DRIVETRAIN AND BRAKES Disassembly 1. Position the shaft assembly in a soft jawed vice. 2. Using the appropriate bearing puller FER.001 (KM3003) and removable collet FER.005 (KM3517) , remove the front bearing.

TV040465

3. Remove the thrust washer (1) and the 4th gear (2).

2

1

TV040464

4. Remove the 3rd / 4th synchroniser assembly.

TV040466

5. Using suitable circlip pliers, remove the circlip (1) and the synchroniser hub (2).

1

2

TV040467

N13–02–71

DRIVETRAIN AND BRAKES 6. Remove the 3rd gear.

TV040468

7. Rotate the shaft 180 degrees. 8. Using the appropriate bearing puller FER.001 (KM3003) with the removable collet FER.006 (KM3518) , remove the front bearing.

TV040469

9. Remove the four-wheel drive gear. (If equipped).

TV040470

10. Remove the 1st gear.

TV040471

N13–02–72

DRIVETRAIN AND BRAKES 11. Remove the 1st gear needle roller bearing (1), spacer (2) and needle roller bearing (3).

1 2 3

TV040472

12. Remove the 1st / 2nd synchroniser assembly.

TV040473

13. Using a suitable bearing puller or hydraulic press, remove the 1st gear bearing sleeve (1), synchroniser hub (2) and 2nd gear (3).

1 2

3 TV040474

N13–02–73

DRIVETRAIN AND BRAKES Assembly 1. Install the 2nd gear (1) and the synchroniser hub (2).

TV040475

2. Using a suitable hydraulic press and an appropriately sized tube, install the 1st gear bearing sleeve.

TV040476

3. Install the 1st / 2nd synchroniser assembly.

TV040473

4. Install the 1st gear needle roller bearing (3), spacer (2) and the 1st gear needle roller bearing (1).

1 2 3

TV040472

N13–02–74

DRIVETRAIN AND BRAKES 5. Install the 1st gear.

TV040471

Note: • The gear should be fitted with the fluted boss against the 1st gear. 6. Using Loctite 649 spline lock or equivalent, install the four-wheel drive gear (If equipped).

TV040470

7. Using a suitable hydraulic press and an appropriately sized tube, install the rear bearing.

TV040477

8. Rotate the shaft 180 degrees. 9. Install the 3rd gear.

TV040468

N13–02–75

DRIVETRAIN AND BRAKES 10. Install the synchroniser hub (2) and using suitable circlip pliers install the circlip (1).

1

2

TV040467

11. Install the 3rd / 4th synchroniser assembly.

TV040466

12. Install the 4th gear (2) and the thrust washer (1).

2

TV040464

13. Using a suitable hydraulic press and an appropriately sized tube, install the front bearing.

TV040478

N13–02–76

1

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — HYDRAULIC MULTIPLATE CLUTCH FOUR-WHEEL DRIVE SHAFT Operation: Disassembly and Assembly of the Hydraulic Multiplate Clutch Four-Wheel Drive Shaft None

Job Code: 13 30 17 xx Standard tools, FER.001 (KM3003), FER.004 (KM3516), KM3521, FER.003 (KM3510)

TV040676

N13–02–77

BHN1302DF

DRIVETRAIN AND BRAKES 1

Output Shaft Flange Retaining Bolt

2

Output Shaft Flange Washer

3

O-ring

4

Output Shaft Flange

5

Oil Seal

6

Output Shaft Flange Spacer

7

Bearing

8

Four-wheel Drive Clutch Housing

9

Shaft Sealing Ring

10

Piston Inner Oil Seal

11

Piston Outer Oil Seal

12

Piston

13

Clutch Plate — Steel

14

Clutch Plate — Friction

15

End Plate

16

Clutch Pack Retaining Ring

17

Spring

18

Spring Retainer

19

Circlip

20

Thrust Washer

21

Thrust Bearing

22

Four-wheel Drive Gear Assembly

23

Needle Roller Bearing

24

Spacer

25

Needle Roller Bearings

26

Thrust Bearing

27

Bearing

28

Shims

29

Spacer

N13–02–78

DRIVETRAIN AND BRAKES Disassembly 1. Position the shaft assembly in a suitable soft jawed vice. 2. Remove the rear sealing ring.

TV040479

3. Using the appropriate bearing puller FER.001 (KM3003) and removable collet FER.004 (KM3516) , remove the rear bearing.

TV040480

4. Remove the thrust washer (1) and the needle roller bearing (2).

1 2

TV040481

5. Remove the four-wheel drive gear assembly.

TV040533

N13–02–79

DRIVETRAIN AND BRAKES 6. Remove the needle roller bearing (1), spacer (2) and needle roller bearing (3).

1 2 3

TV040482

7. Remove the thrust bearing (1) and the thrust washer (2).

1 2

TV040483

8. Remove the clutch pack retaining ring.

TV040534

9. Remove the clutch pack end plate.

TV040535

N13–02–80

DRIVETRAIN AND BRAKES 10. Remove the clutch pack. Note: • Eight plain clutch plates (externally splined) and eight friction clutch plates (internally splined).

TV040536

11. Using the appropriate tool KM3521 and a suitable hydraulic press, compress the piston return spring and release the circlip.

TV040537

12. Remove the circlip (1), spring retainer (2) and the spring (3).

1

2

3

TV040538

N13–02–81

DRIVETRAIN AND BRAKES 13. Remove the clutch piston inner and outer oil seals.

TV040539

14. Remove and discard the piston sealing rings.

TV040545

15. Using the appropriate bearing puller FER.001 (KM3003) and removable collet FER.004 (KM3516) , remove the front bearing.

TV040540

N13–02–82

DRIVETRAIN AND BRAKES Assembly 1. Using a suitable hydraulic press and an appropriately sized tube, install the front bearing.

TV040544

2. Install new piston sealing rings. Note: • To assist assembly, the piston inner and outer oil seals may be warmed in lukewarm water prior to assembly. Note: • The outer oil seal must be fitted with the open edge facing away from the clutch pack.

TV040545

3. Using the appropriate tool FER.003 (KM3510) , compress the piston outer oil seal. The piston should be left in the tool for a minimum of 30 minutes prior to installing the piston into the clutch housing.

TV040546

N13–02–83

DRIVETRAIN AND BRAKES 4. Install the clutch piston.

TV040539

5. Install the spring (3), retainer (2) and the circlip (1).

1

2

3

TV040538

6. Using the appropriate tool KM3521 , and a suitable hydraulic press, compress the piston return spring and locate the circlip into its groove.

TV040537

N13–02–84

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. 7. Install eight plain clutch plates (externally splined) and eight friction clutch plates (internally splined) alternately.

TV040536

8. Install the clutch pack end plate.

TV040535

9. Install the clutch pack retaining ring.

TV040534

10. Install the thrust washer (2) and the needle bearing (1).

1 2

TV040483

N13–02–85

DRIVETRAIN AND BRAKES 11. Install the four-wheel drive gear.

TV040559

12. Install the needle roller bearing (3), spacer (2) and the needle roller bearing (3).

1 2 3

TV040482

13. Install the thrust bearing (2) and the thrust washer (1).

1 2

TV040481

14. Using a suitable hydraulic press and an appropriately sized tube, install the rear bearing.

TV040567

N13–02–86

DRIVETRAIN AND BRAKES Note: • To avoid damage, the sealing ring should be left off until all shimming operations have been completed. 15. Install a new sealing ring and lubricate with a light grease.

TV040479

N13–02–87

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–88

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — DIRECTION CONTROL VALVE

BHN1302DH

Operation: Disassembly and Assembly of the Direction Control Valve None

Job Code: 13 51 17 xx Standard tools

Disassembly Note: • Disassembly of the control valve is not generally recommended as, with the exception of the solenoids, individual parts are non serviceable. It may however be dismantled for cleaning and examination. 1. Remove the direction control solenoid coil retaining nut (1), the solenoid coil (2), washer (3) and the direction control valve (4). Note: • Remove and discard the O-ring oil seal.

1

2

3

4

4

3

TV040459

2. Remove the modulation valve cap (1), the spring (2), the modulation valve (3) and the spring (4).

TV040460

N13–02–89

2

1

DRIVETRAIN AND BRAKES 3. Remove the valve cap (1), the spring (2) and the valve (3).

2

3 TV040462

4. Remove and discard the O-ring oil seals.

TV040461

N13–02–90

1

DRIVETRAIN AND BRAKES Assembly 1. Install the valve (3) the spring (2), and the valve cap (1).

2

3 TV040462

2. Install the spring (4), the modulation valve (3), the spring (2) and the modulation valve cap (1).

4

3

3

4

TV040460

Note: • Install a new O-ring oil seal. 3. Install the direction control valve (4), the washer (3), the solenoid coil (2) and the solenoid coil retaining nut (1).

1

TV040459

4. Install new O-ring oil seals.

TV040461

N13–02–91

2

2

1

1

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–92

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — GEAR LEVER HOUSING Operation: Disassembly and Assembly of the Gear Lever Housing None

BHN1302DJ

Job Code: 13 32 17 xx Standard tools

1

Spacer

2

Bolt and Washer

3

Rubber Boot

4

Clip

5

Clip

6

Gear Stub Lever

7

Pin

8

Gear Lever Seating

N13–02–93

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–94

DRIVETRAIN AND BRAKES SPECIFICATIONS — SYNCHROSHIFT TRANSMISSION

BHN1302SA

General Information Transmission

SynchroShift

Make

Turner

Model

COM-T4-2032

Fermec P/N

6108873M91 3.01:1

Torque Converter Stall Ratio Pump Pressure

13.5 – 15.5bar

Clutch Pressure

12.5 – 15.5bar

Torque Converter Safety Valve Pressure

6.5 – 7.5bar

Lubrication Pressure

0.5 — 2.5bar

Recommended Lubricants 10W or 10W 30 Grade mineral oils or automatic transmission fluids which meet at least one of the following specifications are allowable for use in ambient temperatures of between -20 and 40 Degrees Celsius A.P.I. GL4, Allison C3, MIL-L-2105B, or Caterpillar TO2. The following lubricants meet these requirements: Note: This list has been compiled for guidance only . Turner Powertrain or the appropriate oil company should be consulted on any specific application.

•

A.T.F.

Mineral Oil

Mobil

—

Delvac 1310 or Mobilube HD 80

Shell

Donax TM or TA

Donax TC 10W

B.P.

Autran MBX

Vanellus C3 10W

Esso

Torque Fluid 56

Unifarm

Castrol

—

Castrol RX 10 or Multiplant

Texaco

Texamatic C3, 9230 or 9226

—

Total Fluid ATX

—

Elfmatic G3 or Elfmatic H

—

Finamatic HD

Kappa TD 10W

Oil Company

Total Elf Fina

Capacity System Synchroshift Transmission

Temperatures ALL

Viscocity 10W

Specification ATF

N13–02–95

Capacity 22 ltrs(Total System)

Notes Check oil level with engine running at idle. Clean suction strainer at oil change.

DRIVETRAIN AND BRAKES Recommended Tube Sizes for Replacing Bearings Bearing

Tube Bore

Tube O/D

Countershaft, Four-wheel drive shaft, Output shaft rear and Co-axial input shaft front bearing.

41mm

47mm

Reverse idler, Output shaft front and Input shaft bearing.

36mm

41mm

Output shaft 1st gear bearing sleeve and Co-axial input shaft rear bearing.

50.5mm

58mm

The dummy plug for installing inner detent spring and ball can be made using a piece of bar 18mm diameter x 25mm long.

Special Tools Terex Tool No.

Churchill Tool No.

Description

FER.001

KM 3003

Bearing extractor, use with bearing removal collets.

FER.002

KM 3509

Input / reverse idler shaft bearing removal collet. Bearing Ref. 48548 Pt.No.9713

FER.003

KM 3510

Piston seal sizing ring. (Hydraulic multi plate four-wheel drive only)

FER.004

KM 3516

Four—wheel drive shaft front rear and co-axial input shaft front bearing removal collet. Bearing Ref. 32008 Pt.No.68609

FER.005

KM 3517

Output shaft front bearing removal collet. Bearing Ref. 32207 Pt.No.68116

FER.006

KM 3518

Countershaft and output shaft rear bearing removal collet. Bearing Ref. 33208 Pt.No.68608

—

KM 3519

Co-Axial input shaft rear bearing removal collet. Bearing Ref. 32010 Pt. No.68772

FER.008

KM 3520

Input shaft spring compressor

—

KM 3521

Four-wheel drive shaft spring compressor. (Hydraulic multi plate four-wheel drive only)

FER.007

KM 3522

Countershaft front bearing removal collet. Bearing Ref. 32208 Pt.No.65381

FER.009

KM 3523

Input shaft spring compressor

FER.011

KM 3524

Shimming Adapter

Shaft End Floats All shaft end floats should be 0.025 to 0.075 mm. (0.001 to 0.003 ins.)

Gear End Floats End Float

Gear Input shaft forward and reverse primary gears

0.061 to 0.41 mm (0.0024” to 0.016”)

Output Shaft 4th Gear

0.20 to 0.56 mm (0.008” to 0.022”)

Output Shaft 3rd Gear

0.38 to 0.84 mm (0.015” to 0.033”)

Output Shaft 2nd Gear

0.36 to 0.56 mm (0.014” to 0.022”)

Output Shaft 1st Gear

0.33 to 0.51 mm (0.013” to 0.020”) 0.051 mm. to 0.28 mm (0.002” to 0.011”)

Four-Wheel Drive Output gear

N13–02–96

DRIVETRAIN AND BRAKES Torque Values Description

Nm

Lb.ft

Transmission to engine

71

52

Torque converter

41

30

Hydraulic oil pump

98

72

Gear selector lever

58

43

Differential lock control valve

12

9

Front prop shaft

47

35

Rear prop shaft

47

35

18 — 31

13 — 23

47

35

45 — 64

33 — 47

Transmission drain plug

44

32

Pressure test ports

47

35

Four-wheel drive clutch supply pipe

5

4

Output shaft flange

78

58

Four-wheel drive output shaft flange

78

58

Cold start plug

53

39

Pressure regulator valve

53

39

Torque converter regulator valve

27

20

Temperature sender

24

18

Transmission control valve

7

5

Transmission oil strainer cover

25

18

Gear lever housing assembly

20

15

Filter housing

55

41

Oil filter

9

7

Four-wheel drive solenoid spool

25

18

Four-wheel drive solenoid coil

6

4

Torque converter adaptor plate

37

27

Transmission oil pump Shift rod detent plug Transmission housing

N13–02–97

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–02–98

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM

BHN1303OA

Braking System Overview

5 4 2

3

6

1

7 8

9 TV040957

1

Rear Left Brake Outlet

2

Rear Right Brake Outlet

3

Brake Booster

4

Transmission Oil Reservoir Return

5

Transmission Oil Inlet

6

Brake Booster Supply Hose

7

Right Rear Brake Supply Hose

8

Left Rear Brake Supply Hose

9

Transmission Reservoir Return Hose

The braking system consists of two brake pedals that are independently linked to the brake booster (3). The brake booster contains two pistons that can operate

independently to enable left wheel braking, right wheel braking or all wheel braking. The brake pedals can be linked together with the use of a latching plate.

N13–03–1

DRIVETRAIN AND BRAKES The brake booster uses the same oil as the transmission. The oil is supplied under pressure from the transmission through hose (6) and into the brake booster transmission oil inlet (5), this pressurized oil increases the braking force exerted by the brake booster. The brake booster is also linked directly to the oil reservoir located in the transmission through hose (9) using the brake booster transmission oil reservoir return (4). The pressurized oil is then supplied to the rear left or rear right brake discs (which are housed in the

rear axle) through the brake booster outlets (1) and (2) to the rear axle brake connections. For additional information on the brake components contained in the rear axle, refer to Section N13-04 TWO–WHEEL STEER REAR AXLE or Section N13-05 FOUR-WHEEL STEER AXLE. On machines with four-wheel drive, four-wheel braking is available. With this system no braking components are located in the front axle, instead the braking is achieved using the transmission by engaging four-wheel drive.

N13–03–2

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM SAFIM

BHN1303OB

Braking System Overview

10

1

Left Brake Fluid Reservoir Hose

2

Right Brake Fluid Reservoir Hose

3

Brake Fluid Reservoir

4

Right Brake Supply Union

5

Left Brake Supply Union

6

Brake Balance Pipe

7

Left Brake Master Cylinder

8

Left Brake Master Cylinder Outlet

9

Right Brake Master Cylinder Outlet

10

Right Brake Master Cylinder

The braking system consists of two brake pedals that are independently linked to there own master

cylinders. These brake master cylinders contain pistons that operate independently to enable left

N13–03–3

DRIVETRAIN AND BRAKES wheel braking, right wheel braking or all wheel braking on 4WD models. The brake pedals can be linked together with the use of a latching plate. The braking system uses its own oil contained in a separate reservoir. This oil is supplied from the reservoir to the master cylinders. The oil is then supplied to the rear left or rear right brake discs (which are housed in the rear axle) through the master cylinder outlets to the rear axle

brake connections. For additional information on the brake components contained in the rear axle, refer to Section N13-04 TWO–WHEEL STEER REAR AXLE or Section N13-05 FOUR-WHEEL STEER AXLE. On machines with four-wheel drive, four-wheel braking is available. With this system no braking components are located in the front axle, instead the braking is achieved using the transmission by engaging four-wheel drive.

N13–03–4

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — MASTER CYLINDER (POWER BRAKES)

BHN1303RA

Operation: Removing and Installing the Master Cylinder (Power Brakes) None

Job Code: 13 06 13 xx Standard tools

Removal Note: • Make a note of the position of the hydraulic hoses prior to disconnection to aid installation. Note: • Install blanking plugs to avoid contamination. 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the air cleaner. For additional information, refer to Section P14-01 AIR CLEANER, PAGE P14–01–33 . 3. Disconnect the master cylinder supply and return hoses from the master cylinder (1). 4. Disconnect the left-hand and right-hand brake supply hose from the master cylinder (2).

TV040039

5. Disconnect the clevis from the brake pedals (1). 6. Remove the brake master cylinder (2).

TV040205

Installation Note: • Make sure there is 1.5mm of clearance between the Push rods and the Master cylinder. 1. To install, reverse the removal procedure.

N13–03–5

DRIVETRAIN AND BRAKES 2. Bleed the braking system. For additional information, refer to BRAKE BLEEDING (POWER BRAKES), PAGE N13–03–19 in this section. 3. Check and adjust the transmission oil level as required.

N13–03–6

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — MASTER CYLINDER (SAFIM BRAKES)

BHN1303RF

Operation: Removing and Installing the Master Cylinders (Safim Brakes) None

Job Code: xx xx x xxx Standard tools

Removal 1. Park the machine on firm, level ground.

•

Warning: Place suitable wheel chocks against the wheels to prevent vehicle movement. Failure to follow this instruction may result in personal injury.

2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the brake fluid reservoir. For additional information, refer to Brake Fluid Reservoir, PAGE N13–03–11 in this section. 4. Remove the heater air ducting. For additional information, refer to Section 08-01 HEATER AIR DUCTING, PAGE H08–01–13 . 5. Unlatch the brake pedals.

6. Remove the clevis pin from the left hand brake pedal.

N13–03–7

DRIVETRAIN AND BRAKES

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Make a note of the position of the hoses prior to disconnection to aid installation.

•

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

7. Disconnect the left rear brake hose (1) and the brake balance pipe (2).

8. Detach and reposition the rubber gaiter.

9. Remove the left master cylinder.

N13–03–8

DRIVETRAIN AND BRAKES 10. Detach the right hand clevis pin. 11. Press the left hand pedal and hold down.

TV07062

12. Remove the clevis pin. 13. Disconnect the right rear brake hose (1) and remove the brake balance pipe (2).

14. Detach and reposition the rubber gaiter.

15. Remove the right master cylinder retaining bolts.

N13–03–9

DRIVETRAIN AND BRAKES 16. Remove the right master cylinder.

17. Remove the brake fluid reservoir hoses.

Installation Note: • If a new master cylinder is to be used the bellows must installed from the old master cylinder. 1. To install, reverse the removal procedure. 2. Bleed the braking system. For additional information, refer to BRAKE BLEEDING Safim Brakes in this section.

N13–03–10

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — BRAKE FLUID RESERVOIR (SAFIM BRAKES) Operation: Removing and Installing the Brake Fluid Reservoir (Safim Brakes) None

BHN1303RG

Job Code: xx xx xx xx Standard tools

Removal

1. Park the machine on firm, level ground.

•

Warning: Place suitable wheel chocks against the wheels to prevent vehicle movement. Failure to follow this instruction may result in personal injury.

Note: • Make a note of the position of the hoses prior to disconnection to aid installation.

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Install blanking plugs to avoid contamination.

•

2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the retaining -clips (1) support the brake fluid reservoir and remove the filler cap (2).

4. Collect the brake fluid in a suitable container and dispose of the fluid in an appropriate manner.

N13–03–11

DRIVETRAIN AND BRAKES 5. Disconnect the hoses.

6. Remove the brake fluid reservoir.

Installation 1. To install, reverse the removal procedure. 2. Bleed the braking system. For additional information, refer to BRAKE BLEEDING Safim Brakes, PAGE N13–03–19 in this section.

N13–03–12

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — PARKING BRAKE CALIPER

BHN1303RC

Operation: Removing and Installing the Parking Brake Caliper Suitable wheel chocks

Job Code: 13 07 13 xx Standard tools

Removal

•

Warning: Place suitable wheel chocks against the wheels to prevent vehicle movement. Failure to follow this instruction may result in personal injury.

1. Isolate the battery ground cable. For additional information, refer to section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Remove the parking brake cable retaining clip (1). 3. Remove the parking brake return spring retainer (2). 4. Remove the parking brake return spring (3).

TV040010

5. Remove the parking brake cable adjustment nut (1). 6. Detach the parking brake cable (2).

TV040011

N13–03–13

DRIVETRAIN AND BRAKES 7. Remove the parking brake caliper.

TV040357

Installation 1. To install, reverse the removal procedure. 2. Adjust the parking brake. For additional information, refer to the Operator’s Manual.

N13–03–14

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — PARKING BRAKE DISC

BHN1303RD

Operation: Removing and Installing the Parking Brake Disc None

Job Code: 13 08 13 xx Standard tools, Suitable wheel chocks, Suitable container

Removal 1. Remove the parking brake caliper. Refer to PARKING BRAKE CALIPER, PAGE N13–03–15 in this section. 2. Drain the rear axle oil into a suitable container.

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: • Remove and discard the retaining bolts. 3. Disconnect the propeller shaft from the parking brake disc and secure it to one side.

TV040727

4. Remove the circlip and remove the parking brake disc.

TV040728

Installation 1. To install, reverse the removal procedure.

N13–03–15

DRIVETRAIN AND BRAKES

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

2. Tighten to 47Nm (35 lb.ft).

TV040727

N13–03–16

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — DIFFERENTIAL LOCK SOLENOID VALVE

BHN1303RE

Operation: Removing and Installing the Differential Lock Solenoid Valve

Job Code: 13 02 13 xx

None

Standard tools

Removal 1. Remove the cabin heater air ducting. For additional information, refer to Section H08-01 CABIN HEATER AIR DUCTING, PAGE H08–01–13 . 2. Disconnect the differential lock solenoid valve electrical connector (1). Note: • Make a note of the position of the hydraulic hoses prior to disconnection, to aid installation. 3. Disconnect the hydraulic hoses (2) from the differential lock solenoid valve. Note: • Install blanking plugs to avoid contamination. 4. Remove the differential lock solenoid valve (3).

3

2

1

2 TV040987

Installation 1. To install, reverse the removal procedure. 2. Tighten (3) to 12Nm. 3. Check and adjust the transmission oil level as required.

3

2

1

2 TV040987

N13–03–17

DRIVETRAIN AND BRAKES

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N13–03–18

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — BRAKE BLEEDING POWER BRAKES

BHN1303GA

Operation: Brake Bleeding None

Job Code: 13 04 09 xx Standard tools, Suitable clear tubing, Suitable container

Bleeding

•

Warning: This procedure will require being under the machine while the engine is running and the brake pedals are being depressed. Apply the parking brake, chock the wheels and make sure the machine remains in neutral during this procedure. Failure to follow these instructions may result in personal injury.

1. Start the engine and run at idle speed. 2. Connect a suitable piece of clear tubing to the left hand brake bleed nipple (1) on the rear axle and place the other end into a suitable container. 3. Connect a suitable piece of clear tubing to the right hand brake bleed nipple (2) on the rear axle and place the other end into a suitable container.

2

TV040949

4. Remove the cab front mat to allow full brake pedal(s) travel. Note: • Make sure the brake pedals are latched together. 5. Press both brake pedals 10 times to purge the brake booster. 6. Unlatch the brake pedals. 7. Open the right hand bleed nipple (2) and press the right hand brake pedal until fluid is flowing from the bleed nipple. 8. Close the right hand bleed nipple (2). 9. Press the right hand brake pedal 10 times to build up a hard pedal and hold the pedal down on the final press.

N13–03–19

1

DRIVETRAIN AND BRAKES Note: • As the bleed nipple is opened the pedal will go to the floor. Do not apply excessive pressure to the pedal because the tubing may detach from the bleed nipple. 10. Open the right hand bleed nipple (2) to free the trapped air and with the pedal now on the floor, close the right hand bleed nipple (2). 11. Repeat steps 9 and 10 a further 5 times. 12. Repeat steps 7 to 11 to bleed the left hand brake. 13. Latch the brake pedals together. 14. Press both brake pedals 10 times to build up a hard pedal and hold the pedal down on the final press. Note: As the bleed nipples are opened the pedal will go to the floor. Do not apply excessive pressure to the pedals because the tubings may detach from the bleed nipples.

•

15. Open both bleed nipples (1) and (2) to free the trapped air and with both pedals now on the floor, close the bleed nipples. 16. Repeat steps 14 and 15 a further 5 times. 17. Press the pedals and check the pedals do not travel beyond the position of the differential lock pedal.

2

TV040949

N13–03–20

1

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — BRAKE BLEEDING SAFIM BRAKES

BHN1301GB

Bleeding

•

•

Warning: Place suitable wheel chocks against the wheels to prevent vehicle movement. Failure to follow this instruction may result in personal injury. Warning: Under NO circumstances allow conventional BRAKE FLUID to be added to the system, and never purge the system and refill with brake fluid. Otherwise damage will occur to all the rubber sealing components within the brake system. Use mineral based hydraulic oil only.

Note: • Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner. 1. Park the machine on firm, level ground. 2. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION . 3. Unlatch the brake pedals. 4. Connect a suitable length of tubing to the bleed nipple (1) and place the other end in a suitable container

2

TV040949

5. Remove the cab front mat to allow full brake pedal(s) travel 6. Open the bleed nipple (1). 7. Depress the left brake pedal and hold down Note: • Maintain the fluid level in the reservoir. 8. Tighten the bleed nipple. 9. Release the pedal , repeat steps 6 to 8 until all of the trapped air is released.

N13–03–21

1

DRIVETRAIN AND BRAKES 10. Then repeat the process for the right brake using bleed nipple (2).

2

TV040949

11. After the brakes have been bleed relatch the brake pedals together.

N13–03–22

1

DRIVETRAIN AND BRAKES SPECIFICATIONS — POWER BRAKES

BHN1303SA

General Information Brakes

Oil Immersed Disk Type in the Rear Axle

Booster

Transmission Pressure Activated

Boost ratio

2.60:1

Master Cylinders Diameter

31.75mm (1 1/4”)

Master cylinder seals

Specific for Mineral Oil

Brake Disks Friction Discs (820–860)

2 Each Side

Friction Disks (970)

3 Each Side

Brake Piston Seals

Specific for Mineral Oil

Torque Values Description

Nm

Lb.ft

Propeller Shaft Universal Joints

47

35

Master Cylinder Retaining Bolts

28

21

Parking Brake Caliper Retaining Bolt

150

111

Parking Brake Caliper Bracket Retaining Bolt

45

33

Parking Brake Caliper Flange

80

59

N13–03–23

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–03–24

DRIVETRAIN AND BRAKES SPECIFICATIONS — BRAKES — SAFIM

BHN1303SB

General Information Brake fluid Safim brake system only Type of oil to be used : Mobil LHM ( mineral brake fluid) Brakes

Oil Immersed Disk Type in the Rear Axle

Master Cylinders Diameter

31.75mm (1 1/4”)

Master cylinder seals

Specific for Mineral Brake Fluid

Brake Disks Friction Discs (820–860)

2 Each Side

Friction Disks (970)

3 Each Side

Brake Piston Seals

Specific for Mineral Brake Fluid

Service specifications Fluid level check

Every 10 hours or every day

Fluid change

Every 500 hours

Type of oil

Mobil LHM ( mineral brake fluid)

Oil capacity

225cc

Torque Values Description

Nm

Lb.ft

Propeller Shaft Universal Joints

47

35

Master Cylinder Retaining Bolts

28

21

Parking Brake Caliper Retaining Bolt

150

111

Parking Brake Caliper Bracket Retaining Bolt

45

33

Parking Brake Caliper Flange

80

59

N13–03–25

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–03–26

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — TWO-WHEEL STEER REAR AXLE

BHN1304OA

General Description

1

2

3 5

4

TV040948

1

Wheel Hub Group

2

Differential Group

3

Pinion Group

4

Half Shaft and Brake Group

5

Epicyclic Reduction Gear Group

The axle described in this manual, consists of a beam casing, housing the differential in the centre and a wheel hub unit at each end. The differential mechanical lock, hydraulically controlled — is supported by two bearings mounted on a suitable structure allowing the bevel gear set to be adjusted. The ring bevel gear is adjusted using two ring nuts located opposite each other. The position of the bevel

pinion, supported by two bearings, is adjusted by installing adjusting shims. The wheel hubs containing the epicyclic reduction gears are supported by two tapered roller bearings. The axle also has a braking system fitted with a hydraulic drive for service braking and mechanical control for the parking brake.

N13–04–1

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–04–2

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — TWO-WHEEL STEER REAR AXLE Problem Ring gear tooth broken at the outer side

BHN1304TA

Possible Cause

•

Excessive gear load compared to the one foreseen.

Action

• •

•

Incorrect gear adjustment (excessive backlash).

• •

•

Pinion nut loosened.

• •

Ring gear tooth broken side

•

Load bump.

• •

•

Incorrect gear adjustment (insufficient backlash).

• •

•

Pinion nut loosened.

• •

Pinion or ring gear teeth worn

•

Insufficient lubrication.

• •

•

N13–04–3

REPLACE crown wheel and pinion gear set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion gear set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program.

DRIVETRAIN AND BRAKES Problem Pinion or ring gear teeth worn (continued)

Action

Possible Cause

•

Contaminated oil.

• •

•

•

Incorrect lubrication or depleted additives.

• •

•

•

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

• •

•

Overheated ring and pinion teeth. Check if gear teeth have faded.

•

Prolonged functioning at high temperatures.

• •

•

Incorrect lubrication.

• •

•

Low oil level.

• •

•

Contaminated oil.

• •

Axle beam body bent

• • •

Vehicle overloaded. Vehicle accident. Load bump.

N13–04–4

• • •

REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE axle beam body. REPLACE axle beam body. REPLACE axle beam body.

DRIVETRAIN AND BRAKES Problem Pinion teeth pitting

Action

Possible Cause

•

Excessive wear.

• •

•

Insufficient lubrication.

• •

Worn out or pitted bearings

Oil leakage from gaskets and seals

REPLACE crown wheel and pinion set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals. REPLACE crown wheel and pinion set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive wear.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive wear.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Pinion nut loosened.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Prolonged functioning at high temperature of the oil.

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

• •

Oil gasket assembled incorrectly.

• •

•

Seal lip damaged.

• •

•

Contaminated oil.

• •

N13–04–5

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

DRIVETRAIN AND BRAKES Problem Excessive wearing out of input flange spline

Action

Possible Cause

•

Heavy use.

• • •

•

Pinion nut loosened.

• • •

•

Pinion axle backlash.

• • •

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required. REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required. REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required.

Fatigue failure of pinion teeth. Check if the fracture line is well defined (wave lines, beach lines)

•

Heavy use.

•

REPLACE crown wheel and pinion set.

•

Continuous overload.

•

REPLACE crown wheel and pinion set.

Pinion and ring teeth breakage

•

Crash load of differential components.

•

CHECK and/or REPLACE other differeential components.

Side gear spline worn out. Replace all scratched washers (Excessive backlash)

•

Excessive wear.

•

Thrust washer surface worn out or scratched

•

Insufficient lubrication.

• •

REPLACE differential gear group. REPLACE halfshaft if required.

• •

•

Incorrect lubrication.

• • •

•

Contaminated oil.

• • •

N13–04–6

USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0,1 mm thickness lower than the new ones. USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0,1 mm thickness lower than the new ones.

DRIVETRAIN AND BRAKES Problem

Action

Possible Cause

•

Excessive wear.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Excessive pinion axial backlash.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Contaminated oil.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

Bent or broken halfshaft

•

Vehicle intensively operated or overloaded.

•

REPLACE half shaft.

Halfshaft broken at wheel side

•

Wheel support loosened.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

•

Beam body bent.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

Inner diameter of tapered roller bearing worn out

N13–04–7

DRIVETRAIN AND BRAKES Axle Problem and Diagnosis Problem

Possible Cause

Action

•

Excessive backlash between pinion and ring gear.

•

ADJUST.

• • • •

Worn out pinion and gear ring.

• • • •

REPLACE.

• • • • • • •

Worn out differential bearings.

• • • • • • •

REPLACE.

•

Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing the speed.

•

REPLACE.

Pinion or input flange worn out.

• •

ADJUST.

Intermittent noise

• •

Differential box bolts loosened.

• •

TIGHTEN to torque.

Constant noise

• • • • • • •

Worn out bearings.

• • • • •

REPLACE.

•

Differential thrust washers worn out.

•

REPLACE.

•

Halfshaft spline worn out.

•

REPLACE.

Noise while driving

Noise whilst driving in neutral

Noise while steering

Worn out pinion bearings. Pinion bearings loosened. Excessive axial pinion backlash. Differential bearings loosened. Ring gear out of roundness. Low Lubricant level. Poor or wrong lubricant. Bent halfshaft. Noise coming from axle is usually heard when vehicle moves in neutral gear but are not loud.

Ring gear damaged.

Ring gear teeth or pinion damaged. Pinion spline worn out. Bent halfshaft. Worn out differential gears. Worn out differential box or spider.

N13–04–8

REPLACE. ADJUST. ADJUST.

ADJUST. REPLACE. OIL level. REPLACE. REPLACE. REPLACE or ADJUST (see above).

REPLACE crown wheel and pinion set. REPLACE crown wheel and pinion set. REPLACE. REPLACE. REPLACE. REPLACE.

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — TWO WHEEL STEER REAR AXLE

BHN1304RA

Operation: Removing and Installing the Rear Axle Suitable transmission jack

Job Code: 13 52 13 xx Standard tools

Removal

1. Remove the rear wheels. For additional information, refer to Section M12-01 REAR WHEEL . 2. Isolate the battery ground cable. For additional information, refer to section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the parking brake cable retaining clip (1). 4. Remove the parking brake cable return spring retainer (2). 5. Remove the parking brake cable return spring (3).

TV040010

6. Remove the parking brake cable adjustment nut (1). 7. Detach the parking brake cable from the parking brake calliper (2).

TV040011

N13–04–9

DRIVETRAIN AND BRAKES

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Remove and discard the retaining bolts.

•

8. Detach the rear propeller shaft from the rear differential and secure it to one side.

TV040057

Note: • Install blanking contamination.

plugs

to

avoid

9. Disconnect the rear axle differential lock oil supply pipe (1). 10. Disconnect the rear axle left-hand inboard brake pipe (2).

2

1

TV040058

Note: • Install blanking contamination.

plugs

to

avoid

11. Disconnect the rear axle right-hand inboard brake pipe.

TV040059

N13–04–10

DRIVETRAIN AND BRAKES

•

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury. Warning: Secure the rear axle to the transmission jack. Failure to follow this instruction may result in personal injury.

12. Using a suitable transmission jack, support the rear axle. 13. Remove the rear axle retaining bolts and remove the rear axle (left-hand side shown, right-hand side similar

TV040060

Installation 1. To install, reverse the removal procedure. 2. Tighten to 475Nm (35 lb.ft).

TV040060

N13–04–11

DRIVETRAIN AND BRAKES

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

3. Tighten to 47Nm (35 lb.ft).

TV040057

4. Bleed the brakes. For additional information, refer to Section N13-01 BRAKE BLEEDING, PAGE N13–01–153 . 5. Adjust the parking brake. For additional information, refer to the Operator’s Manual.

N13–04–12

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — BRAKE CALIPER

BHN1304DA

Operation: Disassembly and Assembly of the Brake Caliper

Job Code: 13 12 17 xx

None

Standard tools

19

4

3 18

23 21

22

2 19 20

6

3

1 9 10 11 12 13 5 20 7 8 9 7 14 15 16 17

TV040817

N13–04–13

18

DRIVETRAIN AND BRAKES 1

Front Torque Plate

2

Rear Torque Plate

3

Spacer

4

Adjustment Bolt

5

Brake Friction Pads

6

Spring Clip

7

Outer Cam

8

Inner Cam

9

Ball

10

Seal

11

Boot

12

Lever

13

Thrust Washer

14

Stainless Steel Washer

15

Hardened Washer

16

Adjustment Nut

17

Locking Nut

18

Mounting Bolt

19

Locking Nut

20

Sleeve Seal

21

Bolt

22

Lock Washer

23

Cable Retaining Bracket

N13–04–14

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP

BHN1304DB

Operation: Disassembly and Assembly of the Epicyclic Reduction Gear Group None

Job Code: 13 16 17 xx Standard tools

Disassembly

1. Remove the wheel. For additional information, refer to M12-01 REAR WHEEL, PAGE M12–01–5 . 2. Drain the hub oil. For additional information, refer to L11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 3. Remove the epicyclic reduction gear carrier. Note: • Remove and discard the O-ring oil seal.

TV040763

4. Remove the epicyclic gear retaining bolt (1) and washer (2).

TV040764

N13–04–15

DRIVETRAIN AND BRAKES 5. Remove the locating washer (1) and the epicyclic gear (2). Note: • Recover the needle roller bearings and the needle roller bearings spacer.

TV040767

6. Remove the locating pin (1) and the wear washer (2). 7. Repeat steps 5, 6 and 7 to remove the remaining epicyclic gears. 8. Inspect the pinion pins, if they are in poor condition a new epicyclic reduction gear carrier assembly should be installed.

TV040768

9. If the half-shaft stop (1) is worn, a new epicyclic reduction gear carrier assembly should be installed.

TV040770

N13–04–16

DRIVETRAIN AND BRAKES Assembly 1. Install the wear washer (2) and the locating pin (1).

TV040768

2. Install the epicyclic gear (1) and the first set of needle roller bearings (2).

TV040803

3. Install the needle roller bearings spacer.

TV040804

4. Install the second set of needle roller bearings. 5. Repeat steps 1 to 4 to install the remaining epicyclic gears.

TV040805

6. Install the washer (2) and epicyclic gear retaining bolt (1).

N13–04–17

DRIVETRAIN AND BRAKES 7. Tighten (1) to 79Nm (58 lb.ft).

TV040764

Note: • Install a new O-ring oil seal. 8. Install the epicyclic reduction gear carrier. 9. Tighten to 25Nm (18 LB.FT). 10. Fill the hub with oil. For additional information, refer toL11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 11. Install the rear wheel. For additional information, refer toM12-01 REAR WHEEL, PAGE M12–01–5

TV040763

N13–04–18

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP

BHN1304DC

Operation: Disassembly and Assembly of the Wheel Hub Group None

Job Code: 13 18 17 xx Standard tools, CA715027, CA715026, CA119087

Disassembly 1. Remove the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section. 2. Remove the wheel hub retaining bolts.

TV040769

3. Using two hub retaining bolts, extract the epicyclic reduction group.

TV040200

4. Remove the snap ring (1) and remove the epicyclic gear hub (2) from the epicyclic ring gear (3).

1

2

3 TV040771

N13–04–19

DRIVETRAIN AND BRAKES 5. Using a suitable soft faced hammer, remove the rear axle hub (1). Note: • Recover the outer taper roller bearing (2). 6. Using the special tool CA715027 — Driver for bush remove the hub centering bushes.

1

2

TV040772

7. Remove the inner taper roller bearing.

TV040773

8. Using a suitable lever, remove and discard the hub oil seal (1). 9. Remove the inner and outer taper roller bearing and cones (2).

2

1

TV040849

N13–04–20

DRIVETRAIN AND BRAKES Assembly 1. Using a suitable hydraulic press and the special tool CA715026 — Driver for bearing race , install the inner and outer taper roller bearing cones.

TV040925

Note: • Lubricate the oil seal with a light grease. 2. Using the special tool CA119087 — Driver for oil seal , install a new hub seal.

TV040926

3. Install the inner taper roller bearing.

TV040773

4. Install the rear axle hub (1) . 5. Install the outer taper roller bearing (2).

1

2

TV040772

N13–04–21

DRIVETRAIN AND BRAKES Note: • Install two bushes slightly higher that the hub surface level to be used as dowel pins. 6. Using the special tool CA715027 — Driver for bush partially install the hub centering bushes.

TV040930

7. Install the epicyclic hub (2) to the epicyclic ring gear (3) and install the snap ring (1).

1

2

3 TV040771

8. Assemble the epicyclic group on the wheel hub using the two protruding centering bushes as dowel pins.

TV040200

N13–04–22

DRIVETRAIN AND BRAKES 9. Using the special tool CA715027 — Driver for bush , fully install the remaining centering bushes.

TV040931

10. Install the wheel hub retaining bolts. 11. Tighten to 230Nm (170 LB.FT). 12. Install the epicyclic reduction gear group. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section.

TV040769

N13–04–23

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–04–24

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — HALF SHAFT AND BRAKE GROUP

BHN1304DD

Operation: Disassembly and Assembly of the Half Shaft and Brake Group Suitable lifting equipment

Job Code: 13 18 17 xx Standard tools, CA715386, CA715387

Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section. 2. Drain the axle oil into a suitable container. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 3. Remove the parking brake caliper.

TV040774

4. Using suitable circlip pliers remove the parking brake disc.

TV040924

5. Mark the rear axle housing prior to disassembly to aid installation.

TV040779

N13–04–25

DRIVETRAIN AND BRAKES 6. Remove the stub shaft from the half shaft housing.

TV040777

7. Remove and discard the seal (1). 8. Remove and discard the half shaft housing bushing (2).

1

2 TV040778

Note: • Left hand side half shaft only. 9. Remove the axle breather from the half shaft housing.

TV040781

N13–04–26

DRIVETRAIN AND BRAKES

•

•

Warning: Support the half shaft housing. Failure to follow this instruction may result in personal injury. Caution: Make sure the half shaft remains with the differential housing.

10. Remove the half shaft housing. Note: Remove and discard the O-ring.

•

TV040782

11. Remove the half shaft oil thrower from the half shaft.

TV040783

12. Remove the half shaft from the differential housing.

TV040784

Note: • Check that the friction discs and the fixed discs do not show any sign of burning. If damage is found new components should be installed. 13. Remove the 5 mm fixed steel disc (1). 14. Remove the outer friction disc (2). 15. Remove the brake hub (3).

N13–04–27

DRIVETRAIN AND BRAKES 16. Remove the 11 mm fixed steel disc (4). 17. Remove the inner friction disc (5). 18. Remove the piston pressure disc (6).

5 3 1 6 4 2 TV040785

19. Remove the self-adjust retaining bolts (1) and (2). Note: Recover the self-adjust components.

•

20. Remove the brake piston (3). Note: Remove and discard the brake piston o-ring seals.

•

TV040788

21. Repeat steps 6 to 20 to remove the remaining half shaft housing.

N13–04–28

DRIVETRAIN AND BRAKES Assembly 1. Install the self-adjust bushings into the brake flange until level with the piston inner surface.

TV040827

Note: • Lubricate the brake piston oil seals with a light grease. 2. Install new outer (1) and inner (2) oil seals to the brake piston.

2 1

TV040828

Note: • Lubricate the brake piston oil seals with a light grease. 3. Install the brake piston (3). 4. Install the brake piston self-adjust retaining bolt assemblies (1) and (2). 5. Tighten to 10Nm (7 LB.FT).

1

3 2 TV040830

Note: • If new friction discs are installed, they should be soaked in suitable oil before assembling, 6. Install the piston pressure disc (6). 7. Install the inner friction disc (5).

N13–04–29

DRIVETRAIN AND BRAKES Note: • Install the fixed steel disc with the lip towards the piston. 8. Install the 11 mm fixed steel disc (4). 9. Install the brake hub (3). 10. Install the outer friction disc (2). 11. Install the 5 mm fixed steel disc (1).

5 3 1 6 4 2 TV040785

12. Install the half shaft into the differential housing.

TV040784

13. Install the half shaft oil thrower onto the half shaft.

TV040783

14. Remove the two brake housing retaining bolts.

TV041086

N13–04–30

DRIVETRAIN AND BRAKES

•

Warning: Support the half shaft housing. Failure to follow this instruction may result in personal injury.

Note: Install a new half shaft housing O-ring.

•

15. Install the half shaft housing. 16. Tighten to 130Nm (98 LB.FT).

TV040782

Note: • Left-hand side half shaft only. 17. Install the axle breather into the half shaft housing. 18. Tighten to 15Nm (11 LB.FT).

TV040781

19. Using the special tool CA715386 — Driver for bush , install the half shaft housing bushing (2). Note: Lubricate the oil seal with a light grease.

•

20. Using the special tool CA715387 — Driver for oil seal , install the half shaft housing seal (1).

1

2 TV040778

21. Install the stub shaft into the half shaft housing.

N13–04–31

DRIVETRAIN AND BRAKES 22. Repeat steps 1 to 21 to install the remaining half shaft housing.

TV040777

23. Using suitable circlip pliers Install the parking brake disc.

TV040924

24. Install the parking brake caliper. 25. Tighten to 150Nm (111 LB.FT). 26. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 27. Install the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section.

TV040774

N13–04–32

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP

BHN1304DE

Operation: Disassembly and Assembly of the Differential Group

Job Code: 13 14 17 xx

None

Standard tools, CA715133

10

14

9 8

13

11

7 12

6 5 4 3 2 1

15 16

17 24

18

23

22 21 20 19 TV040929

N13–04–33

DRIVETRAIN AND BRAKES 1

Bolt

2

Locking Plate

3

Differential Adjustment Nut

4

Taper Roller Bearing

5

Snap Ring

6

Differential Lock Selector

7

Housing

8

Thrust Plate

9

Sun Gear

10

Thrust Washer

11

Planetary Gear

12

Planetary Shaft

13

Planetary Shaft

14

Sun Gear

15

Planetary Gear

16

Thrust Washer

17

O-ring

18

Differential Locking Pins

19

Thrust Plate

20

Housing

21

Taper Roller Bearing

22

Differential Adjustment Nut

23

Locking Plate

24

Bolt

Disassembly 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Position the differential in a suitable vice. Note: • Mark the differential carrier disassembly to aid installation.

prior

to

3. Remove the crown wheel.

TV040796

N13–04–34

DRIVETRAIN AND BRAKES 4. Remove the thrust plate (1) and sun gear (2).

TV040797

5. Remove the planetary shafts (1) and the planetary gears (2). Note: • Recover the thrust washers (3).

2 3

1 TV040798

6. Remove the sun gear (1) and thrust plate (2).

TV040799

7. Remove the snap ring (1).

N13–04–35

2

DRIVETRAIN AND BRAKES 8. Remove the Differential lock selector (2). Note: • Recover the differential locking pins. Note: Remove and discard the O-rings.

•

TV040800

9. Using a suitable puller, remove the right-hand side taper roller bearing.

TV040801

10. Using a suitable puller, remove the left-hand side taper roller bearing (1) and the crown wheel (2).

TV040802

N13–04–36

DRIVETRAIN AND BRAKES Assembly 1. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the left-hand side differential taper roller bearing (1) and the crown wheel assembly (2).

TV040802

2. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the right hand side differential taper roller bearing.

TV040801

3. Install new O-ring seals and install the differential locking pins. 4. Install the differential lock selector (2). 5. Install the snap ring (1).

TV040800

N13–04–37

DRIVETRAIN AND BRAKES 6. Install the thrust washer (2) and the sun gear (1).

TV040799

7. Install the Planetary shafts (1), planetary gears (2) and the trust washers (3).

2 3

1 TV040798

8. Install the sun gear (2) and the thrust washer (1).

TV040797

9. Install the crown wheel. Note: • Before installing the crown wheel retaining bolts, apply approved sealant (Loctite 270) to the bolt. 10. Tighten to 155Nm (114 LB.FT).

N13–04–38

2

DRIVETRAIN AND BRAKES 11. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

TV040796

N13–04–39

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–04–40

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — PINION GROUP

BHN1304DF

Operation: Disassembly and Assembly of the Pinion Group None

Job Code: 13 20 17 xx Standard tools, CA119099, CA715022, CA715380, CA715128, CA715388, CA715004, Suitable measuring device

1

2

3

4

5

6

7 8 9 10 11 12

TV040815

1

Sealing Ring

2

O-ring Seal

3

Spacer

4

Pinion Shaft Retaining Nut

5

Lock Washer

6

Pinion Shaft

7

Shim

8

Taper Roller Bearing

9

Washer

10

Elastic Spacer

11

Washer

12

Taper Roller Bearing

N13–04–41

DRIVETRAIN AND BRAKES Disassembly 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Remove the parking brake caliper mounting bracket.

TV040810

3. Remove and discard the pinion sealing ring from the differential housing.

TV040807

4. Remove the O-ring (1) and the spacer (2).

2 1

TV040806

N13–04–42

DRIVETRAIN AND BRAKES

•

Caution: Release the pinion shaft retaining nut locking tabs. Failure to follow this instruction may result in damage to the machine.

5. Using the special tools CA119099 — Wrench for lock nut and CA715022 — Pinion shaft lock tool , remove the pinion shaft retaining nut. Note: • Recover the lock washer.

1

2 TV040813

6. Using a suitable soft faced hammer, remove the pinion shaft from the differential housing. Note: • Recover the outer taper roller bearing, two washers and discard the elastic spacer.

TV040814

7. Using a suitable puller, remove the taper roller bearing from the pinion shaft. Note: • Recover the pinion end float adjustment shim.

TV040927

N13–04–43

DRIVETRAIN AND BRAKES 8. Using a suitable drift, remove the pinion shaft taper roller bearing cups from the differential housing.

TV040816

N13–04–44

DRIVETRAIN AND BRAKES Assembly 1. Using the special tool CA715380 — Bearing races insertion kit install the taper roller bearing cups into the differential housing.

TV040818

2. Install the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

•

Caution: Do not overtighten.

3. Install the lock washer (1) and the pinion shaft retaining nut (2) 4. Tighten until the free play is eliminated.

TV040928

5. Install the brake left-hand side brake housing with three retaining bolts 120° apart. 6. Tighten to 79Nm (58 LB.FT).

N13–04–45

DRIVETRAIN AND BRAKES 7. Repeat steps 5 and 6 for the right-hand side brake housing.

TV041081

Note: • Ensure the false differential box is inserted in both brake housings. 8. Install the special tool CA715388 — false differential box into the differential housing.

TV040820

B A

X

C

9. Using a suitable depth gauge, measure through the false pinion (CA715128) This measurement is “A” . 10. Determine the value “X” as follows: X = (conical distance to be measured) A = (measured value) B = 100mm C = 50mm X = (A + C) — B Example: A = 159.9mm therefore: X = (159.9 + 50) – 100mm X = 109.9mm

TV040821

N13–04–46

DRIVETRAIN AND BRAKES 11. Determine the pinion shaft position adjustment shim “S” as follows: subtract the value “V” (requested conical distance) from the calculated value “X” . S=X—V Example: Shim thickness S = 109.9 – 107.00 = 2.9mm. Shim thickness “S” = 2.9mm

107.00 00

V

TV040811

SHIM RANGE mm

2.5

2.6

2.7

2.8

2.9

3.0

12. Remove the special tool CA715388 — false differential box from the differential housing.

TV040820

13. Remove the brake housing (both sides).

TV041081

N13–04–47

3.1

3.2

3.3

3.4

DRIVETRAIN AND BRAKES 14. Remove the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

15. Install the pinion shaft adjustment shim (1) with chamfer against the gear. 16. Using a suitable hydraulic press and the special tool CA715004 — Driver for bearing install the rear taper roller bearing (2).

2 1

TV040823

Note: • Always use a new elastic spacer. 17. Install the washers and the new elastic spacer onto the pinion shaft. 18. Install the pinion shaft assembly (1) and the front taper roller bearing (2) into the differential housing.

1

2

TV040824

19. Install a new lock washer (1).

N13–04–48

DRIVETRAIN AND BRAKES Note: • Do not tighten at this stage. 20. Install a new pinion shaft retaining nut (2).

TV040928

21. Install the special tool CA715116 — Measurement onto the pinion shaft. Note: Using a suitable soft faced hammer, settle the pinion shaft bearings.

•

22. Using a suitable measuring device (with the cord wound on the 34.87 mm diameter of the special tool CA715116 — measurement ), measure the pinion shaft rotational torque. 23. The rotational torque should be within the following range excluding breakaway torque. 9.2 to 13.7 daN

TV040825

•

Caution: If the stated rotational torque range is exceeded the elastic spacer must be replaced and the procedure repeated

24. The adjustment is carried out by increasing the pinion shaft retaining nut torque setting gradually, being careful not to exceed the stated range. 25. Once the correct rotational torque is achieved, secure the pinion shaft retaining nut.

N13–04–49

DRIVETRAIN AND BRAKES 26. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

1

2 TV040813

N13–04–50

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL HOUSING GROUP

BHN1304DG

Operation: Disassembly and Assembly of the Differential Housing Group Suitable lifting equipment

Job Code: 13 14 13 xx Standard tools, CA715265, CA715391, CA119033, CA715056, CA715146, CA715116, CA715156

Hrs.

Min.

6

30

Disassembly 1. Remove the half shaft and brake group. For additional information, refer to HALF SHAFT AND BRAKE GROUP, PAGE N13–04–25 in this section. 2. Remove the differential lock actuator. Note: • Remove and discard the O-ring seal.

TV040789

3. Using a suitable lever and circlip pliers, remove the differential lock return spring circlip (1). 4. Remove the differential lock bush (2).

1

TV040790

N13–04–51

2

DRIVETRAIN AND BRAKES 5. Remove the bushing (2) and the differential lock return spring (1).

1 2 TV041084

6. Remove the differential lock cover. Note: Remove and discard the O-ring seal.

•

TV040791

7. Remove the differential lock spring (1), spacer (2) shaft (3) and circlip (4).

4

3 2 TV040793

N13–04–52

1

DRIVETRAIN AND BRAKES Exploded View of Differential Lock Control

2 6 7 8 9

1

3 4 5 14 15 16

10

17 11

18 12 13

TV040792

1

Retaining Bolt

2

Plug

3

Piston Housing

4

O-ring

5

Piston Seal

6

Piston

7

Piston Seal

8

Snap Ring

9

Bushing

10

Shaft

11

Spring

12

Fork

13

Snap Ring

14

Spacer

15

Spring

16

O-ring

17

Cover

18

Retaining Bolt

8. Remove the brake housing (both sides). Note: • Remove and discard the O-ring seals.

N13–04–53

DRIVETRAIN AND BRAKES 9. Remove the differential taper roller bearing cone from the brake housing.

TV040794

10. Re-position the differential lock fork (1). 11. Remove the differential assembly (2). Note: Recover the differential lock fork (1).

•

3

2 TV040795

N13–04–54

DRIVETRAIN AND BRAKES Assembly Note: • Position the brake housing on a suitable flat surface. 1. Using the special tool CA715391 — Driver for bearing race and CA119033 — Interchangeable handle , install the differential taper roller bearing cone.

TV040826

2. Loosely install the differential lock fork in the differential housing. 3. Install the differential (2) into the differential housing (3). 4. Install the differential lock fork (1) into the differential (2).

3

2 TV040795

5. Install the left hand side brake housing with three retaining bolts 120° apart. 6. Tighten to 79Nm (58 LB.FT).

N13–04–55

DRIVETRAIN AND BRAKES 7. Repeat steps 5 and 6 for the right hand side brake housing.

TV041081

N13–04–56

DRIVETRAIN AND BRAKES Exploded View of Differential Lock Control

2 6 7 8 9

1

3 4 5 14 15 16

10

17 11

18 12 13

TV040792

N13–04–57

DRIVETRAIN AND BRAKES 1

Retaining Bolt

2

Plug

3

Piston Housing

4

O-ring

5

Piston Seal

6

Piston

7

Piston Seal

8

Snap Ring

9

Bushing

10

Shaft

11

Spring

12

Fork

13

Snap Ring

14

Spacer

15

Spring

16

O-ring

17

Cover

18

Retaining Bolt

8. Install the circlip (4), shaft (3), spacer (2) and differential lock spring (1).

4

3 1

2 TV040793

9. Install the differential lock return spring (1) and the bushing (2).

1 2 TV041084

N13–04–58

DRIVETRAIN AND BRAKES 10. Loosely install the differential lock actuator.

TV040789

11. Install the differential lock cover. 12. Tighten to 27.6Nm.

TV040791

13. Remove the differential lock actuator.

TV040789

14. Using a suitable lever and circlip pliers, lever back the bushing (2) and install the differential lock return spring circlip (1).

1

TV040790

15. Install the differential lock actuator.

N13–04–59

2

DRIVETRAIN AND BRAKES 16. Tighten to 27.6Nm.

TV040789

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Only tighten the differential adjustment nut until the bearing free play is removed and nominal pre-load is achieved.

•

17. Using the special tool CA715265 — Wrench for differential housing lock nut , install the differential adjustment nuts.

TV040832

18. Using a suitable measuring device and special tool CA715146 — Kit for backlash measurement , measure the pinion to crown wheel backlash. 19. The pinion to crown wheel backlash should be within the following range: 0.20mm – 0.30mm

TV040833

N13–04–60

DRIVETRAIN AND BRAKES Note: • Make sure the differential adjustment nuts are adjusted equally to retain the nominal bearing pre-load and no free play. 20. Using the special tool CA715265 — Wrench for differential housing lock nut , adjust the differential adjustment nuts until the correct pinion to crown wheel backlash is achieved.

TV040832

21.

•

•

Measured backlash is greater than the specified range — (A) , adjust the differential assembly closer to the pinion shaft by loosening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment nut equal amounts. Measured backlash is less than the specified range — (B) , adjust the differential assembly away from the pinion shaft by tightening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment nut equal amounts.

A

A

B

B

TV040874

22. Once the correct pinion to crown wheel backlash is achieved, check that the differential taper roller bearings have no free play and no pre-load is evident.

N13–04–61

DRIVETRAIN AND BRAKES 23. Repeat steps 18 to 22 of the whole sequence of the above mentioned operations, until the indicated conditions are reached.

TV040834

24. Install the special tool CA715116 — Measurement onto the pinion shaft.

•

Caution: All adjustments are to be carried out without the pinion shaft oil seal installed.

Note: Using a suitable soft-faced hammer, settle the differential taper roller bearings.

•

Note: Rotate the differential assembly while tightening the adjustment nuts to seat the bearing rollers on their track.

•

25. Using a suitable measuring device (with the cord wound on the 34.87 mm diameter of the special tool CA715116 — measurement ), measure the total rotational torque.

TV040835

26. The total rotational torque should be within the following range excluding breakaway torque. (1.6 + P) to (2.4 + P) daN P = Measured pinion shaft rotational torque. For additional information refer to PINION GROUP, PAGE N13–05–49 in this section.

N13–04–62

DRIVETRAIN AND BRAKES Note: • Make sure the differential adjustment nuts are adjusted equally to retain the set backlash. 27. Using the special tool CA715265 — Wrench for differential housing lock nut , adjust the differential adjustment nuts until the correct differential taper roller bearing pre-load is achieved.

TV040832

28.

•

•

Total pre-load is less than the specified range — (A) , increase the differential taper roller bearing pre-load by tightening the left-hand side (crown wheel side) adjustment nut and tightening the right-hand side adjustment equal amounts. Total pre-load is higher than the specified range — (B) , decrease the differential taper roller bearing pre-load by loosening the left-hand side (crown wheel side) adjustment nut and loosening the right-hand side adjustment equal amounts.

A

A

B

B

TV040876

N13–04–63

DRIVETRAIN AND BRAKES Testing After Adjustment Note: • The marking test should always be carried out on both sides of the crown wheel teeth. 29. To test the marks of the crown wheel teeth, paint the ring gear with red lead paint.

TV040836

30. Check the contact pattern: OK = Correct contact — If the crown wheel is well adjusted, the mark on the teeth surfaces will be regular. Z = Excessive contact on the tooth tip — Adjust the pinion towards the crown wheel and then adjust the crown wheel away from the pinion in order to adjust the backlash. X = Excessive contact at the tooth base — Adjust the pinion away from the crown wheel and then adjust the crown wheel towards the pinion in order to adjust the backlash.

OK

Z

X

TV040837

N13–04–64

DRIVETRAIN AND BRAKES 31. Movements to correct Adjust as required: 1 = move the pinion for type X contact adjustment. 2 = move the pinion for type Z contact adjustment.

2 1 TV040838

32. Lock the differential adjustment nuts in position with the locking tabs (1) and secure with the retaining bolts (2). 33. Tighten to 13Nm.

1

2

TV041085

34. Install the spacer (2) and the O-ring (1).

2 1

TV040806

N13–04–65

DRIVETRAIN AND BRAKES Note: • Lubricate the oil seal with a light grease. 35. Using the special tool CA715156 — Driver for oil seal , install a new pinion shaft oil seal into the differential housing.

TV040807

36. Install the parking brake caliper mounting bracket. 37. Tighten to 80Nm. For 38. Install the half shaft and brake group. additional information, refer to HALF SHAFT AND BRAKE GROUP, PAGE N13–04–25 in this section.

TV040810

N13–04–66

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL Draining 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Loosen the refill plug to release any pressure.

TV040945

3. Remove the drain plug and drain the oil into a suitable container.

TV040944

Filling 1. Install the drain plug and tighten to 60Nm (44 LB.FT).

TV040944

N13–04–67

BHL1304GA

DRIVETRAIN AND BRAKES 2. Fill with oil until the refill hole level is reached.

TV040952

3. Install the refill plug and tighten to 60Nm (44 LB.FT).

TV040945

N13–04–68

DRIVETRAIN AND BRAKES SPECIFICATIONS — TWO-WHEEL STEER REAR AXLE

BHN1304SA

Special Tools Tool No.

Description

CA119033

Interchangeable Handle

CA119087

Driver for Oil Seal

CA119099

Wrench for Lock Nut

CA715004

Driver for Bearing

CA715022

Pinion Shaft Lock Wrench

CA715026

Driver for Bearing Race

CA715027

Driver for Bush

CA715056

Driver for Oil Seal

CA715116

Extension for Pre-load Measurement

CA715128

False Pinion

CA715133

Driver for Bearing

CA715146

Kit for Backlash Measurement

CA715156

Driver for Oil Seal

CA715265

Wrench for Differential Housing Lock Nut

CA715386

Driver for Bush

CA715387

Driver for Oil Seal

CA715388

False Differential

CA715391

Driver for Bearing Race

General Specifications Description

Value

Input rotation

Powershift — counter clockwise Synchro shuttle — clockwise

Grease type

POLYMER 400/L DIN = KHER1R ISO-1–XMR-XM2

Differential Backlash

0.20 — 0.30 daN

Pinion Shaft Bearing Pre-load “P”

“P” = 9.2 — 13.7 daN

Total Pinion/Differential Bearing Pre-load

(1.6 + P) — (2.4 + P) daN

Brake Type

Wet Disc

No. of Brake Friction Discs (Each Side)

2

No. of Counter Discs (Each Side)

3

Nominal Brake Friction Disc Thickness

4.83mm

Nominal Counter Disc Thickness

5/10.8/9mm

Max. Brake Friction Disc Wear (Each Side)

0.15mm

Brake Activation Oil

Mineral Oil

Brake Activation Oil Displacement

12 + 12cc

Max. Operating Pressure

43 bar

Flange Type

END YOLK 1410

N13–04–69

DRIVETRAIN AND BRAKES Capacity System Rear Axle

Temperatures ALL

Viscocity 80W

Specification API GL4 M1135

Capacity

Notes

14.5 + 1.5 + 1.5

Approved oils: Agip Rotra Multi THT, Esso Torque Fluid 62, Mobil Fluid 422 or 424

Torque Values Description

Nm

Lb.ft

Epicyclic Gear

79

58

Wheel Hub

230

170

Hub Drain Plug

60

44

Wheel Studs

70

52

Epicyclic Reduction Hub

25

18

Brake Housing

79

58

Crown Wheel

155

114

Differential Adjustment Nut Locking Tabs

13

10

Half shaft Housing

130

96

Parking Brake Caliper Mounting Bracket

80

59

Parking Brake Caliper

150

111

Parking Brake Caliper Cable Bracket

45

33

Brake Self Adjust Bolts

10

7

Differential Lock Actuator

27.6

20

Differential Lock Cover

27.6

20

Brake Bleed Valve

10

7

Breather Union

15

11

Breather

10

7

Blanking Plug

25

18

N13–04–70

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — FOUR-WHEEL STEER REAR AXLE

BHN1305OA

General Description 1

2

3

4 7

8 9

6

5

10 TV041105

1

Wheel Hub Group

2

Axle Beam Trumpet Group

3

Differential Group

4

Differential Support Group

5

Parking Brake Group

6

Pinion Group

7

Brake Group

8

Epicyclic Reduction Gear Group

9

Steering Cylinder Group

10

Differential Locking Group

The axle described in this manual consists of the following groups: • WHEEL HUB GROUP: wheel support parts containing the epicyclic reduction gears. • AXLE BEAM TRUMPET GROUP: load-bearing shell structure of the axle. • DIFFERENTIAL GROUP: differential parts with crown wheel gear. • DIFFERENTIAL SUPPORT GROUP: differential housing with crown wheel gear adjusting system. • PARKING BRAKE GROUP: parking brake parts and brake support structure.

• • • • •

PINION GROUP: pinion with adjusting and support parts. BRAKE GROUP: brake parts brake shell structure. EPICYCLIC REDUCTION GEAR GROUP: planetary carrier with reduction/transmission parts. STEERING CYLINDER GROUP: steering cylinder parts with adjusting system. DIFFERENTIAL LOCKING GROUP: control parts of the differential locking.

N13–05–1

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–05–2

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — FOUR-WHEEL STEER REAR AXLE Problem Ring gear tooth broken at the outer side

BHN1305TA

Possible Cause

•

Excessive gear load compared to the one foreseen.

Action

• •

•

Incorrect gear adjustment (excessive backlash).

• •

•

Pinion nut loosened.

• •

Ring gear tooth broken side

•

Load bump.

• •

•

Incorrect gear adjustment (insufficient backlash).

• •

•

Pinion nut loosened.

• •

Pinion or ring gear teeth worn

•

Insufficient lubrication.

• •

•

N13–05–3

REPLACE crown wheel and pinion gear set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion gear set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program.

DRIVETRAIN AND BRAKES Problem Pinion or ring gear teeth worn (continued)

Action

Possible Cause

•

Contaminated oil.

• •

•

•

Incorrect lubrication or depleted additives.

• •

•

•

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

• •

•

Overheated ring and pinion teeth. Check if gear teeth have faded.

•

Prolonged functioning at high temperatures.

• •

•

Incorrect lubrication.

• •

•

Low oil level.

• •

•

Contaminated oil.

• •

Axle beam body bent

• • •

Vehicle overloaded. Vehicle accident. Load bump.

N13–05–4

• • •

REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. FOLLOW carefully the recommended operations for the adjustment of crown wheel and pinion set backlash. USE correct lubricants, FILL to the right levels and REPLACE according to the recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE crown wheel and pinion set. USE proper lubrication, FILL to the right level and REPLACE at recommended program. REPLACE axle beam body. REPLACE axle beam body. REPLACE axle beam body.

DRIVETRAIN AND BRAKES Problem Pinion teeth pitting

Action

Possible Cause

•

Excessive wear.

• •

•

Insufficient lubrication.

• •

Worn out or pitted bearings

Oil leakage from gaskets and seals

REPLACE crown wheel and pinion set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals. REPLACE crown wheel and pinion set. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Contaminated oil.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Excessive wear.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Pinion nut loosened.

• •

REPLACE bearings. USE correct lubrication, FILL to the right level and REPLACE at recommended intervals.

•

Prolonged functioning at high temperature of the oil.

•

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

• •

Oil gasket assembled incorrectly.

• •

•

Seal lip damaged.

• •

•

Contaminated oil.

• •

N13–05–5

REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals. REPLACE the gasket or seal and matching surface if damaged. USE correct lubrication and REPLACE at recommended intervals.

DRIVETRAIN AND BRAKES Problem Excessive wearing out of input flange spline

Action

Possible Cause

•

Heavy use.

• • •

•

Pinion nut loosened.

• • •

•

Pinion axle backlash.

• • •

REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required. REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required. REPLACE the flange. CHECK that the pinion spline is not excessively worn out. REPLACE crown wheel and pinion set if required.

Fatigue failure of pinion teeth. Check if the fracture line is well defined (wave lines, beach lines)

•

Heavy use.

•

REPLACE crown wheel and pinion set.

•

Continuous overload.

•

REPLACE crown wheel and pinion set.

Pinion and ring teeth breakage

•

Crash load of differential components.

•

CHECK and/or REPLACE other differeential components.

Side gear spline worn out. Replace all scratched washers (Excessive backlash)

•

Excessive wear.

•

Thrust washer surface worn out or scratched

•

Insufficient lubrication.

• •

REPLACE differential gear group. REPLACE halfshaft if required.

• •

•

Incorrect lubrication.

• • •

•

Contaminated oil.

• • •

N13–05–6

USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0.1 mm thickness lower than the new ones. USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0.1 mm thickness lower than the new ones. USE correct lubrication and FILL to right level. REPLACE at recommended intervals. REPLACE all scratched washers and those with 0.1 mm thickness lower than the new ones.

DRIVETRAIN AND BRAKES Problem

Action

Possible Cause

•

Excessive wear.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Excessive pinion axial backlash.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Insufficient lubrication.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

•

Contaminated oil.

• • •

REPLACE bearing. CHECK pinion axial backlash. USE proper lubrication, FILL to right level and REPLACE at recommended intervals.

Bent or broken halfshaft

•

Vehicle intensively operated or overloaded.

•

REPLACE half shaft.

Halfshaft broken at wheel side

•

Wheel support loosened.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

•

Beam body bent.

• •

REPLACE half shaft. CHECK that wheel support is not worn out or wrongly adjusted.

Inner diameter of tapered roller bearing worn out

N13–05–7

DRIVETRAIN AND BRAKES Axle Problem and Diagnosis Problem

Possible Cause

Action

•

Excessive backlash between pinion and ring gear.

•

ADJUST.

• • • •

Worn out pinion and gear ring.

• • • •

REPLACE.

• • • • • • •

Worn out differential bearings.

• • • • • • •

REPLACE.

•

Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing the speed.

•

REPLACE.

Pinion or input flange worn out.

• •

ADJUST.

Intermittent noise

• •

Differential box bolts loosened.

• •

TIGHTEN to torque.

Constant noise

• • • • • • •

Worn out bearings.

• • • • •

REPLACE.

•

Differential thrust washers worn out.

•

REPLACE.

•

Halfshaft spline worn out.

•

REPLACE.

Noise while driving

Noise whilst driving in neutral

Noise while steering

Worn out pinion bearings. Pinion bearings loosened. Excessive axial pinion backlash. Differential bearings loosened. Ring gear out of roundness. Low Lubricant level. Poor or wrong lubricant. Bent halfshaft. Noise coming from axle is usually heard when vehicle moves in neutral gear but are not loud.

Ring gear damaged.

Ring gear teeth or pinion damaged. Pinion spline worn out. Bent halfshaft. Worn out differential gears. Worn out differential box or spider.

N13–05–8

REPLACE. ADJUST. ADJUST.

ADJUST. REPLACE. OIL level. REPLACE. REPLACE. REPLACE or ADJUST (see above).

REPLACE crown wheel and pinion set. REPLACE crown wheel and pinion set. REPLACE. REPLACE. REPLACE. REPLACE.

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — FOUR-WHEEL STEER REAR AXLE

BHN1305RA

Operation: Removing and Installing the Rear Axle (Four-Wheel Steer) Suitable transmission jack

Job Code: 13 52 13 xx Standard tools

Removal 1. Remove the rear wheels. For additional information, refer to Section M12-01 REAR WHEEL . 2. Isolate the battery ground cable. For additional information, refer to section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 3. Remove the four wheel steer change over valve. for additional information, refer to section L11-04 FOUR WHEEL STEER CHANGE OVER VALVE . Note: • Install blanking contamination.

plugs

to

avoid

4. Disconnect the rear axle steering cylinder supply and return pipes (Rear axle shown removed for clarity).

TV041090

5. Remove the parking brake cable retaining clip (1). 6. Remove the parking brake cable return spring retainer (2). 7. Remove the parking brake cable return spring (3).

TV040010

8. Remove the parking brake cable adjustment nut (1).

N13–05–9

DRIVETRAIN AND BRAKES 9. Detach the parking brake cable from the parking brake caliper (2).

TV040011

Note: • Secure the propshaft to prevent disengagement of the sliding joint. 10. Detach the rear propshaft from the rear axle. Note: Discard the retaining bolts.

•

TV040057

Note: • Install blanking contamination.

plugs

to

avoid

11. Disconnect the rear axle oil supply pipe (1). 12. Disconnect the rear axle left-hand brake supply pipe (2).

2

1

TV040058

N13–05–10

DRIVETRAIN AND BRAKES Note: • Install blanking contamination.

plugs

to

avoid

13. Disconnect the rear axle right-hand brake supply pipe.

TV040059

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: Secure the transmission jack to the rear axle.

•

14. Using a suitable transmission jack, support the rear axle. 15. Remove the rear axle retaining bolts and remove the rear axle (left-hand side shown, right-hand side similar Note: Recover the securing plates.

•

TV040060

N13–05–11

DRIVETRAIN AND BRAKES Installation 1. To install, reverse the removal procedure. Tighten to 260Nm (192 lb.ft).

TV040060

2. Bleed the brakes. For additional information, refer to Section N13-01 BRAKE BLEEDING (POWER BRAKES), PAGE N13–01–153 . 3. Check and adjust the hydraulic oil level as required.

N13–05–12

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — STEERING CYLINDER (FOUR-WHEEL STEER) Operation: Removing and Installing the Steering Cylinder (Four-Wheel Steer) None

BHN1305RC

Job Code: 13 53 13 xx Standard tools, Suitable slide hammer

Removal 1. Remove the rear axle. For additional information, refer to REAR AXLE, PAGE N13–05–9 in this section. 2. Disconnect the inner tie rods from the rear axle steering ram cylinder.

TV040612

3. Remove the rear axle steering ram retaining bolts

TV040613

4. Using a suitable slide hammer, remove the rear axle steering ram retaining sleeves (1) and remove the steering ram (2).

1 1 2

TV040614

Installation 1. To install, reverse the removal procedure.

N13–05–13

DRIVETRAIN AND BRAKES 2. Tighten to 300Nm (221 lb.ft).

TV040612

3. Tighten to 660Nm (487 lb.ft).

TV040613

N13–05–14

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — PARKING BRAKE CALIPER (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Parking Brake Caliper (Four-Wheel Steer) None

BHN1305DA

Job Code: 13 07 17 xx Standard tools

19

4

3 18

23 21

22

2 19 20

6

3

1 9 10 11 12 13 5 20 7 8 9 7 14 15 16 17

TV040817

N13–05–15

18

DRIVETRAIN AND BRAKES 1

Front Torque Plate

2

Rear Torque Plate

3

Spacer

4

Adjustment Bolt

5

Brake Friction Pads

6

Spring Clip

7

Outer Cam

8

Inner Cam

9

Ball

10

Seal

11

Boot

12

Lever

13

Thrust Washer

14

Stainless Steel Washer

15

Hardened Washer

16

Adjustment Nut

17

Locking Nut

18

Mounting Bolt

19

Locking Nut

20

Sleeve Seal

21

Bolt

22

Lock Washer

23

Cable Retaining Bracket

N13–05–16

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP (FOUR WHEEL-STEER) Operation: Disassembly and Assembly of the Epicyclic Reduction Gear Group (Four-Wheel Steer) None

BHN1305DB

Job Code: 13 16 17 xx Standard tools Suitable container

4

14

13

1 11

7 5

12 10 9 8

2 6

3 TV041093

1

Planetary Carrier

2

Drain Plug

3

Retaining Screw

4

O-Ring

5

Thrust Washer

6

Needle Roller Bearings

7

Thrust Washer

8

Needle Roller Bearings

9

Epicyclic Gear

10

Washer

11

Dowel Pin

12

Washer

13

Retaining Bolt

Disassembly 1. Remove the wheel. For additional information, refer to M12-01 REAR WHEEL, PAGE M12–01–5 .

N13–05–17

DRIVETRAIN AND BRAKES 2. Drain the hub oil. For additional information, refer to L11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67 3. Remove the epicyclic reduction gear carrier. Note: • Remove and discard the O-ring oil seal.

TV040763

4. Remove the epicyclic gear retaining bolt (1) and washer (2).

TV040764

5. Remove the locating washer (1) and the epicyclic gear (2). Note: • Recover both sets of needle roller bearings and the needle roller bearings spacers.

TV040767

6. Remove the locating pin (1) and the wear washer (2). 7. Repeat steps 5, 6 and 7 to remove the remaining epicyclic gears.

N13–05–18

DRIVETRAIN AND BRAKES 8. Inspect the pinion pins, if they are in poor condition a new epicyclic reduction gear carrier assembly should be installed.

TV040768

9. If the half-shaft stop (1) is worn, a new epicyclic reduction gear carrier assembly should be installed.

TV040770

Assembly 1. Install the wear washer (2) and the locating pin (1).

TV040768

2. Install the epicyclic gear (1) and the first set of needle roller bearings (2).

TV040803

N13–05–19

DRIVETRAIN AND BRAKES 3. Install the needle roller bearings spacer.

TV040804

4. Install the second set of needle roller bearings. 5. Repeat steps 1 to 4 to install the remaining epicyclic gears.

TV040805

6. Install the washer (2) and epicyclic gear retaining bolt (1). 7. Tighten (1) to 79Nm (58 lb.ft).

TV040764

Note: • Install a new O-ring oil seal. 8. Install the epicyclic reduction gear carrier. 9. Tighten to 25Nm (18 lb.ft). 10. Fill the hub with oil. For additional information, refer toL11-02 DRAINING AND FILLING THE HUB OIL, PAGE L11–02–67

N13–05–20

DRIVETRAIN AND BRAKES 11. Install the rear wheel. For additional information, refer toM12-01 REAR WHEEL, PAGE M12–01–5

TV040763

N13–05–21

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–05–22

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — REAR WHEEL HUB GROUP (FOUR-WHEEL STEER) Operation: Disassembly and Assembly of the Wheel Hub Group (Four-Wheel Steer)

BHN1305DC

Job Code: 13 19 17 xx

Suitable lifting equipment

Standard tools, Ball joint separator, Ca715026, Ca715027, Ca119143

28 19 18 14

25

13 12 11

27

10

26 23

24

8 7 15

22 21

4 3

16

1 17 9 6 2

5

TV041091

N13–05–23

20

DRIVETRAIN AND BRAKES 1

Lock Ring

2

Universal-Joint Shaft Washer

3

Universal-Joint Shaft Washer

4

Epicylic Ring Gear

5

Retaining Bolt

6

Centre Bushes

7

Epicylic Hub

8

Steel Lock Ring

9

Tapper Roller Bearing

10

Stud

11

Wheel Hub

12

Tapper Roller Bearing

13

Oil Seal

14

Swivel Housing

15

Cone

16

Lower Kingpin

17

Retaining Bolt

18

Upper Kingpin

19

Retaining Bolt

20

Bush

21

Lock Nut

22

Steering Angle Adjustment Bolt

23

Bush

24

Oil seal

25

Universal-Joint Shaft End

26

Belleville washers

27

Axle

28

Belleville Washers

Disassembly 1. Remove the rear wheels. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 . 2. Remove the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section. 3. Remove the epicyclic group circlip and spacers (1). 4. Remove the epicyclic group retaining bolts (2).

TV040199

N13–05–24

DRIVETRAIN AND BRAKES 5. Using 2 wheel carrier retaining bolts, extract the epicyclic ring gear.

TV040200

6. Remove the snap ring (1) and remove the epicyclic gear hub (2) from the epicyclic ring gear (3).

1

2

3 TV040771

7. Using a suitable soft faced hammer, remove the rear axle hub (1) and the outer roller bearing (2).

1

2

TV040772

8. Using a suitable lever, remove and discard the hub oil seal (1). 9. Remove the outer taper roller bearing and cones (2).

2

1

TV040849

N13–05–25

DRIVETRAIN AND BRAKES 10. Remove the retaining nut and using a suitable ball joint splitter, detach the tie rod end from the hub carrier.

TV040202

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

11. Using suitable lifting equipment support the rear hub carrier. 12. Remove the rear hub carrier.

1 1

2 TV040203

13. Remove the swivel thrust washers.

TV040854

14. Position the swivel hub on a suitable flat surface. and remove the seal ring with a lever.

N13–05–26

2

DRIVETRAIN AND BRAKES 15. Using a suitable lever, remove the oil seal. Note: • Discard the oil seal.

TV040851

16. Using a suitable drift, remove the swivel housing bush.

TV040852

Assembly 1. Install the swivel thrust washers.

TV040854

2. Using the special tool CA119117 — Driver for oil seal , install the oil seal.

TV040853

3. Install the rear hub carrier.

N13–05–27

DRIVETRAIN AND BRAKES 4. Tighten to 300Nm (221 lb.ft).

1 1

2 TV040203

5. Using a suitable hydraulic press and the special tool CA715026 — Driver for bearing race , install the inner and outer taper roller bearing cones.

TV040925

Note: • Lubricate the oil seal with a light grease. 6. Using the special tool CA119087 — Driver for oil seal , install a new hub seal.

TV040926

7. Install the inner taper roller bearing.

TV040773

8. Install the rear axle hub (1) .

N13–05–28

2

DRIVETRAIN AND BRAKES 9. Install the outer taper roller bearing (2).

1

2

TV040772

10. Install the epicyclic hub (2) to the epicyclic ring gear (3) and install the snap ring (1).

1

2

3 TV040771

Note: • Install two bushes slightly higher that the hub surface level to be used as dowel pins. 11. Using the special tool CA715027 — Driver for bush partially install the hub centering bushes.

TV040930

12. Assemble the epicyclic group on the wheel hub using the two protruding centering bushes as dowel pins.

TV040200

N13–05–29

DRIVETRAIN AND BRAKES 13. Using the special tool CA715027 — Driver for bush , fully install the remaining centering bushes.

TV040931

14. Install the epicyclic group retaining bolts and tighten to 230Nm (170 lb.ft)..

TV040769

15. Install the epicyclic reduction hub. For additional information, refer to EPICYCLIC REDUCTION GEAR GROUP, PAGE N13–04–15 in this section. 16. Install the rear wheels. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 .

N13–05–30

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — AXLE BEAM TRUMPETS AND BRAKE GROUP (FOUR-WHEEL STEER)

BHN1305DD

Job Code: 13 18 17 xx

Operation: Disassembly and Assembly of the Axle Beam Trumpets and Brake Group (Four-Wheel Steer) Suitable lifting equipment

Standard tools, CA715386, CA715387 CA715034 CA715505

1 2 3 5

6 7

8

10

12 13

4

14 9 11

TV041107

1

Central Body

2

Grub Screw

3

Auger

4

O-Ring

5

O-Ring

6

Greaser

7

Special Screw

8

Axle Beam Trumpet

9

Retaining Bolts

10

Upper King Pin Bush

11

Ball Bearing Cup

12

Bush

13

Sealing Rings

14

Universal Joint

N13–05–31

DRIVETRAIN AND BRAKES Disassembly 1. Remove the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section. 2. Drain the axle oil into a suitable container. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section. 3. Remove the parking brake caliper.

TV040774

4. Using suitable circlip pliers remove the parking brake disc.

TV040924

5. Mark the rear axle housing prior to disassembly to aid installation.

TV040779

N13–05–32

DRIVETRAIN AND BRAKES

•

Warning: Support the half shaft housing. Failure to follow this instruction may result in personal injury.

6. Remove the axle beam trumpet retaining bolts and remove the axle beam trumpet housing (both sides). Note: • Remove and discard the O-ring.

TV040782

7. Loosen the grub screw (1), and remove the auger (2) from the double universal joint (3) (both sides).

1 3

2

TV041108

8. Remove the two double universal joints from the axle beam trumpets (both sides).

TV040861

9. Remove the oil seal (2) from the axle housing (both sides). Note: • Discard the oil seal rings.

N13–05–33

DRIVETRAIN AND BRAKES

•

Warning: Be careful not to damage the bush housing.

10. Remove the bushes (1) from the axle beam trumpet housing (both sides). 11. Using a suitable extractor remove the upper king pin bush (3) and the ball bearing cup (4) from the king pin housings (both sides).

3

1

4 2 TV040862

Note: • Check that the friction discs and the fixed discs do not show any sign of burning. If damage is found new components should be installed. 12. 13. 14. 15. 16. 17.

Remove the 5 mm fixed steel disc (1). Remove the outer friction disc (2). Remove the brake hub (3). Remove the 11 mm fixed steel disc (4). Remove the inner friction disc (5). Remove the piston pressure disc (6).

5 3 1 6 4 2 TV040785

18. Remove the self-adjust retaining bolts (1) and (2). Note: Recover the self-adjust components.

•

N13–05–34

DRIVETRAIN AND BRAKES 19. Remove the brake piston (3). Note: • Remove and discard the brake piston O-ring seals.

TV040788

20. Repeat steps 6 to 20 to remove the remaining half shaft housing.

N13–05–35

DRIVETRAIN AND BRAKES Assembly 1. Install the self-adjust bushings into the brake flange until level with the piston inner surface.

TV040827

Note: • Lubricate the brake piston oil seals with a light grease. 2. Install new outer (1) and inner (2) oil seals to the brake piston.

2 1

TV040828

Note: • Lubricate the brake piston oil seals with a light grease. 3. Install the brake piston (3). 4. Install the brake piston self-adjust retaining bolt assemblies (1) and (2). 5. Tighten to 10Nm (7 lb.ft).

1

3 2 TV040830

Note: • If new friction discs are installed, they should be soaked in suitable oil before assembling, 6. Install the piston pressure disc (6). 7. Install the inner friction disc (5).

N13–05–36

DRIVETRAIN AND BRAKES Note: • Install the fixed steel disc with the lip towards the piston. 8. Install the 11 mm fixed steel disc (4). 9. Install the brake hub (3). 10. Install the outer friction disc (2). 11. Install the 5 mm fixed steel disc (1).

5 3 1 6 4 2 TV040785

12. Remove the two brake housing retaining bolts.

TV041086

Note: • Install new oil seals. 13. Using the special tool CA715034 , install the king pin bush (3) in the axle housing (both sides). 14. Using the special tool CA715034 , install the ball bearing cup (4) in the axle housing (both sides). 15. Using the special tool CA715505 , install the bush (1) and the oil seal (2).

3

1

4 2 TV040862

N13–05–37

DRIVETRAIN AND BRAKES 16. Install the bush (1) and the oil seal (2) as shown.

1

2

TV040866

17. Install the two double Universal-Joints into the axle beam trumpet housing (both sides).

TV040861

18. Install the auger (2) onto the double universal joint (3) tighten the grub screw (1) (both sides).

1 3

2

TV041108

•

Warning: Support the half shaft housing. Failure to follow this instruction may result in personal injury.

Note: Install a new half shaft housing O-ring.

•

19. Install the half shaft housing.

N13–05–38

DRIVETRAIN AND BRAKES 20. Tighten to 130Nm (96 lb.ft).

TV040782

21. Using the special tool CA715386 — Driver for bush , install the half shaft housing bushing (2). 22. Using suitable circlip pliers Install the parking brake disc.

TV040924

23. Install the parking brake caliper.

TV040774

24. Tighten to 150Nm (111 lb.ft). 25. Fill the axle with oil. For further information refer to DRAINING AND FILLING AXLE HOUSING OIL in this section.

N13–05–39

DRIVETRAIN AND BRAKES 26. Install the wheel hub group. For additional information, refer to WHEEL HUB GROUP, PAGE N13–04–19 in this section.

TV040774

N13–05–40

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP (FOUR-WHEEL STEER)

BHN1305DE

Operation: Disassembly and Assembly of the Differential Group (Four-Wheel Steer)

Job Code: 13 14 17 xx

None

Standard tools, CA715133

7 5

23 3 18

3 2

22 21

17 6

1

16

4

12

13 19

11

20

10 9

15

8

14 2

TV041109

N13–05–41

DRIVETRAIN AND BRAKES 1

Bush

2

Half Boxes

3

Half Boxes

4

Dowel Pin

5

Bevel Crown Gear

6

Bush

7

Retaining Bolt

8

Bearing Cone

9

Lock Ring

10

Sleeve

11

Pins

12

Differential Housing

13

Thrust Plate

14

Sun Gear

15

Planetary Shaft

16

Planetary Shaft

17

Planetary Gear

18

Thrust Washer

19

Planetary Gear

20

Thrust Washer

21

Sun Gear

22

Thrust Washer

23

Bearing Cone

Disassembly 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Position the differential in a suitable vice. 3. Remove the sleeve (10), and pins (11) from the differential housing.

TV041110

N13–05–42

DRIVETRAIN AND BRAKES Note: • Mark the differential carrier disassembly to aid installation.

prior

to

4. Remove the crown wheel.

TV040796

5. Remove the thrust plate (1) and sun gear (2).

TV040797

6. Remove the planetary shafts (1) and the planetary gears (2). Note: • Recover the thrust washers (3).

2 3

1 TV040798

7. Remove the sun gear (1) and thrust plate (2).

TV040799

N13–05–43

2

DRIVETRAIN AND BRAKES 8. Remove the snap ring (1). 9. Using a suitable puller, remove the right-hand side taper roller bearing.

TV040801

10. Using a suitable puller, remove the left-hand side taper roller bearing (1) and the crown wheel (2).

TV040802

N13–05–44

DRIVETRAIN AND BRAKES Assembly 1. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the left-hand side differential taper roller bearing (1) and the crown wheel assembly (2).

TV040802

2. Using a suitable hydraulic press and the special tool CA715133 — Driver for bearing , install the right hand side differential taper roller bearing.

TV040801

3. Install new O-ring seals and install the differential locking pins. 4. Install the differential lock selector (2). 5. Install the snap ring (1).

TV040800

N13–05–45

DRIVETRAIN AND BRAKES 6. Install the thrust washer (2) and the sun gear (1).

TV040799

7. Install the Planetary shafts (1), planetary gears (2) and the trust washers (3).

2 3

1 TV040798

8. Install the sun gear (2) and the thrust washer (1).

TV040797

9. Install the pins (11), and sleeve (10) into the differential housing.

TV041110

10. Install the crown wheel.

N13–05–46

2

DRIVETRAIN AND BRAKES Note: • Before installing the crown wheel retaining bolts, apply approved sealant (Loctite 270) to the bolt. 11. Tighten to 155Nm (114 lb.ft). 12. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

TV040796

N13–05–47

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–05–48

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — PINION GROUP (FOUR-WHEEL STEER)

BHN1305DF

Operation: Disassembly and Assembly of the Pinion Group (Four-Wheel Steer) None

Job Code: 13 20 17 xx Standard tools, CA119099, CA715022, CA715380, CA715128, CA715388, CA715004, Suitable measuring device

10 9 8 7 6 5

3

4

2 1 TV041096

1

Bevel Pinion

2

Shim

3

Bearing Cone

4

Washer

5

Collapsible Spacer

6

Washer

7

Central Body

8

Bearing

9

Ring Nut Washer

10

Ring Nut

N13–05–49

DRIVETRAIN AND BRAKES Disassembly 1. Disassemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section. 2. Remove the parking brake caliper mounting bracket.

TV040810

3. Remove and discard the pinion sealing ring from the differential housing.

TV040807

4. Remove the O-ring (1) and the spacer (2).

2 1

TV040806

N13–05–50

DRIVETRAIN AND BRAKES

•

Caution: Release the pinion shaft retaining nut locking tabs. Failure to follow this instruction may result in damage to the machine.

5. Using the special tools CA119099 — Wrench for lock nut and CA715022 — Pinion shaft lock tool , remove the pinion shaft retaining nut. Note: • Recover the lock washer.

TV041097

6. Using a suitable soft faced hammer, remove the pinion shaft from the differential housing. Note: • Recover the outer taper roller bearing, two washers and discard the elastic spacer.

TV040814

7. Using a suitable puller, remove the taper roller bearing from the pinion shaft. Note: • Recover the pinion end float adjustment shim.

TV040927

N13–05–51

DRIVETRAIN AND BRAKES 8. Using a suitable drift, remove the pinion shaft taper roller bearing cups from the differential housing.

TV040816

N13–05–52

DRIVETRAIN AND BRAKES Assembly 1. Using the special tool CA715380 — Bearing races insertion kit install the taper roller bearing cups into the differential housing.

TV040818

2. Install the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

•

Caution: Do not overtighten.

3. Install the lock washer (1) and the pinion shaft retaining nut (2) 4. Tighten until the free play is eliminated.

TV040928

5. Install the brake left-hand side brake housing with three retaining bolts 120° apart. 6. Tighten to 79Nm.

N13–05–53

DRIVETRAIN AND BRAKES 7. Repeat steps 5 and 6 for the right-hand side brake housing.

TV041081

Note: • Ensure the false differential box is inserted in both brake housings. 8. Install the special tool CA715388 — false differential box into the differential housing.

TV040820

B A

X

C

9. Using a suitable depth gauge, measure through the false pinion (CA715128) This measurement is “A” . 10. Determine the value “X” as follows: X = (conical distance to be measured) A = (measured value) B = 100mm C = 50mm X = (A + C) — B Example: A = 159.9mm therefore: X = (159.9 + 50) – 100mm X = 109.9mm

TV040821

N13–05–54

DRIVETRAIN AND BRAKES 11. Determine the pinion shaft position adjustment shim “S” as follows: subtract the value “V” (requested conical distance) from the calculated value “X” . S=X—V Example: Shim thickness S = 109.9 – 107.00 = 2.9mm. Shim thickness “S” = 2.9mm

107.00 00

V

TV040811

SHIM RANGE mm

2.5

2.6

2.7

2.8

2.9

3.0

12. Remove the special tool CA715388 — false differential box from the differential housing.

TV040820

13. Remove the brake housing (both sides).

TV041081

N13–05–55

3.1

3.2

3.3

3.4

DRIVETRAIN AND BRAKES 14. Remove the special tool CA715128 — False pinion with the pinion shaft taper roller bearings.

TV040819

15. Install the pinion shaft adjustment shim (1) with chamfer against the gear. 16. Using a suitable hydraulic press and the special tool CA715004 — Driver for bearing install the rear taper roller bearing (2).

2 1

TV040823

Note: • Always use a new elastic spacer. 17. Install the washers and the new elastic spacer onto the pinion shaft. 18. Install the pinion shaft assembly (1) and the front taper roller bearing (2) into the differential housing.

1

2

TV040824

19. Install a new lock washer (1).

N13–05–56

DRIVETRAIN AND BRAKES Note: • Do not tighten at this stage. 20. Install a new pinion shaft retaining nut (2).

TV040928

21. Install the special tool CA715116 — Measurement onto the pinion shaft. Note: Using a suitable soft faced hammer, settle the pinion shaft bearings.

•

22. Using a suitable measuring device (with the cord wound on the 34.87 mm diameter of the special tool CA715116 — measurement ), measure the pinion shaft rotational torque. 23. The rotational torque should be within the following range excluding breakaway torque. 9.2 to 13.7 daN

TV040825

•

Caution: If the stated rotational torque range is exceeded the elastic spacer must be replaced and the procedure repeated

24. The adjustment is carried out by increasing the pinion shaft retaining nut torque setting gradually, being careful not to exceed the stated range. 25. Once the correct rotational torque is achieved, secure the pinion shaft retaining nut.

N13–05–57

DRIVETRAIN AND BRAKES 26. Assemble the differential housing group. For additional information, refer to DIFFERENTIAL HOUSING GROUP, PAGE N13–04–51 in this section.

TV041097

N13–05–58

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — TOE-IN ADJUSTMENT (FOUR-WHEEL STEER) Operation: General Procedure Toe-in Adjustment (Four-Wheel Steer) None

BHN1305GA

Job Code: 13 23 01 xx Standard tools, Two one-metre-long bars

General Procedure The toe-in of the rear wheels must be within ± 3mm toe-in as measured 500mm from the centre of the wheel hub. To check the exact value of the toe-in setting, proceed as follows. 1. Remove the rear wheels. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–3 . Note: • The bars must be fixed flat against the wheel hub flange and have an equal distance from the centre of the wheel hub. 2. Install two equal one-metre-long bars to the wheel side of the wheel hubs and lock in place with two wheel retaining nuts.

500mm

500mm

TV040979

3. Measure the distance (A) between the ends of the two bars. 4. Measure the distance (B) between the ends of the two bars. 5. The distance (A) must be within ± 3mm of distance (B).

A

B TV040980

N13–05–59

DRIVETRAIN AND BRAKES Note: • Make sure the same number of threads are visible at the end of the left-hand and right-hand inner track rod end ball joints. 6. If it is necessary to correct the toe-in adjustment. Loosen the lock nut (1) on the left-hand and the right-hand side. Turn the inner track rod end ball joints (2) equally to achieve the specified toe-in adjustment. 7. Tighten (1) to 120Nm (86 lb. ft).

1

2

TV040981

N13–05–60

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL (FOUR-WHEEL STEER) Operation: Draining and filling the rear axle housing oil (Four-Wheel Steer) Suitable Container

Job Code: 13 18 09 xx Standard tools

Draining 1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Loosen the filler/level plug to release any pressure.

TV040945

3. Remove the drain plug and drain the oil into a suitable container.

TV040944

Filling 1. Install the drain plug and tighten to 60Nm (44 lb.ft)..

TV040944

N13–05–61

BHN1305GB

DRIVETRAIN AND BRAKES 2. Fill with oil until the filler/level hole level is reached.

TV040952

3. Install the filler/level plug and tighten to 60Nm.

TV040945

N13–05–62

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL (FOUR-WHEEL STEER) Draining 1. Remove rear the wheel. For additional information, refer to M12-01 REAR WHEEL, PAGE M12–01–5 . 2. Rotate the hub until the drain/filler plug is positioned at the top. Loosen the drain/filler plug to release any pressure. 3. Rotate the hub until the drain/filler plug is positioned at the bottom. Remove the drain/filler plug and drain the hub oil into a suitable container.

TV040197

Filling 1. Rotate the hub until the drain/filler plug is at the 3 o’clock position. Fill with oil until the drain/filler hole level is reached. 2. Install the drain/filler plug and tighten to 60Nm (44 lb.ft). 3. Install the rear wheel. For additional information, refer to M12-01 REAR WHEEL, PAGE M12–01–5 .

TV040934

N13–05–63

BHN1305GC

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–05–64

DRIVETRAIN AND BRAKES SPECIFICATIONS — FOUR-WHEEL STEER REAR AXLE

BHN1305SA

Special Tools Tool No.

Description

CA119033

Interchangeable Handle

CA119087

Driver for Oil Seal

CA119099

Wrench for Lock Nut

CA715004

Driver for Bearing

CA715022

Pinion Shaft Lock Wrench

CA715026

Driver for Bearing Race

CA715027

Driver for Bush

CA715056

Driver for Oil Seal

CA715116

Extension for Pre-load Measurement

CA715128

False Pinion

CA715133

Driver for Bearing

CA715146

Kit for Backlash Measurement

CA715156

Driver for Oil Seal

CA715265

Wrench for Differential Housing Lock Nut

CA715386

Driver for Bush

CA715387

Driver for Oil Seal

CA715388

False Differential

CA715391

Driver for Bearing Race

General Specifications Description

Value

Input rotation 4 wheel steer rear axle

Counter — clockwise

Dry Weight

539

Steering Angle

33° 0–2mm

Toe-in

A ±1

Bevel Gear Ratio

2.5/1

Epicyclic Reduction Gear Ratio

6.923/1

Total Ratio

17.307/1

Input Rotation

Clockwise (C.W)

Bevel Gear Set Backlash

0.20÷0.28mm

Differential Backlash

0.20 — 0.30 daN

Pinion Bearings Preloading (measured on D=34.8mm without seals

“P” = 9.22÷13.83 daN

Total Pinion-ring Gear Bearing Preloading (measured on D=34.8mm without seals)

T=(P+1.84)÷(P+2.77) daN

Brake Activation Oil

Mineral Oil

Brake Activation Oil Displacement

12 + 12cc

Max. Operating Pressure

43 bar

N13–05–65

DRIVETRAIN AND BRAKES Capacity System Rear Axle

Temperatures ALL

Viscocity 80W

Specification API GL4 M1135

Capacity

Notes

14.5 + 1.5 + 1.5

Approved oils: Agip Rotra Multi THT, Esso Torque Fluid 62, Mobil Fluid 422 or 424

Torque Values Description

Nm

Lb.ft

Epicyclic Gear

79

58

Wheel Hub

230

170

Hub Drain Plug

60

44

Wheel Studs

70

52

Epicyclic Reduction Hub

25

18

Brake Housing

79

58

Crown Wheel

155

114

Differential Adjustment Nut Locking Tabs

13

10

Half shaft Housing

130

96

Parking Brake Caliper Mounting Bracket

80

59

Parking Brake Caliper

150

111

Parking Brake Caliper Cable Bracket

45

33

Brake Self Adjust Bolts

10

7

Differential Lock Actuator

27.6

20

Differential Lock Cover

27.6

20

Brake Bleed Valve

10

7

Breather Union

15

11

Breather

10

7

Blanking Plug

25

18

N13–05–66

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION – CARRARO

BHN1306OA

Schematic View Synchroshift Transmission – Carraro 1

2

3

4

5

6

7

8

9

20 10

19

11

18 12 17

16

15

TV051272

N13–06–1

14

13

DRIVETRAIN AND BRAKES 1

Transmission Oil Pump

2

Reverse Gear Drive

3

Reverse Idler Gear Driven

4

Reverse Clutch Pack

5

Forward Clutch Pack

6

Reverse Idler Gear Drive

7

Forward Gear Drive

8

Fourth Speed Gear Driven

9

Third Speed Gear Driven

10

Output Flange

11

Third/Fourth Speed Synchroniser

12

Third Speed Gear Drive

13

Fourth Speed Gear Drive

14

Four Wheel Drive (4WD) Gear Drive

15

4WD Clutch

16

4WD Output Flange

17

First Speed Gear Drive

18

Second Speed Gear Drive

19

First/Second Speed Synchroniser

20

Second Speed Gear Driven

N13–06–2

DRIVETRAIN AND BRAKES

N13–06–3

22 TV051274

28

29

30

1

27

2

26

3

25

4

5

24

23

6

21

7

20

19

8

18

9

17

10

16

11

15

14

13

12

Transmission Hydraulic Circuit

DRIVETRAIN AND BRAKES 1

Torque Converter Pressure Relief Valve

2

Hydraulic Differential Lock Solenoid Valve

3

Pressure Regulator

4

Torque Converter Pressure Check Port

5

Torque Converter

6

Forward/Reverse Modulating Valve

7

Oil Cooler

8

Oil Cooler Back Temperature Thermostat Port

9

Forward Clutch Pressure Check Port

10

Oil Cooler Back Shaft Lubrication Pressure Check Port

11

Forward Clutch

12

Forward/Reverse Selection Valve

13

Reverse Clutch

14

1st, 2nd, 3rd, 4th Gear Shaft Lubrication

15

Transmission Sump

16

Forward/Reverse Shaft Lubrication

17

Reverse Clutch Pressure Check Port

18

Brake Oil Port Return To Sump

19

Modulation Relief Valve

20

Forward/Reverse Main Pressure Check Port

21

Oil Flow Divider/Pressure Regulator Valve

22

Oil Outlet Port To Brake

23

Transmission Oil Pump

24

Suction Filter

25

Spin-On Delivery Filter

26

Oil Filter Relief Valve

27

Four Wheel Drive (4WD) Engagement/Disengagement(Easy-Shift)

28

4WD Disengagement Solenoid Valve

29

4WD Pressure Check Port

30

Hydraulic Differential Lock Engagement/Disengagement

N13–06–4

DRIVETRAIN AND BRAKES Shaft Location

TV051273

N13–06–5

DRIVETRAIN AND BRAKES 1

Shaft A — Input Shaft

2

Shaft D — Reverse Idler Shaft

3

Shaft B — Idler Shaft

4

Shaft C — Primary Shaft

5

Shaft E — Four Wheel Drive (4WD) Shaft

N13–06–6

DRIVETRAIN AND BRAKES Component Location

2

7

6

23

24

9

16 8 11

13 TV051270

N13–06–7

12

DRIVETRAIN AND BRAKES 1

Not Shown, Spin-On Filter Oil Delivery Attachment

2

Oil Pump Assembly: max pressure 16 bar

3

Not Shown, Forward Shift Solenoid Valve 28W-12V D.C.

4

Not Shown, Reverse Shift Solenoid Valve 28W-12V D.C.

5

Not Shown, 4WD Shift Solenoid Valve 28W-12V D.C.

6

Breather Plug

7

Speed Shift Lever

8

Oil Inlet Port From Cooler

9

Oil Outlet port to Cooler

10

Not Shown, Transmission Oil Thermostat

11

SAE 3 Torque Converter Bell Housing

12

Suction Filter

13

Magnetic Oil Drain Plug (SW 1/2”)

14

Not Shown, Dipstick Fitting Hole

15

Not Shown, Lifting Attachment Eyebolt Holes

16

4th Gear Lock Out

17

Not Shown, Oil Cooler Back Pressure Check Port (0.5–3.5 bar on FWD/RVS clutch position and 0.5–5 bar on NEUTRAL clutch position

18

Not Shown, FWD Clutch Pressure Check Port (11.0–13.0 bar) max pressure in NEUTRAL (0.3 bar)

19

Not Shown, RVS Clutch Pressure Check Port (11.0–13.0 bar) max pressure in NEUTRAL (0.3 bar)

20

Not Shown, FWD/RVS Clutch Pressure Check Port (11.0–13.0 bar) max pressure in neutral (0.3 bar)

21

Not Shown, Four–Wheel Drive (4WD) Clutch Pressure Check Port at 900 RPM (13.0–14.0 bar) at 2200 RPM (13.0–15.5 bar)

22

Not Shown, Torque Converter Pressure Check Port (0.5–9.0 bar)

23

Oil Outlet Port To Brake

24

Spin-On Filter Oil Return Attachment

25

Not Shown, Hydraulic Differential Lock Supply Port

26

Not Shown, Hydraulic Differential Lock Valve

27

Not Shown, Oil Inlet Port From Brake

N13–06–8

DRIVETRAIN AND BRAKES

1

27

19

4

15

3

14

22

20

18

19

18

25

17

10

26

15

5

TV051268

N13–06–9

21

DRIVETRAIN AND BRAKES 1

Spin-On Filter Oil Delivery Attachment

2

Not Shown, Oil Pump Assembly: max pressure 16 bar

3

Forward Shift Solenoid Valve 28W-12V D.C.

4

Reverse Shift Solenoid Valve 28W-12V D.C.

5

4WD Shift Solenoid Valve 28W-12V D.C.

6

Not Shown, Breather Plug

7

Not Shown, Speed Shift Lever

8

Not Shown, Oil Inlet Port From Cooler

9

Not Shown, Oil Outlet port to Cooler

10

Transmission Oil Thermostat

11

Not Shown, SAE 3 Torque Converter Bell Housing

12

Not Shown, Suction Filter

13

Not Shown, Magnetic Oil Drain Plug (SW 1/2”)

14

Dipstick Fitting Hole

15

Lifting Attachment Eyebolt Holes

16

Not Shown, 4th Gear Lock Out

17

Oil Cooler Back Pressure Check Port (0.5–3.5 bar on FWD/RVS clutch position and 0.5–5 bar on NEUTRAL clutch position

18

FWD Clutch Pressure Check Port (11.0–13.0 bar) max pressure in NEUTRAL (0.3 bar)

19

RVS Clutch Pressure Check Port (11.0–13.0 bar) max pressure in NEUTRAL (0.3 bar)

20

FWD/RVS Clutch Pressure Check Port (11.0–13.0 bar) max pressure in neutral (0.3 bar)

21

Four–Wheel Drive (4WD) Clutch Pressure Check Port at 900 RPM (13.0–14.0 bar) at 2200 RPM (13.0–15.5 bar)

22

Torque Converter Pressure Check Port (0.5–9.0 bar)

23

Not Shown, Oil Outlet Port To Brake

24

Not Shown, Spin-On Filter Oil Return Attachment

25

Hydraulic Differential Lock Supply Port

26

Hydraulic Differential Lock Valve

27

Oil Inlet Port From Brake

N13–06–10

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO

•

Caution: All checks and tests must be performed with the oil at working temperature: 80 °C ±2.

Stall test In order to create ideal conditions for troubleshooting, the converter stall procedure must be performed first. The purpose of this test is to determine whether the torque converter and hydraulic clutch units are operating correctly. This operation will also bring the oil up to its working temperature of 80°C ±2, allowing any problems in the engine, converter or transmission to be identified. Proceed as follows: • Check the oil level. • Activate the parking brake to lock the wheels. • Start the engine and keep it ticking over at idle speed (800 — 1000 [rpm]). • Put the gear lever into 4th. • Put the forward/reverse lever in the FORWARD position. • Increase the engine speed for short periods to a maximum of 1500 — 1700 [rpm], to bring the oil up to working temperature.

•

• •

Caution: The converter stall test must not exceed a maximum duration of 30 seconds each time. After this 30 second period, put the forward/reverse lever in NEUTRAL for 15 seconds, then repeat the procedure. Failure to keep to these test periods may result in the oil overheating and attendant damage to the clutches, filter, converter and seals.

BHN1306TA

Mechanical problems Check that all of the transmission’s internal and external mechanical parts are correctly fitted (see disassembly and assembly chapters). • Check the efficiency of the parking brake. • Check that the cooling system is in good operating condition. • Check the efficiency of the engine. Make sure that the engine’s idling speed is set correctly and that it complies with the maximum speed specifications under loadless conditions. Hydraulic problems • Check the transmission oil level • Use the specified transmission oil • Check that the hydraulic system is correctly filled. • Check the efficiency of the hydraulic system. Check for oil leaks. • Check the efficiency of the transmission’s hydraulic components (converter, oil pump, filter, connections, hoses). Pressure check Several transmission breakdowns can be identified by running pressure checks. Irregular measurements might indicate that there is a problem. For test port locations refer to PRESSURE TESTING in this section. Electrical problems • Check the efficiency and correct installation of the vehicle battery. • Check the efficiency and correct installation of all electrical components outside the transmission (wiring, cables, alternator, battery, etc.). • Check the efficiency and correct installation of all transmission electrical components (wiring, sensors, solenoid valves, EGM/ECU, etc.)

•

Gradually reduce the engine speed to minimum. Put the forward/reverse lever in NEUTRAL.

N13–06–11

DRIVETRAIN AND BRAKES Troubleshooting This list of possible failures and remedies provides no more than an indication of what the problem might be and how to fix it. It should be remembered that problems are not caused by just one part, but by that part’s interaction with other elements; accordingly, additional action over and above the steps described is frequently required. This list may not cover all possible problems and remedies. Problem Vehicle does not move

Vehicle has reduced power transmission

Cause

Action

• •

Faulty supply to solenoid valves

• • • • • • • • • • • • • •

Oxidised contacts in electrical wiring

• • • • •

Damaged rotary seals

•

Incorrect oil temperature

•

Wait for oil to reach working temperature (stall test)

•

Transmission oil overheating

•

Restore acceptable temperature values

•

Incorrect operating pressure

•

Check hydraulic circuit and replace (oil pump, filters, control valve)

• • • •

Damaged converter

• • • •

Replace

• •

Overheating solenoids

• •

Replace

•

Damaged sensors

•

Replace

Damaged wiring connections between transmission and vehicle Break in electric cable Damaged solenoids Damaged sensors Short circuits or false contacts Incorrect oil level Check for leaks Blocked intake filter Damaged oil pump Damaged oil pump relief valve Blocked/damaged transmission filter Damaged/jammed control valve Damaged converter Oil temperature below 0°C

• •

Check/Replace

• • • • • • • • • • • • • •

Clean

• Damaged synchronisers • Blocked reverser lever • Worn clutch unit • No drive transmission (broken gears, shafts, •

Repair/Replace

Replace Replace Replace Check/replace fuses Top up Repair/Top up Clean Replace Replace oil pump Replace Replace Replace Wait for oil to reach working temperature (stall test) Replace Replace Repair Replace/Repair clutch unit Check/Repair/Replace

bearings, etc.)

Incorrect oil level Worn clutch unit 4WD clutch failure

Damaged transmission and vehicle wiring connections

N13–06–12

Top up Replace/Repair Repair/Replace 4WD shaft group Repair/Replace

DRIVETRAIN AND BRAKES Problem Overheating

Wheels rotate when vehicle is raised

Noi se

Irregular actuation

Gear remains engaged

Action

Cause

• • • • •

Damaged hydraulic cooling system

• • • • • • • • • • • • • •

• • • • •

Repair

Braking force outside transmission: irregular axle operation

•

Check/Repair axle

Clutch plate drag

• • • • • • •

Repair/Replace

• • • • • •

Replace oil and filters

Dirty heat exchanger Parking brake inadvertently activated Excessive dirt on axle wheel hubs Seizing (broken gears, shafts, bearings, etc.)

Damaged converter Damaged oil thermostat Incorrect oil level Worn oil pump Clutch plate drag Low oil temperature (high oil viscosity) Incorrect oil specifications Damaged control valve Faulty reverser locking Damaged converter Damaged oil pump Aeration/Cavitation

Clean Release lean Check/Repair/Replace

Replace Replace Top up Replace Repair/Replace Wait for oil to reach working temperature (stall test) Replace Repair/Replace Replace Replace Check oil level / Check oil specifications

•

Seizing (broken gears, shafts, bearings, etc.)

•

Check/Repair/Replace

• • • • • • • •

Worn clutch plates

• • • • • • • •

Replace

• • • • • • • • •

Overheating

• • • • • • • • •

See «overheating»

Worn synchroniser actuation unit Worn 4WD clutch Damaged control valve Electrical system fault Worn clutch plates Damaged converter Low oil temperature (high oil viscosity)

Damaged hydraulic system Damaged/jammed shuttleshaft lever Electrical system fault Damaged control valve Damaged hydraulic system Damaged clutch unit Damaged gear lever rod Damaged synchronisers

N13–06–13

Replace Replace Replace Repair/Replace Replace Replace Wait for oil to reach working temperature (stall test) Repair/Replace Repair/Replace Repair/Replace Replace Repair/Replace Repair/Replace Replace Replace

DRIVETRAIN AND BRAKES Problem No 4WD power transmission

Gear shift won’t engage

Action

Cause

• • • • • • •

Damaged 4WD clutch Hydraulic system fault Damaged control valve Faulty brake sensor Electrical system fault Damaged shifter Damaged synchronisers

N13–06–14

• • • • • • •

Replace Repair/Replace Replace Check/Replace Repair/Replace Replace Replace

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO PRESSURE TESTING Note: • The transmission oil, should be at an approximate temperature of 80 Degrees Celsius during pressure tests. Note: Install a suitable 9/16” — 18 UNF — 2B fitting.

•

Oil cooler back pressure • FORWARD/REVERSE clutch position — Pressure should be 0.5 to 3.5 bar at an engine speed of 900 to 2200 rpm • NEUTRAL clutch position — Pressure should be 0.5 to 5.0 bar at an engine speed of 900 to 2200 rpm

TV051275

Note: • Install a suitable 9/16” — 18 UNF — 2B fitting. Forward clutch pressure • Pressure at (1) should be 11.0 to 13.0 bar at an engine speed of 900 to 2200 rpm Note: Maximum pressure in NEUTRAL should be 0.3 bar.

•

1

TV051276

N13–06–15

BHN1306TB

DRIVETRAIN AND BRAKES Note: • Install a suitable 9/16” — 18 UNF — 2B fitting. Reverse clutch pressure • Pressure at (1) should be 11.0 to 13.0 bar at an engine speed of 900 to 2200 rpm Note: Maximum pressure in NEUTRAL should be 0.3 bar.

•

1

TV051431

Note: • Install a suitable 9/16” — 18 UNF — 2B fitting. Forward/reverse clutch pressure • Pressure should be 11.0 to 13.0 bar at an engine speed of 900 to 2200 rpm Note: Maximum pressure in NEUTRAL should be 0.3 bar.

•

TV051434

Note: • Install a suitable fitting.

N13–06–16

DRIVETRAIN AND BRAKES Four-wheel drive (4WD) pressure • Pressure should be 13.0 to 14.0 bar at an engine speed of 900 rpm • Pressure should be 13.0 to 15.5 bar at an engine speed of 2200 rpm

TV051433

Note: • Install a suitable 9/16” — 18 UNF — 2B fitting. Torque converter pressure Pressure should be 0.5 to 9.0 bar at an engine speed of 900 to 2200 rpm

•

TV051432

N13–06–17

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–18

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — SYNCHROSHUTTLE TRANSMISSION — CARRARO Operation: Removing and Installing the Synchroshuttle Transmission — Carraro Suitable lifting equipment, Suitable transmission jack Suitable container (30Ltrs)

BHN1306A

Job Code: 13 25 13 xx Standard tools

Removal Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: • Always install blanking plugs to any open ports to avoid contamination.

•

Warning: This component is very heavy. Make sure the supporting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Position suitable 150mm blocks under each stabilizer and fully lower. 2. Remove the right-hand rear wheel. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 . 3. Raise the front of the machine level to the rear. Note: • Make sure there is a minimum of 875 mm clearance between the chassis and the ground. 4. Using suitable lifting equipment, support the machine.

915mm TV051247

5. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 .

N13–06–19

DRIVETRAIN AND BRAKES 6. Remove the drain plug and drain the transmission oil into a suitable container.

TV051201

7. Install the transmission oil drain plug and a new O-ring. Tighten to __Nm (__ lb.ft). 8. Detach the boosted brake return hose.

TV051248

9. Remove the parking brake caliper. For additional information, refer to Section N13-03 PARKING BRAKE CALIPER, PAGE N13–03–13 .

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

10. Remove the four retaining bolts and detach the rear propeller shaft from the rear differential. Secure it to one side. Note: Discard the retaining bolts.

•

TV040057

N13–06–20

DRIVETRAIN AND BRAKES

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

11. Remove the retaining bolts and remove the rear propeller shaft from the transmission. Note: Discard the retaining bolts.

•

TV051249

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

12. Remove the retaining bolts and detach the front propeller shaft from the transmission. Secure it to one side. Note: Discard the retaining bolts.

•

TV051250

13. Remove the retaining bolts and detach the transmission oil filter housing.

TV051251

N13–06–21

DRIVETRAIN AND BRAKES 14. Remove the cabin heater air ducting. For additional information, refer to Section H08-01 CABIN HEATER AIR DUCTING, PAGE H08–01–13 . 15. Remove the retaining clips and detach the gearshift lever boot. Note: • Discard the retaining clips.

TV051253

16. Disconnect the transmission dump button electrical connector (1). 17. Remove the gearshift selector lever return spring (2), retaining bolt (3) and the gearshift selector lever (4).

1

4 2

3 TV051254

Note: • Make a note of the position of the transmission wiring harness electrical connectors to aid installation. 18. Disconnect the forward solenoid electrical connector (1) and the reverse solenoid electrical connector (2). 19. Disconnect the differential lock solenoid (3), four-wheel drive solenoid (4) and the transmission temperature sender (5) electrical connectors.

N13–06–22

DRIVETRAIN AND BRAKES 20. Position the transmission wiring harness to one side.

1 5 2

3 TV051255

N13–06–23

4

DRIVETRAIN AND BRAKES 21. Disconnect the differential lock supply hose (1). 22. Disconnect the steering supply hose (2).

1

2 TV051256

23. Remove the upper hydraulic oil pump retaining bolt.

TV051257

24. Remove the lower hydraulic oil pump retaining bolt (1).

•

Warning: Take extreme care, this component is very heavy. Failure to follow this instruction may result in personal injury.

25. Detach the hydraulic oil pump (2) from the transmission and secure it to one side.

2 TV051258

N13–06–24

1

DRIVETRAIN AND BRAKES 26. Disconnect the transmission oil cooler inlet pipe.

TV051259

27. Disconnect the transmission oil cooler outlet pipe.

TV051260

28. Remove the torque converter housing cover plate.

TV051261

29. Remove the transmission oil level dipstick.

TV051262

N13–06–25

DRIVETRAIN AND BRAKES 30. Detach the transmission oil filler tube.

TV051263

31. Using the access hole remove the eight torque converter retaining bolts.

TV040166

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

32. Using suitable lifting equipment, support the engine. 33. Cut the cable ties and position the wiring harness and hydraulic hoses to one side.

TV051264

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

34. Using a suitable transmission jack, support the transmission.

N13–06–26

DRIVETRAIN AND BRAKES Note: • Transmission shown removed for clarity. 35. Remove the transmission retaining bolts.

TV051265

•

•

Warning: Take extreme care when removing the transmission from the engine. Failure to follow this instruction may result in personal injury. Caution: Make sure the torque converter is removed with the transmission.

36. Remove the transmission from the engine. Remove the transmission from the right-hand side of the machine.

TV051266

N13–06–27

DRIVETRAIN AND BRAKES Installation 1. To install, reverse the removal procedure. Tighten to 71Nm (52 lb.ft).

TV051265

2. Tighten to 41Nm (30 lb.ft).

TV051267

3. Tighten to 30Nm (22 lb.ft).

TV051261

4. Tighten retaining bolt (1) to 98Nm (72 lb.ft).

2 TV051258

N13–06–28

1

DRIVETRAIN AND BRAKES 5. Tighten to 100Nm (75 lb.ft).

TV051257

6. Tighten (3) to 60Nm (45 lb.ft).

1

4 2

3 TV051254

7. Install new retaining clips.

TV051253

8. Tighten to 40Nm (30 lb.ft).

TV051251

N13–06–29

DRIVETRAIN AND BRAKES Note: • Install new retaining bolts. 9. Tighten to 47Nm (35 lb.ft).

TV051250

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

10. Tighten to 47Nm (35 lb.ft).

TV051249

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: Install new retaining bolts.

•

11. Tighten to 47Nm (35 lb.ft).

TV040057

N13–06–30

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — PLUGS AND FILTERS

BHN1306DA

Operation: Disassembly and Assembly of the Plugs and Filters

Job Code: 13 54 17 xx

None

Standard tools, Suitable puller

1

2

3

4

5 6 7

12 8 11 9

19 18 17 16 15 TV051419

N13–06–31

10

13

14

DRIVETRAIN AND BRAKES 1

Plug

2

Connector

3

O-ring Seal

4

Adaptor

5

Plug

6

O-ring Seal

7

Spool

8

Spring

9

Four-Wheel Drive (4WD) Priority Valve

10

Plug

11

Oil Temperature Sensor

12

Oil Temperature Sensor Electrical Connector

13

Breather

14

Plug

15

Drain Plug

16

Suction Strainer

17

O-ring Seal

18

Suction Strainer Cover Plate

19

Retaining Bolts

N13–06–32

DRIVETRAIN AND BRAKES Disassembly Note: • Make a note of the position of any hydraulic hoses prior to disconnection to aid installation. Note: Always install blanking plugs to any open ports to avoid contamination.

•

1. Remove the retaining bolts and remove the suction strainer cover.

TV051401

2. Remove the O-ring seal (1) and the suction strainer (2). Note: • Discard the O-ring seal.

2 1

TV051402

3. Disconnect the oil filter lines. Note: • Discard the O-ring seal.

TV051414

N13–06–33

DRIVETRAIN AND BRAKES 4. Remove the adaptor from the transmission housing.

TV051403

5. Remove the connector (1) from the adaptor (2). Note: • Discard the O-ring seal.

2

TV051404

6. Remove the O-ring seal from the adaptor. Note: • Discard the O-ring seal.

TV051405

N13–06–34

1

DRIVETRAIN AND BRAKES 7. Remove the spool (1) and the spring (2).

2 1

TV051406

8. Using a suitable puller, remove the 4WD priority valve.

•

Caution: Do not try to disassemble or adjust the 4WD priority valve. If any parts are faulty, install a new 4WD priority valve.

TV051407

Assembly 1. Install the 4WD priority valve.

TV051407

2. Install the spring (2) and spool (1).

2 1

TV051406

N13–06–35

DRIVETRAIN AND BRAKES Note: • Install a new O-ring seal. 3. Install the O-ring seal to the adaptor.

TV051405

Note: • Install a new O-ring seal. 4. Install the connector (1) into the adaptor (2).

2

TV051404

5. Install the adaptor to the transmission housing. Tighten to 50Nm (37 lb.ft).

TV051403

6. Install the oil filter supply and return lines.

TV051414

N13–06–36

1

DRIVETRAIN AND BRAKES Note: • Install a new O-ring seal. 7. Install the suction strainer (2) and the O-ring seal (1).

2 1

TV051402

8. Install the suction strainer cover and the retaining bolts. Tighten to 23Nm (7 lb.ft).

TV051401

N13–06–37

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–38

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — TRANSMISSION OIL PUMP Operation: Disassembly and Assembly — Transmission Oil Pump None

BHN1306DB

Job Code: 13 55 17 xx Standard tools,

4 3 2

1

TV051420

1

Oil Seal

2

Retaining Bolts

3

Transmission Oil Pump

4

O-ring Seal

N13–06–39

DRIVETRAIN AND BRAKES Disassembly 1. Mark the transmission oil pump and the transmission front housing prior to removal to aid installation.

TV051408

2. Remove the retaining bolts and remove the oil pump. Note: • The only serviceable component within the oil pump assembly is the shaft oil seal. If the oil pump is faulty or damaged it must be replaced.

TV051409

3. Remove the O-ring seal. Note: • Discard the O-ring seal.

TV051410

N13–06–40

DRIVETRAIN AND BRAKES 4. Remove the shaft oil seal. Note: • Discard the oil seal.

TV051411

Assembly Note: • Use a new oil seal. 1. Using special tool number CA715409 — driver , install the shaft oil seal.

TV051471

Note: • Use a new O-ring seal. 2. Install the O-ring seal.

TV051410

N13–06–41

DRIVETRAIN AND BRAKES 3. Lubricate the input shaft sealing ring.

TV051334

•

Caution: If a new pump is being installed, make sure the oil passageways in the oil pump casing and the transmission housing are aligned. Failure to follow this instruction may result in failure of the oil pump.

4. Install the oil pump making sure that the reference marks on the oil pump and the casing are correctly aligned.

TV051335

5. Install the transmission oil pump retaining bolts. Tighten to 23Nm (17 ft.lbs).

TV051409

N13–06–42

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — HYDRAULIC CONTROL VALVE

BHN1306DD

Operation: Disassembly and Assembly — Hydraulic Control valve

Job Code: 13 56 17 xx

None

Standard tools,

36

16 14 13

10 12

9 8

39

11

7

38

34 35

15

1

37

40

52

33

51

32

6

31

5

50

30

4

49

29

3

48

2 28

44

18

43

17

19

26 27

20

21

25

22 23

24

TV051422

N13–06–43

41

42

47

45 46

DRIVETRAIN AND BRAKES 1

Control Valve

27

Copper Washer

2

Retaining Plug

28

Retaining Plug

3

O-Ring Seal

29

Piston

4

Spring

30

Washer

5

Washer

31

Spring

6

Distributor Body

32

Solenoid Pipe

7

Retaining Plug

33

O-Ring Seal

8

Washer

34

Reverse Solenoid

9

Retaining Bolt

35

O-Ring Seal

10

Retaining Plug

36

Forward Solenoid

11

Copper Washer

37

O-Ring

12

Retaining Plug

38

Retaining Nut

13

O-Ring Seals

39

Spring

14

Differential Lock Solenoid Valve

40

Ball

15

O-Ring

41

Snap Ring

16

Retaining Nut

42

Inward Piston

17

Retaining Plug

43

Pin

18

O-Ring Seal

44

Spring

19

Circlip

45

Spring

20

Piston

46

Spring

21

Spring

47

Outward Piston

22

Bush

48

Plate Gasket

23

Lower Gasket

49

Plate

24

Feeding Plate

50

Plate Gasket

25

Upper Gasket

51

Valve Cover

26

Retaining Bolt

52

Retaining Bolt

N13–06–44

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–45

DRIVETRAIN AND BRAKES Disassembly 1. Remove the retaining bolts and remove the hydraulic control valve.

TV051206

2. Remove the upper gasket. Note: • Discard the gasket.

TV051207

3. Remove the retaining bolts and remove the feeding plate.

TV051208

N13–06–46

DRIVETRAIN AND BRAKES 4. Remove the lower gasket. Note: • Discard the gasket.

TV051209

Note: • Using a vice fitted with soft jaws. 5. Secure the distributor body and remove the retaining plug. Note: • Discard the O-ring seal.

TV051210

6. Using suitable circlip pliers, remove the circlip.

TV051211

N13–06–47

DRIVETRAIN AND BRAKES 7. Remove the piston (1). 8. Remove the spring (2). 9. Remove the bush (3).

1 2

3

TV051212

10. Remove the retaining plug. Note: Discard the O-ring seal.

•

TV051213

11. Remove the spring (1). 12. Remove the washer (2).

1 2

TV051214

13. Remove the retaining bolts and remove the valve cover assembly.

TV051216

N13–06–48

DRIVETRAIN AND BRAKES 14. Remove the upper gasket (1), plate (2) and lower gasket (3). Note: • Discard the gaskets.

1 2

3

TV051217

15. 16. 17. 18.

Remove Remove Remove Remove

the outer piston (1). the springs (2). the pin (3). the inner piston (4).

1

4 2 3 TV051218

19. Remove the ball (1) and the spring (2).

1 2

TV051219

N13–06–49

DRIVETRAIN AND BRAKES 20. Remove the retaining nut. Note: • Discard the O-ring seal.

TV051220

21. Remove the forward solenoid (1) and the reverse solenoid (2). Note: • Discard the O-ring seals.

1 2

TV051221

22. Remove the solenoid pipe assembly.

TV051222

N13–06–50

DRIVETRAIN AND BRAKES 23. Disassemble the piston from the solenoid pipe. Compress the spring (1) using the washer (2). Whilst holding the washer firmly against the solenoid tube (3), release the spool (4) from the solenoid tube.

2 3

4

1 TV051223

24. Remove the differential lock solenoid retaining nut.

TV051224

25. Remove the differential lock solenoid. Note: Discard the O-ring seals.

•

TV051225

N13–06–51

DRIVETRAIN AND BRAKES 26. Remove the spool from the valve block. Note: • Discard the O-ring seals.

TV051246

Assembly Note: • Install new O-ring seals. 1. Install the spool into the valve block. Tighten to 27Nm (20 lb.ft).

TV051246

Note: • Install new O-ring seals. 2. Install the differential lock solenoid.

TV051225

N13–06–52

DRIVETRAIN AND BRAKES 3. Install the retaining nut. Tighten to 7Nm (5 lb.ft).

TV051224

4. Assemble the piston and the solenoid pipe. Compress the spring (1) using the washer (2). Holding the washer firmly against the solenoid tube (3), engage the spool (4) into the solenoid tube.

2 3

4

1 TV051223

5. Install the solenoid pipe assembly. Tighten to 24Nm (18 lb.ft).

TV051222

N13–06–53

DRIVETRAIN AND BRAKES Note: • Install new O-ring seals. 6. Install the forward (1) and reverse solenoid (2).

1 2

TV051221

Note: • Install new O-ring seals. 7. Install the retaining nut. Tighten to 10Nm (7 lb.ft).

TV051220

8. Install the spring (2) and the ball (1).

1 2

TV051219

N13–06–54

DRIVETRAIN AND BRAKES 9. Install the inner piston (4). 10. Install the pin (3). 11. Install the springs (2). 12. Install the outer piston (1).

1

4 2 3 TV051218

Note: • Install new gaskets. 13. Install the valve plate (2), upper gasket (1) and lower gasket (3).

1

3

TV051217

N13–06–55

2

DRIVETRAIN AND BRAKES 14. Install the valve cover assembly and the retaining bolts. Tighten to 11Nm (8 lb.ft).

TV051216

15. Install the washer (2). 16. Install the spring (1).

1 2

TV051214

Note: • Install a new O-ring seal. 17. Install the retaining plug and O-ring seal. Tighten to 24Nm (18 lb.ft).

TV051213

N13–06–56

DRIVETRAIN AND BRAKES 18. Install the bush (3). 19. Install the spring (2). 20. Install the piston (1).

1 2

3

TV051212

21. Using suitable circlip pliers, install the circlip.

TV051211

Note: • Using a vice fitted with soft jaws. 22. Secure the distributor body. Note: Install a new O-ring seal.

•

23. Install the retaining plug. Tighten to 24Nm (18 lb.ft).

TV051210

N13–06–57

DRIVETRAIN AND BRAKES Note: • Make sure all component mating faces are clean. Note: • Install a new gasket. 24. Install the lower gasket.

TV051209

Note: • Make sure all component mating faces are clean. 25. Install the hydraulic control valve feeding plate. Tighten to 23Nm (17 ft.lb).

TV051208

Note: • Make sure all component mating faces are clean. Note: Install a new gasket.

•

26. Install the upper gasket.

TV051207

N13–06–58

DRIVETRAIN AND BRAKES Note: • Make sure all component mating faces are clean. 27. Install the hydraulic control valve. Tighten to 23Nm (17 lb.ft).

TV051206

N13–06–59

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–60

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SOLENOID VALVE

BHN1306DE

Operation: Disassembly and Assembly — Four wheel drive solenoid valve None

Job Code: 13 57 17 xx Standard tools,

2 3

1 4 5 6 8

7

TV051424

1

Solenoid Housing

2

Retaining Bolts

3

Retaining Nut

4

Solenoid

5

Solenoid Pipe

6

O-ring Seals

7

Gasket

8

Check Valve

N13–06–61

DRIVETRAIN AND BRAKES Disassembly 1. Remove the retaining bolts and remove the four wheel drive solenoid valve.

TV051202

2. Remove the retaining nut and remove the solenoid.

TV051203

3. Remove the solenoid pipe. Note: • Discard the O-ring seals.

TV051204

N13–06–62

DRIVETRAIN AND BRAKES 4. Remove the check valve from the valve block. Note: • The check valve is a non serviceable item.

TV051205

Assembly 1. Install the check valve into the valve block.

TV051205

Note: • Install new O-ring seals. 2. Install the solenoid pipe into the valve block. Tighten to 24Nm (18 ft.lb).

TV051204

N13–06–63

DRIVETRAIN AND BRAKES 3. Install the solenoid onto the solenoid pipe and secure with the retaining nut. Tighten to 8Nm (6 lb.ft).

TV051203

Note: • Make sure all component mating faces are clean. Note: • Install a new gasket. 4. Install the four wheel drive solenoid valve onto the transmission housing and secure with the retaining bolts. Tighten to 23Nm (17 lb.ft).

TV051202

N13–06–64

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — TRANSMISSION HOUSING

BHN1306DF

Operation: Disassembly and Assembly of the Transmission Housing

Job Code: 13 34 17 xx

Suitable lifting equipment

Standard tools, Suitable puller, CA715496, CA715354

17

18

19 21

16 9

10

11

22 23 24

12

25

20

15 14

26

13

27

8

28 29

7 30 31

6

32 34

5

35 36

4 37

3 2

38

1

39 40 43

42

41

TV051415

N13–06–65

33

DRIVETRAIN AND BRAKES 1

Retaining Bolt

23

Retaining bolt

2

Washer

24

Roll Pin

3

O-Ring Seal

25

O-Ring Seal

4

Retaining Bolt

26

Shift Collar

5

Retaining Bolt

27

Retaining Bolt

6

Circlip

28

Washer

7

Bearing

29

O-Ring Seal

8

O-Ring Seal

30

2WD Shaft Flange

9

Retaining Plugs

31

Oil Seal

10

Washer

32

Reatining Bolt

11

Spring

33

Cover

12

Detent Balls

34

Teflon Seal

13

Circlip

35

Thrust Washer

14

Bearing

36

Retaining Bolt

15

Hydraulic Pump Drive Shaft

37

Bearing

16

Dowel

38

Bearing

17

Retaining Bolt

39

Transmission Front Housing

18

Shifter Tower Assembly

40

Oil Seal

19

O-Ring Seal

41

O-Ring Seal

20

Detent Balls

42

4WD Flange Seal Carrier

21

Plate

43

4WD Drive Shaft Flange

22

Retaining Bolt

44

Transmission Rear Housing

N13–06–66

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–67

DRIVETRAIN AND BRAKES Disassembly 1. Remove the transmission oil pump. For additional information, Refer to TRANSMISSION OIL PUMP, PAGE N13–06–39 in this section. 2. Using suitable snap ring pliers, remove the input shaft bearing snap ring.

TV051226

3. Remove the retaining bolt and remove the four wheel drive (4WD) shaft flange. Note: • Discard the O-ring seal.

TV051231

4. Remove the retaining bolts and remove the 4WD flange seal carrier.

TV051229

N13–06–68

DRIVETRAIN AND BRAKES 5. Remove the O-ring seal and the oil seal from the 4WD flange seal carrier. Note: • Discard the O-ring seal. Note: Discard the oil seal.

•

TV051230

6. Remove the retaining bolt and remove the two wheel drive (2WD) shaft flange. Note: • Discard the O-ring seal.

TV051522

7. Remove the three shifter tower assembly retaining bolts.

TV051233

N13–06–69

DRIVETRAIN AND BRAKES 8. Remove the shifter tower assembly. Note: • Discard the O-ring seal.

TV051234

9. Remove the eight retaining bolts and remove the transmission rear cover.

TV051235

10. Using suitable circlip pliers, remove the circlip and remove the hydraulic pump drive shaft.

TV051236

N13–06–70

DRIVETRAIN AND BRAKES 11. Remove the 2WD flange oil seal. Note: • Discard the oil seal.

TV051523

12. Using a suitable punch, remove the roll pins and remove the shift collars.

TV051237

13. Remove the retaining bolts and remove the detent balls retaining plate.

TV051238

14. Remove the detent balls.

TV051239

N13–06–71

DRIVETRAIN AND BRAKES 15. Remove the detent spring and ball retaining plugs.

TV051240

16. Remove the detent springs (1) and detent balls (2).

2 1

2

TV051241

17. Using suitable snap ring pliers, remove the input shaft bearing snap ring.

TV051242

18. Remove the nine rear facing front transmission housing retaining bolts. Note: Leave one bolt in each side at this stage.

•

TV051243

N13–06–72

1

DRIVETRAIN AND BRAKES

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

19. Using suitable lifting equipment, raise the transmission. 20. Using suitable supporting equipment, support the transmission on it’s rear face. 21. Remove the two rear facing transmission housing retaining bolts. 22. Remove the forward facing front transmission housing retaining bolts.

TV051244

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

23. Using suitable lifting equipment, remove the front transmission housing.

TV051245

24. Remove the 4WD output shaft bearing.

TV051351

N13–06–73

DRIVETRAIN AND BRAKES 25. Remove the primary shaft B (1) and the secondary shaft C (2) bearings.

2 1

TV051352

26. Remove the O-ring transmission housing.

seals

from

the

front

Note: Discard the O-ring seals.

•

TV051353

Assembly Note: • Make sure all component mating faces are clean. Note: Install new O-ring seals.

•

1. Install the O-ring seals into the rear transmission housing.

TV051353

N13–06–74

DRIVETRAIN AND BRAKES 2. Install the primary shaft B (1) and secondary shaft C (2) bearings.

2 1

TV051352

3. Install the 4WD output shaft bearing.

TV051351

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

4. Apply a thin bead of approved sealant to the transmission housing mating face. Refer to SPECIFICATIONS, PAGE N13–06–145 in this section. 5. Using suitable lifting equipment, install the front transmission housing.

TV051245

N13–06–75

DRIVETRAIN AND BRAKES 6. Install the forward facing front transmission housing retaining bolts. Tighten to 50Nm (37 lb.ft).

TV051244

7. Install the nine rear facing front transmission housing retaining bolts. Tighten to 50Nm (37 lb.ft).

TV051243

8. Using suitable snap ring pliers, install the snap ring.

TV051242

9. Install the detent springs (1) and balls (2).

2 1

2

TV051241

N13–06–76

1

DRIVETRAIN AND BRAKES 10. Install the detent ball and spring retaining plugs. Tighten to 80Nm (60 lb.ft).

TV051240

11. Install the detent balls.

TV051239

Note: • Before installing the retaining bolts, apply the approved thread sealant.. Refer to SPECIFICATIONS, PAGE N13–06–145 in this section. 12. Install the detent balls retaining plate and the retaining bolts. Tighten to 50Nm (37 lb.ft).

TV051238

N13–06–77

DRIVETRAIN AND BRAKES 13. Install the shift collars and roll pins.

TV051237

Note: • Install a new oil seal. 14. Using the special tool CA715496 — Driver , install the 2WD oil seal.

TV051523

15. Using a soft faced hammer, install the hydraulic pump drive shaft and using suitable circlip pliers, install the circlip.

TV051236

Note: • Make sure all component mating faces are clean. 16. Apply a thin bead of approved sealant to the transmission rear cover mating face. Refer to SPECIFICATIONS, PAGE N13–06–145 in this section.

N13–06–78

DRIVETRAIN AND BRAKES 17. Install the transmission rear cover and the eight retaining bolts. Tighten to 50Nm (37 lb.ft).

TV051235

Note: • Install a new O-ring seal. 18. Locate the shift lever into the shift collars and install the shifter tower assembly.

TV051234

19. Install the three shifter tower assembly retaining bolts. Tighten to 23Nm (17 lb.ft).

TV051233

N13–06–79

DRIVETRAIN AND BRAKES Note: • Install a new O-ring seal. 20. Install the 2WD shaft flange and retaining bolt. Tghten to 139Nm (102 lb.ft).

TV051522

Note: • Install a new oil seal. 21. Using the special tool CA715354 — Driver , install the oil seal into the 4WD flange seal carrier.

TV051348

Note: • Install a new O-ring seal. 22. Install the O-ring seal onto the 4WD flange seal carrier.

TV051230

N13–06–80

DRIVETRAIN AND BRAKES 23. Install the 4WD flange seal carrier and the retaining bolts. Tighten to 23Nm (17lb.ft).

TV051229

Note: • Install a new O-ring seal. 24. Install the 4WD flange and the retaining bolt. Tghten to 139Nm (102 lb.ft).

TV051231

25. Using suitable snap ring pliers, install the input shaft bearing snap ring.

TV051226

26. Install the transmission oil pump. For additional information, Refer to TRANSMISSION OIL PUMP, PAGE N13–06–39 in this section.

N13–06–81

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–82

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — INPUT SHAFT AND IDLER SHAFT

BHN1306DG

Operation: Disassembly and Assembly-Input Shaft A and Reverse Idler Shaft D

Job Code: 13 58 17 xx

Suitable lifting equipment

Standard tools, Clutchpack retaining clips Suitable puller, CA715358, CA715499, CA715415, CA715495, CA715497, CA715356, CA715046, CA715743, CA715746, CA715745, CA715623,

3 2

14 12

1

13

11 31

10

9

30

8 6

29

7

28

5

27

4 25

26 42

24

41

23 39

22

38

21 20

36

19 18

37

46

35

45

34

17 33

16 15

40

44

32 43

TV051423

N13–06–83

DRIVETRAIN AND BRAKES 1

Bearing

24

Roll Pin

2

Idler Shaft

25

Seals

3

Bearing

26

Seals

4

Teflon Seals

27

Piston

5

Circlip

28

Sleeve

6

Bearing

29

Spring

7

Spacer

30

Cover

8

Needle Bearing

31

Snap Ring

9

Gear

32

Clutch Plate, Driven

10

Spacer

33

Clutch Plate, Driving

11

Snap Ring

34

Clutch Plate Lock Ring

12

Clutch Plate Lock ring

35

Snap Ring

13

Clutch Plate, Driving

36

Spacer

14

Clutch Plate, Driven

37

Gear

15

Snap Ring

38

Needle Bearing

16

Cover

39

Spacer

17

Spring

40

Bearing

18

Sleeve

41

Circlip

19

Piston

42

Teflon Seals

20

Seals

43

Circlip

21

Seals

44

Bearing

22

Roll pin

45

Hydraulic Pump Drive Shaft

23

Input Shaft

46

Teflon Seal

N13–06–84

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–85

DRIVETRAIN AND BRAKES Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Remove the front half of the transmission housing. For additional information, refer to TRANSMISSION HOUSING, PAGE N13–06–65 in this section. Note: • The input shaft A and the idler shaft B must be removed from the transmission housing together. 2. Remove the input shaft A (1) and the idler shaft B (2) from the transmission housing.

1 2

TV051277

Note: • Using a vice fitted with soft jaws. 3. Secure the input shaft assembly with the reverse clutch up. 4. Remove the Teflon seal (1). Note: • Discard the Teflon seal. 5. Using suitable circlip pliers, remove the circlip (2).

1 2

TV051278

N13–06–86

DRIVETRAIN AND BRAKES 6. Using a suitable puller, release the gear from the shaft.

TV051279

7. Remove the bearing (1), thrust washer (2) and the reverse gear (3).

1

2

3

TV051280

8. Remove the needle roller bearing (1). 9. Remove the thrust washer (2).

1 2

TV051281

10. Remove the roll pin.

TV051282

N13–06–87

DRIVETRAIN AND BRAKES 11. Using suitable snap ring pliers, remove the snap ring.

TV051283

12. Remove the clutch pack cover plate.

TV051283

13. Mark the clutch plates, friction discs and the friction bell housing.

TV051285

14. Remove the seven drive plates and the six friction plates.

TV051286

15. Using the special tool CA715358 — clutch assembly/disassembly, compress the spring cover.

N13–06–88

DRIVETRAIN AND BRAKES 16. Using suitable circlip pliers, remove the snap ring.

TV051300

17. Remove the spring cover (1). 18. Remove the spring (2).

1 2

TV051288

19. Remove the sleeve.

TV051289

Note: • Use compressed air through the piston delivery hole to lift the piston. 20. Remove the clutch piston.

TV051290

21. Remove the outer Teflon seal (1) and the outer O-ring seal (2).

N13–06–89

DRIVETRAIN AND BRAKES 22. Remove the inner Teflon seal (3) and the inner O-ring seal (4). Note: • Discard the Teflon seals and O-ring seals.

3 4

1

2 TV051291

23. Turn the shaft over. 24. Remove the Teflon seal (1) 25. Using suitable snap ring pliers, remove the snap ring (2). Note: Discard the seals.

•

1 2

TV051292

26. Repeat steps 5 to 22 to disassemble the forward clutch. 27. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from both clutch packs. Note: Any plates found to be warped, damaged or worn must be replaced.

•

TV051295

N13–06–90

DRIVETRAIN AND BRAKES 28. Using a suitable puller, remove the bearings from the idler shaft.

TV051331

Assembly Note: • Install new Teflon seals and O-ring seals. 1. Install the outer O-ring seal (1) and the outer Teflon seal (2). 2. Install the inner O-ring seal (3) and the inner Teflon seal (4).

4 3

2

1 TV051296

Note: • Using a vice fitted with soft jaws. 3. Secure the input shaft assembly with the reverse clutch up. Note: • Apply a thin film of grease to the seals to assist in assembly. 4. Using the special tool CA715499 — protector , (2), install the clutch piston (1) into the friction bell housing.

1 2

TV051297

N13–06–91

DRIVETRAIN AND BRAKES 5. Install the sleeve onto the input shaft.

TV051298

6. Install the spring (1). 7. Install the spring cover (2).

2 1

TV051299

8. Using the special tool CA715358 — clutch assembly/disassembly , compress the spring. 9. Using suitable snap ring pliers, install the snap ring.

TV051300

10. Install the roll pin.

TV051301

N13–06–92

DRIVETRAIN AND BRAKES 11. Install the thrust washer. Note: • Make sure the notch in the inner edge of the thrust washer fits over the roll pin and that the oil grooves in the thrust washer are facing downwards.

TV051302

12. Install the needle roller bearing.

TV051303

13. Make two ’clutch pack retaining clips’ from 2 mm aluminium sheet.

35 mm

TV051304

N13–06–93

DRIVETRAIN AND BRAKES 14. Install the clutch plate lock ring (1) onto the gear (2).

2

1 TV051305

Note: • Alternate the drive plates and the friction plates until the correct amount of plates are installed. The first and last plates are steel. 15. Install the seven drive plates and the six friction plates.

TV051306

16. Turn the clutch and gear assembly over. Note: Make sure all six clutch friction plates have engaged the splines on the gear.

•

TV051307

N13–06–94

DRIVETRAIN AND BRAKES 17. Install the two clutch pack retaining clips.

TV051308

18. Place the heads of two retaining bolts under the gear teeth.

TV051309

19. Install the clutch and gear assembly.

TV051310

20. Using a suitable punch, carefully install the clutch pack cover. 21. Remove the two retaining bolts and the clutch pack retainers.

TV051311

N13–06–95

DRIVETRAIN AND BRAKES 22. Using suitable circlip pliers, install the snap ring.

TV051312

23. Install the thrust washer.

1

2

TV051313

24. Using suitable circlip pliers, install the circlip (2).

1 2

TV051278

25. Using a suitable bearing heater, heat the bearing to 80 to 100ºC. 26. Using the special tool CA715004 — driver , install the bearing into the input shaft.

TV051314

N13–06–96

DRIVETRAIN AND BRAKES

•

Caution: Take care not to damage the Teflon seal. If the Teflon seal is damaged, it must be replaced. Failure to follow this instruction may result in damage to the transmission.

Note: • Install new Teflon seals. 27. Install the Teflon seal onto the input shaft. 28. Install the special tool CA715415/7 – spacer , onto the shaft. Note: Make sure the deep internally chamfered end is facing towards the clutch.

•

TV051316

— 29. Install the special tool CA715495 expander/protector , over the special tool CA715415/7 – spacer .

TV051317

30. Heat the Teflon seal to 60 to 80ºC. 31. Install the Teflon seal onto the special tool CA715495 — expander/protector .

TV051318

32. Install the special tool CA715497 – pusher , over the special tool CA715495 — expander/protector . 33. Install the Teflon seal.

N13–06–97

DRIVETRAIN AND BRAKES 34. Remove the special tools.

TV051319

Note: • Make sure the deep internally chamfered end is facing towards the clutch. 35. Using the special tool CA715356 — gauger , resize the Teflon seal. Note: Make sure the seal is correctly seated in the groove.

•

TV051320

36. Remove the special tool. Re-install the special tool CA715356 — gauger using the narrow internally chamfered end facing towards the clutch. Leave the gauger in place for 15 minutes until the seal has cooled. Remove the special tool.

TV051321

37. Turn the input shaft over with the forward clutch up. 38. Repeat steps 1 to 21 to assemble the forward clutch 39. Using the special tool CA715046 — driver , install the bearing.

N13–06–98

DRIVETRAIN AND BRAKES

•

Caution: Take care not to damage the Teflon seal. If the Teflon seal is damaged, it must be replaced. Failure to follow this instruction may result in damage to the transmission.

Note: • Install new Teflon seals. 40. The Teflon seals must be installed in the order indicated, using the following instructions.

4

3

2 TV051322

41. Install the special tool CA715743/1 – spacer , into the special tool CA715743–expander/protector .

TV051323

42. Install the assembled special tools onto the shaft.

TV051324

43. Heat the Teflon seal to 60 to 80ºC.

N13–06–99

1

DRIVETRAIN AND BRAKES 44. Install the Teflon seal onto the special tool CA715743–expander/protector .

TV051325

45. Install the special tool CA715746 – pusher , over the special tool CA715743 — expander/protector . 46. Install the Teflon seal. 47. Remove the special tools.

TV051326

Note: • Make sure the deep internally chamfered end is facing towards the clutch. 48. Using the special tool CA715745 — gauger , resize the Teflon seal. Note: • Make sure the Teflon seal is correctly seated in the groove.

TV051327

N13–06–100

DRIVETRAIN AND BRAKES 49. Remove the special tool. Re-install the special tool CA715356 — gauger , using the narrow internally chamfered end facing towards the clutch. Leave the gauger in place for 15 minutes until the seal has cooled. Remove the special tool.

TV051328

50. Repeat steps 41 to 49 to install the remaining Teflon seals. Use the spacers identified below for each of the Teflon seals. 2nd Teflon seal: CA715743/2 3rd Teflon seal: CA715743/3 4th Teflon seal: CA715743/4 51. Test the functionality of the clutches. Apply compressed air (at approximately 6 bar) to the forward clutch hydraulic passageway (1) in the shaft. The forward clutch piston (2) will move and the forward clutch plates (3) will close, locking the forward drive gear (4). 52. Apply compressed air (at approximately 6 bar) to the reverse clutch hydraulic passageway (5) in the shaft. The reverse clutch piston (6) will move and the reverse clutch plates (7) will close, locking the reverse drive gear (8). Note: • If either clutch does not work correctly, disassemble the faulty clutch and establish the cause. Assemble the clutch and re-test.

N13–06–101

DRIVETRAIN AND BRAKES

6

2 5

1 4 8

3

7

TV051329

1

Forward Clutch Hydraulic Passageway

2

Forward Clutch Piston

3

Forward Clutch Plates

4

Forward Drive Gear

5

Reverse Clutch Hydraulic Passageway

6

Reverse Clutch Piston

7

Reverse Clutch Plates

8

Reverse Drive Gear

53. Using the special tool CA715623 — driver , install the two bearings onto the idler shaft.

TV051332

N13–06–102

DRIVETRAIN AND BRAKES

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

Note: The input shaft A and the idler shaft B must be installed together.

•

54. Install the input shaft A and the idler shaft B.

TV051330

55. Install the rear half of the transmission housing. For additional information, refer to TRANSMISSION HOUSING, PAGE N13–06–65 in this section.

N13–06–103

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–104

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — SHAFTS C AND B

BHN1306DH

Operation: Disassembly and Assembly of the Primary shaft C and the Secondary Shaft B

Job Code: 13 59 17 xx

Suitable lifting equipment

4

Standard tools Suitable feeler gauges Suitable bearing heater Suitable puller CA715496 CA71549 CA715004 21 22

5

3

19

2

23

20 24

18

1

39

17

38

16 13

37 36

15 35

14 12 10

33

11

34 32

9 8

31

7

30

6 25

29 40

28 27

43

44

42 41

26 TV051416

N13–06–105

DRIVETRAIN AND BRAKES 1

Bearing

24

4WD Gear

2

Snap Ring

25

3

Shim

First/Second Speed Synchroniser Assembly

4

Thrust Washer

26

Roll Pin

5

Second Speed Gear

27

Fourth Speed Gear

6

Spacer

28

Clutch Ring

7

Synchroniser Ring

29

Friction Ring

8

Steel Ring

30

Synchroniser Hub

9

Sintered Ring

31

Spring

10

Tapered Friction Ring

32

Ball

11

Synchroniser Hub

33

Plates

12

Spring

34

Sleeve

13

Plates

35

Tapered Friction Ring

14

Ball

36

Clutch Ring

15

Sleeve

37

Third Speed Gear

16

Tapered Friction Ring

38

Thrust Washer

17

Sintered Ring

39

Bearing

18

Steel Ring

40

Synchroniser Assembly

19

Synchroniser Ring

41

Bearing

20

Spacer

42

Primary Shaft

21

First Speed Gear

43

Bearing

22

Circlip

43

Bearing

23

Snap Ring

44

Secondary Shaft

N13–06–106

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–107

DRIVETRAIN AND BRAKES Disassembly

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

1. Using the special tool CA715496 — B and C shaft hooks , remove the primary shaft B and the secondary shaft C from the transmission, complete with gear selector forks.

TV051425

2. Remove the gear selector forks.

TV051374

Note: • Using a vice fitted with soft jaws. 3. Secure the shaft. 4. Using a suitable puller, remove the secondary shaft bearing.

TV051375

N13–06–108

DRIVETRAIN AND BRAKES 5. Remove the thrust washer.

TV051376

6. Remove the third speed gear.

TV051377

7. Assess the serviceability of the synchroniser. Using a suitable feeler gauge, measure the clearance between the clutch ring (1) and the tapered friction ring (2). The clearance with used parts in good condition should be approximately 1.0mm. If the clearance is 0.5mm or less, a new synchroniser assembly must be installed.

2 1

TV051493

8. Remove the third/fourth speed synchroniser assembly.

TV051378

N13–06–109

DRIVETRAIN AND BRAKES Note: • There are no serviceable parts within the synchroniser assembly. Disassembly of the synchroniser should only be carried out for inspection purposes. 9. Remove the clutch rings from each side of the synchroniser assembly.

TV051379

10. Remove the tapered friction rings from each side of the synchroniser assembly.

TV051380

N13–06–110

DRIVETRAIN AND BRAKES

•

Caution: When the sleeve is removed from the synchroniser hub the springs, plates and detent balls will be released under pressure. Make sure the parts are not lost.

11. Remove the sleeve from the synchroniser hub assembly.

TV051381

12. Remove the fourth speed gear.

TV051383

13. Turn the shaft over so that the 2nd gear end is uppermost.

N13–06–111

DRIVETRAIN AND BRAKES

•

Caution: Do not try to remove the bearing and gear together as there is a snap ring between them. Failure to follow this instruction may result in damage to the transmission.

14. Using a suitable puller, remove the bearing inner race.

TV051384

15. Using suitable circlip pliers, remove the circlip.

TV051385

16. Remove the spacer and shims.

TV051386

17. Remove the roll pin.

TV051387

N13–06–112

DRIVETRAIN AND BRAKES 18. Remove the second speed gear.

TV051388

19. Remove the spacer.

TV051389

20. Check the serviceability of the synchroniser assembly. Using a suitable feeler gauge, measure the clearance between the synchroniser ring (1) and the friction ring (2). The clearance with used parts in good condition should be approximately 1.0mm. If the clearance is 0.5mm or less, a new synchroniser assembly must be installed.

2

1

TV051426

21. Turn the synchroniser over. 22. Repeat step 19 for the other side of the synchroniser assembly.

N13–06–113

DRIVETRAIN AND BRAKES Note: • There are no serviceable parts within the synchroniser assembly. Further disassembly should only be carried out for inspection purposes. 23. Remove the first/second speed synchroniser assembly.

TV051390

24. Remove the synchroniser ring.

TV051391

25. Remove the steel ring (1) and the sintered ring (2).

1 2

TV051392

26. Remove the tapered friction ring.

TV051393

N13–06–114

DRIVETRAIN AND BRAKES 27. Turn the synchroniser assembly over. 28. Remove the synchroniser ring.

TV051391

29. Remove the steel ring (1) and the sintered ring (2).

1 2

TV051392

30. Remove the tapered friction ring.

TV051393

N13–06–115

DRIVETRAIN AND BRAKES

•

Caution: When the sleeve is removed from the synchroniser hub the springs, plates and detent balls will be released under pressure. Make sure the parts are not lost.

31. Remove the sleeve from the synchroniser hub assembly.

TV051381

32. Remove the spacer (1) and the first speed gear (2).

1 2

TV051394

N13–06–116

DRIVETRAIN AND BRAKES 33. Using suitable circlip pliers, remove the circlip.

TV051395

34. Remove the 4WD gear.

TV051396

35. Turn the shaft over and secure in the vice. 36. Using suitable snap ring pliers, remove the snap ring.

TV051397

37. Secure the secondary shaft B in a soft jawed vice. 38. Using a suitable puller, remove the bearing inner race.

TV051398

39. Turn the shaft over and secure in the vice.

N13–06–117

DRIVETRAIN AND BRAKES 40. Using a suitable puller, remove the bearing.

TV051399

N13–06–118

DRIVETRAIN AND BRAKES Assembly Note: • Using a vice fitted with soft jaws. 1. Secure the secondary shaft. 2. Using suitable snap ring pliers, install the snap ring.

TV051397

3. Turn the shaft over and secure in a soft jawed vice. 4. Install the 4WD gear.

TV051396

5. Using suitable circlip pliers, install the circlip.

TV051395

6. Install the first speed gear (2) and the spacer (1).

1 2

TV051394

N13–06–119

DRIVETRAIN AND BRAKES 7. Assemble the first/second speed synchroniser. • Install the springs in the hub, and the plates on the springs. The plates are not yet pushed down into the sleeve and are holding the hub out of the sleeve. The balls are loose in the recess of the plates. • Using a suitable punch or screwdriver, push the balls onto the flat plates and to push the plates down so that the balls are on the flat faces of the teeth, but not into the detent grooves. When all the balls are in position push the hub and the plates down until the balls move into the detent holes.

TV051463

Note: • Lubricate with clean transmission oil. 8. Install the sintered ring (2) and the steel ring (1).

1 2

TV051392

Note: • Make sure the flat side of the synchroniser ring is facing upwards. Failure to follow this instruction may result in damage to the transmission. 9. Install the synchroniser ring.

TV051496

N13–06–120

DRIVETRAIN AND BRAKES 10. Turn the synchroniser assembly over in the vice. Note: • Lubricate with clean transmission oil. 11. Install the sintered ring (2) and the steel ring (1).

1 2

TV051392

Note: • Make sure the flat side of the synchroniser ring is facing upwards. Failure to follow this instruction may result in damage to the transmission. 12. Install the synchroniser ring onto the synchroniser assembly.

TV051496

13. Install the assembly.

first/second

speed

synchroniser

TV051390

N13–06–121

DRIVETRAIN AND BRAKES 14. Install the spacer.

TV051389

15. Install the second speed gear.

TV051388

16. Install the roll pin.

TV051387

17. Install the shims and spacer.

TV051386

N13–06–122

DRIVETRAIN AND BRAKES 18. Using suitable snap ring pliers, install the snap ring.

TV051385

19. Using suitable feeler gauges, measure the backlash between the lower shim and the gear: the value must be between 0.2 to 0.42 MM

TV051462

20. If the backlash is more than the value prescribed, remove the snap ring and the washer, using the shims in the chart to reach the prescribed value. Shims Range Specs./Thick. MM

0.05

0.1

0.3

21. Using a suitable bearing heater, heat the inner race of the bearing to 80 to 100°C. 22. Using special tool CA71549 — Driver , install the inner race of the bearing.

TV051428

N13–06–123

0.5

DRIVETRAIN AND BRAKES 23. Install the bearing outer race.

TV051465

24. Turn the shaft over in the vice. 25. Install the fourth speed gear.

TV051383

26. Assemble the third/fourth speed synchroniser. • Install the springs in the hub, and the plates on the springs. The plates are not yet pushed down into the sleeve and are holding the hub out of the sleeve. The balls are loose in the recess of the plates. • Using a suitable punch or screwdriver, push the balls onto the flat plates and to push the plates down so that the balls are on the flat faces of the teeth, but not into the detent grooves. When all the balls are in position push the hub and the plates down until the balls move into the detent holes.

TV051463

N13–06–124

DRIVETRAIN AND BRAKES 27. Install the tapered friction rings to each side of the synchroniser assembly.

TV051380

28. Install the clutch rings to each side of the synchroniser assembly.

TV051379

29. Install the third/fourth speed synchroniser on to the shaft.

TV051378

Note: • Lubricate with clean transmission oil. 30. Install the third speed gear.

TV051377

N13–06–125

DRIVETRAIN AND BRAKES Note: • Lubricate with clean transmission oil. 31. Install the thrust washer.

TV051376

32. Using a suitable bearing heater, heat the bearing to 80 to 100°C. 33. Install the bearing.

TV051429

34. Using a suitable bearing heater, heat the bearing inner race to 80 to 100°C. 35. Secure the primary shaft in a soft jawed vice with 3rd gear uppermost. 36. Using the special tool CA715149 — Driver , install the bearing inner race.

TV051430

37. Turn the primary shaft over in the vice. 38. Using a suitable bearing heater, heat the bearing inner race to 80 to 100°C.

N13–06–126

DRIVETRAIN AND BRAKES 39. Using the special tool CA715004 — Driver , install the bearing.

TV051430

40. Install the gear selector forks.

TV051374

•

Warning: This component is very heavy. Make sure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

41. Using the special tool CA715496 — B and C shafts hook , install the primary shaft B and the secondary shaft C into the transmission housing complete with selector forks.

TV051425

N13–06–127

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–128

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SHAFT (E)

BHN1306DJ

Operation: Disassembly and Assembly — Four Wheel Drive Shaft (E)

Job Code: 13 60 17 xx

None

Standard tools, Suitable puller

16 15 14 13 12 11 10 9 8 7 6 5 3

4

2 1

TV051417

1

Circlip

2

Washer

3

Spring Retainer

4

Springs

5

Sleeve

6

O-ring Seals

7

Teflon Seals

8

Four Wheel Drive Shaft

9

O-ring Seal

10

Valve

11

Spring

12

O-ring Seal

13

Cylinder

14

O-ring Seal

15

Circlip

16

Four Wheel Drive Clutch Gear

17

Four Wheel Drive Shaft Bearing

N13–06–129

17

DRIVETRAIN AND BRAKES Disassembly 1. Remove the rear half of the transmission housing. For additional information, refer to TRANSMISSION HOUSING, PAGE N13–06–65 in this section. 2. Remove shaft C (1). For additional information refer, to SHAFTS B-C, PAGE N13–06–105 in this section. 3. Remove shaft E (2) from the transmission housing.

2 1

TV051337

4. Remove the four wheel drive (4WD) clutch gear.

TV051361

5. Remove the four wheel drive shaft bearing.

TV051362

N13–06–130

DRIVETRAIN AND BRAKES 6. Using special tool CA715493 – Compressor , compress the springs and remove the snap ring.

TV051363

7. Remove the washer (1) and spring retainer (2).

1 2

TV051364

8. Remove the springs.

TV051365

9. Remove the sleeve.

TV051366

10. Remove the O-ring seals (1). Note: Discard the O-ring seals

•

N13–06–131

DRIVETRAIN AND BRAKES 11. Remove the Teflon Seals (2). Note: • Discard the Teflon Seals.

2 1 1

TV051367

12. Turn the shaft. 13. Using suitable circlip pliers, remove the circlip.

TV051368

14. Remove the cylinder.

TV051369

15. Remove the O-ring seals from the cylinder. Note: Discard the O-ring seals.

•

TV051370

N13–06–132

2

DRIVETRAIN AND BRAKES 16. Remove the valve and spring from the cylinder.

TV051371

Assembly 1. Assemble the spring and valve into the cylinder.

TV051371

Note: • Use new O-ring seals. 2. Install the O-ring seals onto the cylinder.

TV051370

3. Install the cylinder into the shaft.

TV051369

N13–06–133

DRIVETRAIN AND BRAKES 4. Install the circlip.

TV051368

N13–06–134

DRIVETRAIN AND BRAKES Note: • Use new O-ring seals. 5. Install the O-ring seals onto the shaft.

TV051338

6. Install the sleeve onto the shaft.

TV051366

7. Install the springs into the holes in the sleeve.

TV051365

8. Install the spring retainer.

TV051364

N13–06–135

DRIVETRAIN AND BRAKES 9. Position the washer and the circlip on the shaft. Using special tool CA715493 — Compressor , compress the spring retainer until the circlip can be installed into the groove.

TV051363

Note: • Use a new Teflon seal. 10. Install the inner of the two teflon seals onto the shaft.

•

Caution: It is important that the teflon seal is fitted as described in the following steps. Failure to do so will result in premature failure of the seal and subsequent damage to the transmission. Take care not to damage the seal at any time during the installation procedure. If the seal is damaged a new seal must be fitted.

11. Place the special tool CA715263 — Expander/protector , onto the shaft. The expander/protector will stop in the correct position to install the Teflon sealing ring in the groove. 12. Heat the teflon seal to 60 – 80ºC (140 – 176ºF) and install it onto the expander/protector.

TV051342

N13–06–136

DRIVETRAIN AND BRAKES 13. Using the special tool CA715497 — Pusher , slide the sealing ring along until it drops into the groove in the shaft. Remove the special tools from the shaft.

TV051343

14. Install the special tool CA715356 – Gauger , onto the shaft with the deep internal chamfer on the inside of the tool up against the seal. Using a twisting motion, push the tool backwards and forwards over the seal. This will ensure the seal is properly seated in the groove. 15. Turn the gauger around and slide the end with the narrow chamfer over the shaft and seal ring. Leave the seal compressor in place for 15 minutes until the sealing ring has cooled and is properly sized and seated in the groove. Remove the seal compressor.

TV051344

Note: • Use a new Teflon seal. 16. Using special tool CA715257 — Expander/Protector , fit the outer of the two teflon seals using the same method. 17. Install the four wheel drive shaft bearing.

TV051362

N13–06–137

DRIVETRAIN AND BRAKES 18. Install the four wheel drive clutch gear.

TV051361

19. Lubricate the bearing housing in the transmission housing and Install shaft C (1). For additional information, refer toSHAFTS B-C, PAGE N13–06–105 in this section. 20. Install shaft E (2).

2 1

TV051337

21. Install the front half of the transmission housing. For additional information, refer to TRANSMISSION HOUSING, PAGE N13–06–65 in this section.

N13–06–138

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — SPEED CONTROLS

BHN1306GA

Operation: Disassembly and Assembly of the Speed Controls

Job Code: 13 61 17 xx

None

Standard tools

11

12 13

10

14

9 8

15

7 6 5 4 3 2 1

TV051418

1

Third and Fourth Gear Control Fork

2

Roll Pin

3

First and Second Gear Control Fork

4

Roll Pin

5

Circlip

6

Bushing

7

Spring

8

O-Ring Seal

9

Shifter Tower Assembly

10

Retaining Bolts

11

Roll Pin

12

Roll Pin

13

Shift Lever

14

Boot

15

Retaining Clip

N13–06–139

DRIVETRAIN AND BRAKES Disassembly 1. Remove the O-ring seal. Note: • Discard the O-ring seal.

TV051354

2. Remove the boot retaining clip.

TV051355

3. Remove the boot.

TV051356

4. Remove the roll pins.

TV051357

N13–06–140

DRIVETRAIN AND BRAKES 5. Using suitable circlip pliers, remove the circlip.

TV051358

6. Remove the bushing (1) and spring (2).

2

TV051359

7. Using a suitable punch, remove the roll pins securing the gear control forks.

TV051202

N13–06–141

1

DRIVETRAIN AND BRAKES Assembly 1. Using a suitable punch, install the roll pins securing the gear control forks.

TV051202

2. Install the spring (2) and bushing (1) onto the shift lever.

2

TV051359

3. Using suitable circlip pliers, install the circlip.

TV051358

4. Using a suitable punch, Install the roll pins.

TV051357

N13–06–142

1

DRIVETRAIN AND BRAKES 5. Install the boot.

TV051356

6. Install the boot retaining clip.

TV051355

Note: • Install a new O-ring seal. 7. Install the O-ring seal.

TV051354

N13–06–143

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–144

DRIVETRAIN AND BRAKES SPECIFICATIONS — SYNCHROSHUTTLE TRANSMISSION — CARRARO

BHN1306SA

Special Tools Special Tool No.

Description

CA119033

Handle

CA715004

Driver

CA715046

Driver

CA715149

Driver

CA715257

Protection

CA715263

Protection

CA715354

Driver

CA715356

Gauger

CA715358

Clutch D & A

CA715409

Driver

CA715493

Snap Ring D & A

CA715495

Protection & Shims

CA715496

B & C Shafts Hook

CA715497

Pusher

CA715499

Protection

CA715501

Driver

CA715623

Driver

CA715743

Protection & Shims

CA715745

Gauger

CA715746

Pusher

General Information Transmission

Syncroshuttle

Make

Carraro

Model

TLB1 UP 4WD

Carraro Pt. No.

CA641868

Terex Pt. No.

________

Transmission Dry Weight

208 Kg

Max input speed

3000 rpm

Output/4WD shaft ratio

0.800

Suction oil filtering capacity

250 µm

Filtering capacity and delivery oil filter type

10 µm — AGV BETA 2.2

Engine flange type

SAE 3

Rear output flange type

END YOKE 1410

PTO shaft

14T D.P. 12/24 SAE C

PTO flange type

SAE C 127-2 Bolt

N13–06–145

DRIVETRAIN AND BRAKES Recommended Lubricants Oil Company

ATF

TOTAL FINA®

HY-Tran (CASE MS1207)

TOTAL FINA®

HY-Tran ULTRA (CASE MS1209) (CNH MAT 3505)

TOTAL FINA®

HY-Tran PLUS (CASE MS1223)

PAKELO®

Special Transmission Fluid

MOBIL®

Mobil fluid 424

CHEVRON TEXACO®

Textran 7045

PETROL OFISI® (Turkish)

PO ATF 2

Recommended Adhesive and Sealants Application

Loctite®

Superbond®

Technical Characteristics

Strength

Transmission housing

510

529

Flat surface sealing

High

Transmission rear cover

518

539

Uneven sealing surface

High

Detent balls retaining plate

542

321

Locking of threaded parts

Medium

N13–06–146

DRIVETRAIN AND BRAKES Torque Values Description

Nm

Lb.ft

Transmission to engine

71

52

Torque converter

41

30

Transmission housing

50

37

Detent ball retaining plugs

80

60

Detent ball retaining plate

50

37

Transmission rear cover

50

37

Shift tower assembly

23

17

Four wheel drive (4WD) flange

139

102

Two wheel drive (2WD) flange

139

102

4WD flange seal carrier

23

17

Front propeller shaft

47

35

Rear propeller shaft

47

35

Transmission oil pump

23

17

4WD solenoid pipe

24

18

4WD solenoid

8

6

4WD solenoid valve

23

17

Differential lock solenoid spool

27

20

Differential lock solenoid

7

5

Forward/reverse solenoid pipe

24

18

Forward/reverse solenoid

10

7

Control valve cover

11

8

Control valve retaining plug

24

18

Feeding plate

23

17

Hydraulic control valve

23

17

Transmission oil temperature sender

30

22

N13–06–147

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–06–148

DRIVETRAIN AND BRAKES DESCRIPTION AND OPERATION — CARRARO POWERSHIFT TRANSMISSION Identification Of The Unit

• •

Model and type of the unit Unit serial number

Schematic View Powershift Transmission

N13–07–1

BHN1307OA

DRIVETRAIN AND BRAKES 1

Input Drive Shaft

2

Torque Converter

3

Charge Pump

4

Reverse Drive Gear

5

Reverse Drive Clutch

6

Forward Drive Gear

7

Forward Drive Clutch

8

Power Take Off

9

2nd Speed Clutch and Gear

10

1st Speed Clutch and Gear

11

Rear Output Coupling

12

4 Wheel Drive Clutch

13

4th Speed Clutch and Gear

14

Front Output Coupling

15

Speed Sensor

16

3rd Speed Clutch and Gear

N13–07–2

DRIVETRAIN AND BRAKES Transmission Hydraulic Circuit

N13–07–3

DRIVETRAIN AND BRAKES The transmission and torque converter function together through a common hydraulic system. The charging pump draws oil through the suction oil strainer and directs it to the oil filter. Protecting the filter from system pressure in excess of 3.45 Bar (50 PSI) is a by-pass valve . A pressure regulating valve maintains the pressure for the control valve and clutches at 18.5 bar (268 PSI) and excess oil is returned to the torque converter circuit. The torque converter is protected from pressures over 5.5 bar (80 PSI) by a safety valve located internally in the charge pump. After leaving the torque converter, the oil flows through the oil cooler then on to lubricate and cool the transmission bearings and clutches. The oil drains back to the transmission sump under gravity. The transmission is composed of five main assemblies. 1

The torque converter and charging pump drive section

2

The input or directional clutches

3

The range clutches

4

The output section

5

The transmission controls

N13–07–4

DRIVETRAIN AND BRAKES Transmission Assembly and Controls 1. The Torque Converter and Charging Pump Drive Section

axis D

R

F

PTO

axis A

2^

axis B 1^ 1 3^ axis C

4^

axis E

REAR

FRONT

TV073862

N13–07–5

DRIVETRAIN AND BRAKES Engine power is transmitted from the engine flywheel to the impeller through the impeller cover. This element is the charging portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components with the torque converter which results in torque multiplication. The impeller can be compared to a centrifugal pump in that it picks up fluid at its centre and discharges at its outer diameter. The torque converter turbine is mounted opposite the to impeller and is connected to the turbine shaft or directional clutch shaft. This element receives fluid at its outer diameter and discharges at its centre. The stator of the torque converter is located between the impeller and turbine elements, at the centre of there diameters. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. This recirculation will make the converter multiply torque. The stator can also freewheel when the impeller and turbine RPM are similar to each other allowing a fluid

coupling operation in order to achieve a high speed on the road. This in turn means less heat is generated and fuel consumption is reduced. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. In the impeller cover a splined shaft is installed which runs inside the turbine shaft to drive a hydraulic pump which is fitted at the back of the transmission. Since the shaft is connected to the centre of the impeller cover, the hydraulic pump speed will be the same as engine speed. The rear side of the impeller cover has a tanged drive which drives the transmission charging pump located in the converter housing. The transmission charging pump speed is also the same as the engine speed and provides fluid under pressure to allow engagement of the various clutches.

N13–07–6

DRIVETRAIN AND BRAKES 2. Input or Directional Clutches

2

axis D

R

F

PTO

axis A

2^

axis B 1^

3^ axis C

4^

axis E

REAR

FRONT

TV073863

N13–07–7

DRIVETRAIN AND BRAKES The turbine shaft driven from the turbine transmits power to the forward or reverse clutches. These clutches consist of a drum with splines and a bore to receive a hydraulic actuated piston. The piston is oil tight by the use of sealing rings, also these pistons have drain orifices for a quick release when the clutch is being disengaged. A steel disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc with teeth at the internal diameter is inserted. Discs are alternated until the required total is achieved. A backing plate is then inserted and secured with a snap ring. A hub with outer diameter teeth is inserted into the discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the control valve which is fitted on the top of the transmission will direct oil under pressure through tubes and passages to the selected clutch shafts. Oil seals are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft to the desired clutch.

Pressure of the oil forces the piston and discs against the backing plate. The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil will drain back via the control valve into the transmission sump. The powershift transmission has one reverse clutch and one forward clutch. This, in combination with the four range clutches, results in the transmission having 4 forward speeds and 3 reverse speeds. The engagement of the directional clutches is modulated; which means that clutch pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving and will allow smooth engagement of drive. The forward and reverse clutches are modulated by the Trax software. The modulation of the gear clutches is controlled by a ramp valve in the control valve. The 4WD clutch and differential lock are not modulated

N13–07–8

DRIVETRAIN AND BRAKES 3. The Range Clutches

Once a directional clutch is engaged, power is transmitted to the range clutches. Operation and actuation of the range clutches is similar to the directional clutches. The engagement of the range clutches is also modulated to enable a smooth engagement.

The modulation for these clutches is achieved by means of a ramp valve fitted in the control valve. This is controlled manually by a spring and which limits oil flow to the clutch during gear changes.

N13–07–9

DRIVETRAIN AND BRAKES 4. The Output Section

With a range clutch engaged power is finally transmitted to the output shafts. The powershift transmission has a upper output at the rear of the transmission , and a lower output at the front side. Output rotation of the rear upper output is the same engine rotation when the forward clutch is engaged, while output rotation of the front output is the opposite as the engine rotation with the forward clutch engaged.

The lower front output has a four wheel drive clutch to enable four-wheel drive / two wheel drive to be selected. The clutch is similar to the other clutches. The four wheel drive clutch is controlled electrically. The clutch is engaged with an electrical signal through a solenoid located in the transmission control valve.

N13–07–10

DRIVETRAIN AND BRAKES 5. The Transmission Controls

Transmission EGM / ECU located under floor RHS

Transmission control valve

Operation of the transmission control valve is as follows: (Refer to transmission hydraulic circuit) The control valve has 8 solenoids, and a ramp valve. Regulated pressure between 14 bar — 18.5 bar dependent on the engine RPM is directed to the control valve. In the control valve the pressure is then directed to the solenoid activated spool valves. When a gear is selected a solenoid for the relevant gear is activated this lifts a spool valve allowing fluid into the clutch activating the gear. As the gear is activated, the ramp valve will give a smooth progressive engagement of the gear. When forward is selected the forward proportional solenoid is activated. When reverse is selected the reverse proportional solenoid is activated. The power flow goes through a reverse idler changing the rotation of the transmission. The smooth engagement of the forward and reverse clutches is controlled by the Trax software. Range is selected as follows: When the 1st speed solenoid is activated this will shift the spool engaging the 1st speed clutch.

As each speed is selected the previous speed clutch disengages. The clutches also have modulation which operates as follows: When the range is changed, oil will flow through the ramp valve to the chosen range clutch engaging the clutch in a progressive manner. This protects the transmission from harsh gear changes and excessive strain on the transmission. The control valve also controls the front lower output (four-wheel drive) clutch. If the solenoid is activated this will shift the spool engaging the (four-wheel drive) clutch. The ECU has an input from a speed sensor. The sensor measures the speed of the rear output shaft. This information is used in the electronic gear selector to determine shift logic. Since the sensor picks up output gear speed, the signal will be in direct relation to the turbine speed if any directional clutch is engaged.

N13–07–11

DRIVETRAIN AND BRAKES Control Valve Solenoid Activation Activated Solenoids Transmission Gear

Direction Solenoids F

R

Range Solenoids 1

2

3

4

Four-Wheel Drive Solenoid

Engaged Clutches

F1

Forward , 1st

F2

Forward 2nd

F3

Forward 3rd

F4

Forward 4th

R1

1st Reverse

R2

2nd Reverse

R3

3rd Reverse

Four-Wheel Drive

Four-Wheel Drive = Active Solenoid

N13–07–12

DRIVETRAIN AND BRAKES Power Flows 1st Gear — Forward clutch engaged

When 1st gear forward is engaged the forward clutch is locked, this then will transmit the power from the torque convertor on axis A through axis B onto the 1st speed clutch on axis C. The 1st speed clutch is locked

this then transmits the power to the rear output shaft, if 4WD is selected the power is also directed to the front output shaft on axis E.

N13–07–13

DRIVETRAIN AND BRAKES 2nd Gear — Forward clutch engaged

When 2nd gear forward is engaged the forward clutch is locked, this then will transmit the power from the torque convertor on axis A through axis B onto the 2nd speed clutch. The 1st speed clutch will be

disengaged and the 2nd speed clutch is locked this transmits the power to the rear output shaft axis C, if 4WD is selected the power is also directed to the front output shaft on axis E.

N13–07–14

DRIVETRAIN AND BRAKES 3rd Gear — Forward clutch engaged

When 3rd gear forward is engaged the forward clutch is locked, this then will transmit the power from the torque convertor on axis A through axis B onto axis C. The 2nd speed clutch will be disengaged and the 3rd

speed clutch is locked this transmits the power to the rear output shaft axis C, if 4WD is selected the power is also directed to the front output shaft on axis E.

N13–07–15

DRIVETRAIN AND BRAKES 4th Gear — Forward clutch engaged

When 4th gear forward is engaged the forward clutch is locked, this then will transmit the power from the torque convertor on axis A through axis B onto axis C. The 3rd speed clutch will be disengaged and the 4th speed clutch is locked this transmits the power to the rear output shaft axis C, if 4WD is selected the power is also directed to the front output shaft on axis E. When 4th gear is selected on the transmission control the transmission will enter an automatic mode. The transmission ECU will select the gear relevant to the rear output shaft speed and make gear changes the speed increases.

N13–07–16

DRIVETRAIN AND BRAKES Reverse 1st Gear — Reverse engaged

When 1st gear reverse is engaged the reverse clutch is locked, this then will transmit the power from the torque convertor on axis A through axis D. This axis reverses the direction onto axis B. The 1st speed clutch is locked this transmits the power to the rear output shaft axis C, if 4WD is selected the power is also directed to the front output shaft on axis E.

N13–07–17

DRIVETRAIN AND BRAKES

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N13–07–18

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION The following information is presented as an aid to isolate and determine the specific problem area in a transmission that is not functioning correctly. When diagnosing a transmission problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connection lines, and controls, including the engine as a complete system. By analysing the description and operation together with the information in this section and the pressure testing section, it should be possible to identify and correct any malfunction which may occur in the system.

Diagnosing Procedures In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is the “life blood” of the transmission. It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping and to cool and lubricate the working components. Faults fall into three general categories: mechanical, hydraulic and electrical. Stall Test Use a stall test to identify whether the transmission, torque converter, or the engine is the malfunctioning component when a complaint of poor performance is made. Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure may also be measured.

BHN1307TA

Mechanical And Electrical Checks Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical checks should be made: • Check the parking brake for correct adjustment. • Ensure all lever linkages are properly connected and adjusted in each segment and at all connecting points. • The controls are actuated electrically. Check the wiring and electrical components. • Ensure that all components of the cooling system are in good condition and operating correctly. • The radiator must be clean to maintain the proper operating temperatures for the engine and transmission. Clean the radiator, if necessary using compressed air. • The engine must be operating correctly. Ensure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications. Hydraulic Check Note: • The transmission fluid must be at the operating temperatures of 80° C (180° F) to achieve correct fluid level and pressure readings.

•

Caution: Do not attempt to make these checks with cold oil.

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check: The Check the oil level in the transmission. transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with torque converter at “stall”. (Refer to torque converter stall procedure).

N13–07–19

DRIVETRAIN AND BRAKES Torque Converter Stall Procedure

•

•

•

Caution: If the operating pressures at idle are too low, do not carry out this test. Caution: Do not operate the torque converter at stall condition longer than 30 seconds at one time, shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature 120°C (250°F) maximum will cause damage to transmission clutches, fluid, torque converter, and oil seals. Caution: If the engine RPM recorded by the tachometer exceeds the maximum specified RPM, reduce the engine RPM to idle immediately. Clutch slippage is indicated.

Permitted Torque Converter Stall Speeds 860 Elite Maximum no-load engine RPM

2350 ± 25

Stall against the hydraulics @ 225 bar

2300 ± 25

Stall against the transmission

2200 ± 25

Stall against transmission and the hydraulics

2000 ± 50

Stall against the transmission, hydraulics and the steering

2000 ± 50

Note: • Transmission fluid level and engine coolant level must be correct. Both fluids must be at normal operating temperature Note: • The transmission fluid must be at the operating temperature of 80° C (180° F) to achieve the correct readings. Note: Check the engine is capable of obtaining the specified maximum no-load engine RPM before stall testing.

•

•

Caution: Be careful that the vehicle does not move unexpectedly when operating the engine and torque converter at stall RPM.

1. Put the vehicle against a solid barrier, such as a wall, apply the parking brake, service brakes and block the wheels. 2. Start the engine. 3. Select the highest gear and increase the engine speed to the maximum RPM until the tachometer reading stabilizes. 4. Put the directional control lever in FORWARD (or REVERSE, as applicable). 5. Read the stall speed RPM on the tachometer.

N13–07–20

DRIVETRAIN AND BRAKES Problem

Action

Possible Cause

Stall speed to high

•

Low oil level

Low clutch pressure(s).

Stall speed too low

• • • •

Internal damage within the torque converter.

•

REPAIR/REPLACE the torque converter.

• •

Low oil level.

• •

FILL to proper level.

• •

Faulty charging pump.

• •

REPLACE charging pump.

• •

Low oil level.

• •

FILL to correct oil level.

• • • • •

Defective charging pump.

• • • • •

REPLACE charging pump.

• • •

Worn charging pump.

• • •

REPLACE.

•

Low engine RPM at torque converter stall.

•

CHECK engine governor.

•

See “Overheating” and make same checks.

•

MAKE corrections as explained in “Overheating”.

Low clutch pressure

Low charging pump output

Overheating

Noisy torque converter

Lack of power

•

• Slipping clutch(es). • Engine maximum no-load RPM • speed too low.

Clutch pressure regulating valve stuck open. Broken or worn clutch shaft or piston sealing rings. Suction screen blocked.

Dirty oil cooler. Restriction in cooler lines. Low oil level. Worn oil sealing rings.

Worn charging pump. Worn or damaged bearings.

N13–07–21

CHECK the oil level (should always be checked prior to stall testing). CHECK clutch pressure(s). CHECK clutch(es). CHECK engine controls and performance.

CLEAN valve spool and housing. REPLACE sealing rings.

CLEAN suction screen and charging pump. CLEAN oil cooler. CHANGE cooler lines. FILL to correct oil level. REMOVE, DISASSEMBLE and REBUILD torque converter assembly. REPLACE. A complete DISASSEMBLY will be necessary to determine which bearing is faulty.

DRIVETRAIN AND BRAKES Problem

Cause

Action

Vehicle does not move

Faulty supply to the solenoid valves

Check / Replace

Damaged wiring connection between transmission and vehicle

Repair / Replace

Oxidised contacts in the electrical wiring

Clean

Break in electrical harness

Replace

Damaged solenoids

Replace

Damaged sensors

Replace

Short circuits or false contacts

Check / Replace fuses

Irregular functioning of the electronic gear management (EGM / ECU)

Replace EGM / ECU

Incorrect oil Level

Top up

Check for leaks

Repair / Top up

Blocked intake filter

Clean

Damaged oil pump

Replace

Damaged oil pump relief valve

Replace oil pump

Blocked / damaged transmission filter

Replace

Damaged / jammed control valve

Replace

Damaged converter

Replace

Oil temperature below 0ºC

Wait for the oil to reach working temperature (stall test)

Damaged rotary seals

Replace

Valid for TLB2

N13–07–22

DRIVETRAIN AND BRAKES Problem

Cause

Action

Vehicle has reduced power transmission

Incorrect oil temperature

Wait for the oil to reach working temperature (stall test)

Transmission oil overheating

Restore acceptable temperature values

Incorrect operating pressure

Check hydraulic circuit and replace (oil pump, filters, control valve)

Damaged converter

Replace

Incorrect oil level

Top up

Worn clutch unit

Replace / Repair

4WD clutch failure

Repair / Replace 4WD shaft group

Overheating solenoids

Replace

Damaged transmission and vehicle wiring connections

Repair / Replace

Damaged EGM / ECU logic

Replace EGM / ECU

Damaged sensors

Replace

Damaged hydraulic cooling system

Repair

Dirty heat exchanger

Clean

Parking brake inadvertently activated

Release

Excessive dirt on axle wheel hubs

Clean

Seizing (broken gears, shafts, bearings, etc)

Check / Repair / Replace

Braking force outside transmission: irregular axle operation

Check / Repair axle

Clutch plate drag

Repair / Replace

Damage converter

Replace

Damaged oil thermostat

Replace

Incorrect oil level

Top up

Worn oil pump

Replace

Overheating

N13–07–23

DRIVETRAIN AND BRAKES Problem

Cause

Action

Wheels rotate when machine is raised

Clutch plate drag Low oil temperature (high oil viscosity) Incorrect oil specifications Damaged control valve Faulty reverse locking

Repair / Replace Wait for oil to working temperature (stall test) Replace oil and filters Replace Repair / Replace

Noise

Damaged converter

Replace

Seizing (broken gears, shafts, bearings, etc. )

Check / Repair / Replace

Worn clutch plates

Replace

Worn synchroniser actuation unit

Replace

Worn 4WD clutch

Replace

Irregular actuation

Damaged control valve Electrical system fault Worn clutch plates Damaged converter Low oil temperature (high oil viscosity ) Overheating Faulty EGM / ECU operation Damaged hydraulic system

Replace Repair / Replace Replace Replace Wait for the oil to reach working temperature (stall test) See overheating Replace EGM / ECU Repair / Replace

Gear remains engaged

Damaged / jammed shuttleshaft lever

Repair / Replace

Electrical system fault

Repair / Replace

Damaged control valve

Replace

Damaged hydraulic system

Repair / Replace

Damaged clutch unit

Repair / Replace

Irregular EGM / ECU operation

Replace EGM / ECU

No 4WD power transmission

Damaged 4WD clutch Hydraulic system fault Damaged control valve Faulty brake sensor Electrical system fault Faulty EGM / ECU operation

Replace Repair / Replace Replace Check / Replace Repair / Replace Replace EGM / ECU

Gear Shift won’t engage

Damaged clutch unit Damaged hydraulic system Damaged control valve Damaged pressure sensors Electrical system fault Irregular EGM / ECU operation

Repair / Replace Repair / Replace Replace Check / Replace Repair / Replace Replace EGM / ECU

N13–07–24

DRIVETRAIN AND BRAKES Fault Codes Trax (Transmission EGM / ECU) Diagnostics — Startup When the TRAX controller is connected to the vehicle, at key on : • If for 0.5 seconds all the gear lamps come on, then the ECU is working OK. (at least the power supply and the dash board connection is ok ) • If this does not illuminate the transmission may have developed a fault, then follow these 5 steps. 1

Checkfor a12 volt supply at pin 1,2,5,8,34.

2

Check the ground at pin at 29.

3

Check the dashboard connection.

4

Try to connect via a serial line

5

Substitute the ECU

Error Codes The Powershift transmission controller has an inbuilt diagnostic facility. This facility utilises a blink code that will be displayed via theTransmission Status lamp. The Trax controller continuously monitors the inputs and outputs if a problem occurs then an error / blink code will be display via the Transmission Status lamp In order to eliminate confusion the error / blink codes can only be displayed one at a time, if two or more errors have occurred then the priority code will be shown first. Using a Carraro-Terex service tool all codes can be displayed at the same time. Blink Codes / CTC Codes Error / blink codes are displayed with a numeric code called CTC (Carraro Trouble Code) of two digits (except CTC 2 no errors). The first digit is represented with a long pulse, the second digit with a short pulse. So four long pulses followed by two short pluses this means error / blink code 42 is active. The illustration shows the position of the dash board mounted blink light.

N13–07–25

DRIVETRAIN AND BRAKES The table below lists the error / blink codes. CTC

Meaning

Reaction

Action

2

No errors

None

No action

21

Main ring pressure not ok, or main ring pressure switch failure

Vehicle down

1. Check for continuity between the sensor and ECU pin n.44 2. Check for continuity between sensor and ground 3. Remove the sensor and check the pressure is over 11 bar with the engine running 4. Replace the sensor

23

Engine speed rpm not correct

Use 1600 rpm as default, degraded modulation performance

Check for continuity between engine alternator output for the frequency speed signal and pin 53 ECU

25

FNR lever input pattern error

Vehicle down

1. Check the for continuity between the direction lever and ECU pin 18,46,19,47 2. Check power supply and ground continuity 3. Replace the lever

32

Temperature signal temperature to high over 110º C

No action

1. Cool the transmission 2. Check the transmission cooling system

33

Temperature signal temperature to low below — 20º C

No action

Warm up the transmission

36

Temperature signal sensor failure

1. Check the continuity between the sensor and ECU pin 43 Use 60º C as default, degraded 2. Check the continuity modulation performance between the sensor and ground 3. Replace the sensor

42

Temperature sensor signal to high, temperature sensor not correctly connected

43

Temperature sensor signal to low, temperature sensor short circuited to ground

53

Power supply over voltage

No action ECU damaged over 40 V

54

Power supply under voltage

Vehicle down

57

PWM 1 Forward clutch proportional solenoid over current

Forward direction down

1. Check wiring of the FWD solenoid 2. Check continuity to the ECU pin 3,12 3. Replace the solenoid

58

PWM 4 Reverse clutch proportional solenoid over current

REV Direction down

1. Check wiring of the REV solenoid 2. Check continuity to the ECU pin 7,41 3. Replace the solenoid

CTC

Meaning

Reaction

Action

N13–07–26

1. Check power supply to the ECU pins 1,2,5,8,34 2. Admitted range 10 V — 16 V 3. Check the ground continuity ECU pin 29

DRIVETRAIN AND BRAKES 61

Digital out 1–2 First and second gear solenoids over current

1st and 2nd gear down

1. Check wiring of the 1st and 2nd gear solenoids 2. Check continuity to the ECU pin 9,37 3. Replace 1st and 2nd gear solenoids

62

Digital out 3–4 Third and forth gear solenoids over current

3rd and 4th gear down

1. Check wiring of the 3rd and 4th gear solenoids 2. Check continuity to the ECU pin 10,38 3. Replace 3rd and 4th gear solenoids

64

Digital out 7–8 Auto and transmission status lamps over current

Auto and status lamps down

1. Check wiring of lamps auto and transmission status 2. Check continuity to the ECU pin 42,14 3. Replace auto and transmission status lamps

71

PWM 1 Forward clutch proportional solenoid measured current over reference current / reference current over zero, measured current zero

Forward direction down

Same as CTC 57

PWM 4 Reverse clutch proportional solenoid measured current over reference current / reference current over zero, measured current zero

Reverse direction down

Same as CTC 58

88

Serial line communication error

None

Check serial line continuity, then restart ECU

89

Minor internal recoverable ECU error

None

Restart ECU

99

Unrecoverable ECU error

None

Substitute ECU

77

N13–07–27

DRIVETRAIN AND BRAKES

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N13–07–28

DRIVETRAIN AND BRAKES DIAGNOSING AND TESTING — CARRARO POWERSHIFT TRANSMISSION PRESSURE TESTING

•

Warning: Do not work on or around hydraulic systems without wearing safety glasses. Failure to follow this instruction, may result in personal injury.

Note: All pressure tests to completed with the transmission at 80°C.

•

Note: All temperature and pressure test ports have 9/16” — 18 UNF-2B.

•

Measure pressures at 900 — 2200 RPM engine speed with the oil temperature at 80°C. Pump acceptance criteria on bench test : 19 ltr per min total pump flow at 900 rpm measured before filter. 1

Torque Converter pressure test port

2

Forward clutch pressure test port

3

Reverse clutch pressure test port

4

Lubrication pressure test port

5

Gear pressure test port

6

Control valve pressure test port

7

Differential lock pressure test port

1. Gear pressure test port Transmission top view

2. Forward clutch pressure test port Transmission top view — Select forward first • Pressure should be 13.5 – 16.5 bar • Max pressure 0.3 bar in neutral

N13–07–29

BHN1307TB

DRIVETRAIN AND BRAKES 3. Reverse clutch pressure test port Transmission top view — Select reverse first • Pressure should be 13.5 – 16.5 bar • Max pressure 0.3 bar in neutral

4.

Differential lock pressure Transmission right side view • Pressure should be 14 — 17 bar

test

port

5. Control valve pressure test port Transmission top view • Pressure should be 14 — 17 bar

N13–07–30

DRIVETRAIN AND BRAKES 6. Torque converter inlet pressure test port Transmission left hand side view • Pressure should read between 3.0 — 9.0 bar.

7. Lubrication pressure test port Transmission top view • Pressure should be 1 — 5 bar on neutral clutch position • Pressure should be 1 — 5 bar on FWD / REV clutch position

N13–07–31

DRIVETRAIN AND BRAKES

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N13–07–32

DRIVETRAIN AND BRAKES REMOVAL AND INSTALLATION — CARRARO POWERSHIFT TRANSMISSION

BHN1307RA

Operation: Removing and Installing the Powershift Transmission Suitable lifting equipment, Suitable transmission jack

Job Code: xx xx xx xx Standard tools

Removal

1. Park the machine on firm level ground. 2. Position 150mm blocks under each stabiliser and fully lower. Raise the front of the machine to the same level and position 150 mm blocks under each front wheel. 3. Remove the right-hand rear wheel. For additional information, refer to Section M12-01 REAR WHEEL, PAGE M12–01–5 . 4. Support the machine. Note: • Ensure there is at least 915mm clearance between the ground and the chassis .

915mm TV051247

5. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . Note: • Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner. 6. Drain the transmission fluid into a suitable container. 7. Install the transmission drain plug and a new O-ring. 8. Tighten to 44Nm (32 lb.ft).

N13–07–33

DRIVETRAIN AND BRAKES 9. Detach the rear propeller shaft from the rear axle.

TV040057

10. Remove the rear propeller shaft from the transmission.

TV040086

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Remove and discard the retaining bolts.

•

11. Disconnect the speed sensor electrical connector.

N13–07–34

DRIVETRAIN AND BRAKES 12. Disconnect the transmission temperature sensor electrical connector.

For 13. Remove the cabin heater air ducting. Section additional information, refer to H08-01 CABIN HEATER AIR DUCTING, PAGE H08–01–13 . 14. Disconnect the transmission fluid pressure sensor electrical connector.

Note: • Make a note of the position of any electrical connectors prior to disconnection to aid installation. 15. Disconnect the 8 transmission valve block electrical connectors.

N13–07–35

DRIVETRAIN AND BRAKES 16. Remove the wiring harness cable ties.

TV051264

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: • Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner. 17. Disconnect the differential lock hydraulic feed hose from the differential lock.

18. Disconnect the oil filter feed hose from the transmission.

N13–07–36

DRIVETRAIN AND BRAKES 19. Detach the oil filter mounting bracket from the transmission mounting bracket and position to one side.

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

Note: • Support the hydraulic pump using suitable straps. 20. Release the hydraulic pump from the rear of the transmission and position to one side.

TV040359

TV040360

N13–07–37

DRIVETRAIN AND BRAKES

•

Caution: Clean around any hoses or pipe work prior to being disturbed. Blank-off any resulting apertures to prevent the ingress of dirt or foreign objects which may result in damage to the machine.

Note: Be prepared for some fluid loss. Collect the fluid in a suitable container and dispose of the fluid in an appropriate manner.

•

21. Release the oil cooler inlet hose.

22. Release the oil cooler outlet hose.

23. Detach the front transmission.

propeller

shaft from the

N13–07–38

DRIVETRAIN AND BRAKES 24. Remove the front propeller shaft.

25. Remove the dipstick / oil filler tube from the transmission.

26. Remove the torque converter housing cover plate.

27. Remove the torque converter bolt access hole blanking plug.

TV040166

N13–07–39

DRIVETRAIN AND BRAKES 28. Using the access hole remove the torque converter retaining bolts.

TV040362

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

29. Position a suitable transmission jack under the transmission and secure the bell housing using suitable straps or chains. 30. Position a suitable jack under the engine and support. 31. Reposition the hydraulic hoses and wiring harness for access to the mounting bolts. Note: Left-hand side shown, right-hand side similar.

•

32. Remove the transmission rear mounting bracket retaining bolts (1) and the mounting bolts (2) remove the mounting brackets (3).

3

2

33. Remove the transmission mounting brackets and secure the rear of the transmission to the transmission jack. Note: Position of the earth straps

•

34. Remove the transmission retaining bolts. 35. Detach the transmission from the engine. 36. Lower the transmission and withdraw from the machine.

N13–07–40

DRIVETRAIN AND BRAKES Installation 1. To install, reverse the removal procedure. 2. Tighten to 71 Nm (52 lb.ft).

TV040361

3. Tighten to 41 Nm (30 lb.ft).

TV040362

Note: • Install new propeller shaft retaining bolts. 4. Tighten to 47 Nm (35 lb.ft).

5. Tighten to 98Nm (72 lb.ft).

TV040360

N13–07–41

DRIVETRAIN AND BRAKES 6. Tighten to 98Nm. (72 lb.ft).

TV040359

Note: • Install new retaining bolts. 7. Tighten to 47 Nm (35 lb.ft).

TV040086

•

Caution: Make sure the propeller shaft universal joints are in line. Failure to follow this instruction may result in damage to the machine.

Note: • Install new retaining bolts. 8. Tighten to 47Nm (35 lb.ft).

TV040057

N13–07–42

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION

BHN1307DA

Operation: Disassembly and Assembly of the Powershift Transmission

Job Code: xx xx xx xx

Suitable lifting equipment

Standard tools, Locally fabricated transmission housing lifting tool, Suitable puller, Bearing heater

Disassembly Note: • Mount the transmission to a suitable stand 1. Remove the torque converter.

2. Remove and discard the transmission oil filter. 3. Remove the rear drive flange retaining bolt. Recover the washer, O-ring seal and remove the rear drive flange. Note: • Remove and discard the rear drive flange seal.

4. Remove the power take off flange retaining bolts.

N13–07–43

DRIVETRAIN AND BRAKES 5. Remove the power take off flange.

6. Remove the power take off drive shaft.

Note: • Mark the position of the transmission oil pump to aid reassemble. 7. Remove the transmission oil pump retaining bolts and then remove the transmission oil pump.

TV040257

8. Using suitable snap ring pliers, remove the input shaft bearing snap ring.

N13–07–44

DRIVETRAIN AND BRAKES 9. Remove the four-wheel drive flange retaining bolt. Recover the washer, O-ring seal and remove the four-wheel drive flange. Note: • Remove and discard the 4WD flange oil seal.

10. Remove the solenoid block. Note: Remove and discard the gasket.

•

11. Remove the front casing retaining bolts.

N13–07–45

DRIVETRAIN AND BRAKES

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

12. Remove the front casing .

13. Remove and discard the O-ring seals.

14. Remove the reverse idler shaft.

15. Remove the input shaft forward and reverse clutch assembly.

N13–07–46

DRIVETRAIN AND BRAKES 16. Remove the oil retaining cover. Note: • Using the Carraro CA715732 special tool 17. Remove the third and fourth clutch assembly (1) with the second clutch assembly (2) complete with the four wheel drive clutch (3).

2 3

1

N13–07–47

DRIVETRAIN AND BRAKES Assembly Note: • Install new O-ring seals.

• •

•

Caution: Take care not to damage the sealing rings. Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

1. To assemble, reverse the disassembly procedure.

N13–07–48

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT FORWARD AND REVERSE CLUTCHES Operation: Disassembly and Assembly of the Forward and Reverse Clutches None

Job Code: xx xx xx xx Standard tools, Clutch piston spring compressor

N13–07–49

BHN1307DB

DRIVETRAIN AND BRAKES 1

Seal ring

2

Snap ring

3

Bearing

4

Spacer

5

Needle bearing bush

6

Gear Z37 (rvs)

7

Lockring

8

Clutch plate lockring

9

Clutch kit

10

Thrust washer

11

Lockring

12

Lock-spring cover

13

Spring

14

Clutch sleeve

15

Clutch piston

16

Seal ring

17

Seal ring

18

Inner shaft

19

Split pin

20

Rivet

21

Gear Z37 (fwd)

22

Bearing

23

Snap ring

24

Seal ring

25

Snap ring

26

Bearing

27

PTO transmission shaft

N13–07–50

DRIVETRAIN AND BRAKES Disassembly — Reverse clutch 1. Remove the circlip.

2. Using a suitable puller release the bearing from the shaft.

3. Remove the spacer.

4. Remove the reverse drive gear.

N13–07–51

DRIVETRAIN AND BRAKES 5. Remove the needle bearing bush (1) and the thrust washer (2).

6. Remove the snap ring (1) and the retaining ring (2).

7. Remove the roll pin (1) and the clutch pack (2).

8. Using a suitable hydraulic press, compress the piston return spring. 9. Using suitable circlip pliers, release the piston return spring retaining circlip.

TV040284

N13–07–52

DRIVETRAIN AND BRAKES 10. Remove the retaining ring

11. Remove the spring.

12. Remove the clutch sleeve.

13. Remove the clutch piston

N13–07–53

DRIVETRAIN AND BRAKES 14. Remove and discard the clutch piston outer seal (1) and inner seal (2).

Assembly reverse clutch Note: • Install new seals. 1. Install the clutch piston outer seal (1) and inner seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

N13–07–54

DRIVETRAIN AND BRAKES 3. Install the clutch sleeve.

4. Install the piston return spring.

5. Install the retaining ring.

6. Using a suitable hydraulic press, compress the piston return spring. 7. Using suitable snap ring pliers, install the circlip. Note: Make sure the snap ring is correctly located in the groove.

•

N13–07–55

DRIVETRAIN AND BRAKES 8. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: • Any plates found to be warped, damaged or worn must be replaced

TV051295

Note: • Soak new friction discs in transmission oil before assembly. Note: Alternate the friction and steel discs until the correct amount of discs are installed.

•

9. Install the clutch pack (2) and roll pin (1).

10. Install the retaining ring (2) and the snap ring (1).

N13–07–56

DRIVETRAIN AND BRAKES 11. Install the spacer (2) and the bearing (1).

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

12. Install the reverse drive gear.

13. Install the spacer.

14. Using a suitable hydraulic press and sleeve install the bearing. 15. Install the circlip.

N13–07–57

DRIVETRAIN AND BRAKES Disassembly Forward clutch 1. Remove the circlip.

2. Using a suitable puller release the bearing from the shaft.

3. Remove the spacer.

4. Remove the forward drive gear.

N13–07–58

DRIVETRAIN AND BRAKES 5. Remove the needle bearing bush (1) and the spacer (2).

6. Remove the snap ring.

7. Remove the retaining ring.

8. Remove the roll pin and clutch pack.

9. Using a suitable hydraulic press, compress the piston return spring.

N13–07–59

DRIVETRAIN AND BRAKES 10. Using suitable circlip pliers, release the piston return spring retaining circlip.

11. Remove the retaining ring (1) and the spring (2).

12. Remove the clutch sleeve.

Note: • The position of the piston in the clutch. 13. Remove the clutch piston assembly.

N13–07–60

DRIVETRAIN AND BRAKES 14. Remove and discard the clutch piston outer seal (1) and inner seal (2).

N13–07–61

DRIVETRAIN AND BRAKES Assemble forward clutch Note: • Install new seals. 1. Install the clutch piston inner seal (1) and outer seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

•

Caution: Take care not to damage the sealing rings.

2. Install the clutch piston into the clutch drum.

3. Install the clutch sleeve.

N13–07–62

DRIVETRAIN AND BRAKES 4. Install the piston return spring (1) and the retaining ring (2).

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly located in the groove.

TV040284

7. Using a suitable straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: • Any plates found to be warped, damaged or worn must be replaced.

TV051295

N13–07–63

DRIVETRAIN AND BRAKES Note: • Soak new friction discs in transmission oil before assembly. Note: • Alternate the friction and steel discs until the correct amount of discs are installed. 8. Install the clutch pack and the roll pin.

9. Install the retaining ring.

10. Install the snap ring.

N13–07–64

DRIVETRAIN AND BRAKES 11. Install the spacer (2) and the needle bearing bush(1).

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

12. Install the forward drive gear.

13. Install the spacer.

14. Using a suitable hydraulic press and sleeve install the bearing. 15. Install the cir-clip.

N13–07–65

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–07–66

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 2ND SPEED CLUTCH Operation: Disassembly and Assembly of the 2nd Speed Clutch None

BHN1307DC

Job Code: xx xx xx xx Standard tools, Clutch piston spring compressor

N13–07–67

DRIVETRAIN AND BRAKES 1

Bearing

2

Reverse shaft

3

Seal ring

4

Bearing

5

Gear Z45

6

Snap ring

7

Thrust washer

8

Needle bearing bush

9

Gear Z28

10

Lockring

11

Clutch plate lockring

12

Clutch kit

13

Thrust washer

14

Lockring

15

Lock spring cover

16

Spring

17

Clutch sleeve

18

Clutch piston

19

Seal ring

20

Seal ring

21

Split pin

22

Rivet

23

Shaft

24

Bearing

25

Seal ring

Disassembly 1. Using a suitable puller, remove the bearing (1) and the gear (2).

N13–07–68

DRIVETRAIN AND BRAKES 2. Using suitable circlip pliers, remove the clutch gear circlip.

3. Remove the spacer.

4. Remove the roll pin.

5. Remove the gear.

N13–07–69

DRIVETRAIN AND BRAKES 6. Remove the needle bearing bush (1) and the spacer (2).

7. Remove the spacer.

8. Remove the snap ring.

9. Remove the retaining ring.

N13–07–70

DRIVETRAIN AND BRAKES 10. Remove the clutch pack.

11. Using a suitable hydraulic press, compress the piston return spring. 12. Using suitable snap ring pliers, release the piston return spring retaining snap ring

13. Remove the retaining ring (1) and the spring (2).

14. Remove the clutch sleeve.

N13–07–71

DRIVETRAIN AND BRAKES 15. Remove the piston.

16. Remove and discard the clutch piston outer seal (1) and inner seal (2).

N13–07–72

DRIVETRAIN AND BRAKES Assembly Note: • Install new seals. 1. Install clutch piston inner seal (1) and outer seal (2).

•

Caution: Take care not to damage the sealing rings.

Note: The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

•

2. Install the clutch piston into the clutch drum.

3. Install the clutch sleeve.

N13–07–73

DRIVETRAIN AND BRAKES 4. Install the piston return spring (2), spring retaining ring (1).

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly located in the groove. 7. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: Any plates found to be warped, damaged or worn must be replaced.

•

TV051295

Note: • Soak new friction discs in transmission oil before assembly. Note: • Alternate the friction and steel discs until the correct amount of discs are installed. 8. Install the clutch plates.

N13–07–74

DRIVETRAIN AND BRAKES 9. Install the clutch retaining plate.

10. Install the snap ring.

11. Install the spacer.

12. Install the spacer (2) and the bearing (1).

N13–07–75

DRIVETRAIN AND BRAKES

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

13. Install the 2nd gear.

14. Install the roll pin.

15. Install the spacer.

N13–07–76

DRIVETRAIN AND BRAKES 16. Using suitable circlip pliers, install the clutch gear circlip.

17. Using a suitable hydraulic press and sleeve, install the gear and bearing.

N13–07–77

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–07–78

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 1ST CLUTCH Operation: Disassembly and Assembly of the 1st Speed Clutch None

BHN1307DD

Job Code: xx xx xx xx Standard tools

23

Locking ring

24

Clutch plate lockring

25

Clutch kit

26

Lockring

27

Lock-spring cover

28

Spring

29

Clutch piston

30

Seal ring

31

Needle bearing bush

32

Bush

33

O-ring

N13–07–79

DRIVETRAIN AND BRAKES Disassembly 1. Remove the snap ring.

2. Remove the retaining plate.

3. Remove the clutch pack.

4. Using a suitable hydraulic press, compress the piston return spring. 5. Using suitable snap ring pliers release the piston return spring retaining snap ring.

N13–07–80

DRIVETRAIN AND BRAKES 6. Remove the retaining ring (1) and the spring (2).

7. Remove the piston.

8. Remove and discard the piston seals.

N13–07–81

DRIVETRAIN AND BRAKES Assembly Note: • Install new seals. 1. Install the clutch piston inner seal.

2. Install the clutch piston outer seal.

•

Caution: Take care not to damage the seals.

3. Install the clutch piston into the clutch drum.

4. Install the spring (2) and the retaining ring (1).

N13–07–82

DRIVETRAIN AND BRAKES 5. Using a suitable hydraulic press, and special tool compress the piston return spring. 6. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly positioned in the groove.

7. Using a suitable straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: • Any plates found to be warped, damaged or worn must be replaced.

TV051295

Note: • Soak new friction discs in transmission oil before assembly. Note: • Alternate the friction and steel discs until the correct amount of discs are installed. 8. Install the clutch plates.

N13–07–83

DRIVETRAIN AND BRAKES 9. Install the clutch retaining plate.

10. Install the snap ring.

N13–07–84

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 3RD AND 4TH SPEED CLUTCHES Operation: Disassembly and Assembly of the 3rd and 4th speed Clutch None

Job Code: xx xx xx xx Standard tools, Bearing heater

N13–07–85

BHN1307DE

DRIVETRAIN AND BRAKES 1

Bearing

2

Thrust washer

3

Gear Z44

4

Lockring

5

Clutch plate lockring

6

Clutch kit

7

Needle bearing bush

8

Thrust washer

9

Lockring

10

Lock-spring cover

11

Spring

12

Clutch sleeve

13

Clutch piston

14

Seal ring

15

Seal ring

16

Seal ring

17

Shaft Z60

18

Rivet

19

Split pin

20

Clutch kit

21

Gear Z30

22

Gear Z51

N13–07–86

DRIVETRAIN AND BRAKES Disassembly 3rd speed clutch 1. Using a suitable puller, remove the bearing and spacer.

2. Remove the 3rd speed gear and bearing.

3. Remove the bearing.

4. Remove the spacer

N13–07–87

DRIVETRAIN AND BRAKES 5. Remove the roll pin.

6. Remove the snap ring.

7. Remove the retaining plate.

8. Remove the clutch pack.

9. Using a suitable hydraulic press, compress the piston return spring.

N13–07–88

DRIVETRAIN AND BRAKES 10. Using suitable snap ring pliers release the piston return spring retaining snap ring.

11. Remove the retaining ring (1) and the spring (2)

12. Remove the clutch sleeve.

13. Remove the piston.

N13–07–89

DRIVETRAIN AND BRAKES 14. Remove and discard the clutch piston outer seal (1) and inner seal (2).

N13–07–90

DRIVETRAIN AND BRAKES Assembly 3rd speed clutch Note: • Install new seals. 1. Install clutch piston outer seal (1) and inner seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

•

Caution: Take care not to damage the seals.

2. Install the clutch piston into the clutch drum.

3. Install the clutch sleeve.

N13–07–91

DRIVETRAIN AND BRAKES 4. Install the piston return spring (2), retaining ring (1).

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly positioned in the groove.

TV040284

7. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: • Any plates found to be warped, damaged or worn must be replaced.

TV051295

Note: • Soak new friction discs in transmission oil before assembly.

Note: Alternate the friction and steel discs until the correct amount of discs are installed.

•

N13–07–92

DRIVETRAIN AND BRAKES 8. Install the clutch plates.

9. Install the retaining plate.

10. Install the snap ring.

11. Install the roll pin.

N13–07–93

DRIVETRAIN AND BRAKES 12. Install the spacer.

13. Install the bearing.

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: • Align the splines on the clutch gear with the internal teeth of the steel discs. 14. Install the 3rd speed drive gear and bearing.

15. Using a suitable hydraulic press and sleeve install the spacer and bearing.

N13–07–94

DRIVETRAIN AND BRAKES Disassembly 4th speed clutch 1. Using a suitable bearing puller remove the bearing (1) and the oil sleeve (2).

2. Using a suitable bearing puller remove the 1st speed gear and bearing.

3. Remove the gear.

4. Remove the bearing (1) and the spacer (2).

N13–07–95

DRIVETRAIN AND BRAKES 5. Remove the roll pin.

6. Remove the snap ring.

7. Remove the retaining plate.

8. Remove the clutch pack.

9. Using a suitable hydraulic press compress the piston return spring.

N13–07–96

DRIVETRAIN AND BRAKES 10. Using suitable snap ring pliers, release the piston return spring retaining snap ring.

TV040284

11. Remove the retaining ring (1) and the spring (2).

12. Remove the clutch sleeve.

13. Remove the piston.

N13–07–97

DRIVETRAIN AND BRAKES 14. Remove and discard the outer seal (1) and the inner seal (2).

Assembly 4th speed clutch Note: • Install new seals. 1. Install clutch piston outer seal (1) and inner seal (2). Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size until the new seal is flush with the outer diameter of the piston.

•

Caution: Take care not to damage the seals.

2. Install the clutch piston into the clutch drum.

N13–07–98

DRIVETRAIN AND BRAKES 3. Install the clutch sleeve.

4. Install the piston return spring (2), retaining ring (1).

5. Using a suitable hydraulic press, compress the piston return spring. 6. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly positioned in the groove.

TV040284

N13–07–99

DRIVETRAIN AND BRAKES 7. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack. Note: • Any plates found to be warped, damaged or worn must be replaced.

TV051295

Note: • Soak new friction discs in transmission oil before assembly. Note: Alternate the friction and steel discs until the correct amount of discs are installed.

•

8. Install the clutch plates.

9. Install the retaining plate.

N13–07–100

DRIVETRAIN AND BRAKES 10. Install the snap ring.

11. Install the roll pin.

N13–07–101

DRIVETRAIN AND BRAKES 12. Install the spacer (2) and the bearing (1).

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the steel discs.

•

13. Install the 4th speed drive gear.

•

Caution: Take care not to damage the sealing ring.

14. Using a suitable hydraulic press and sleeve install the oil sleeve (2) and the bearing (1).

2

N13–07–102

1

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT 4WD CLUTCH Operation: Disassembly and Assembly of the 4WD Clutch None

BHN1307DF

Job Code: xx xx xx xx Standard tools, Suitable puller

N13–07–103

DRIVETRAIN AND BRAKES 1

Bolt M12x25

2

Washer

3

O-ring

4

Bearing

5

Snap ring

6

Shim 0.1mm

6

Shim 0.3mm

6

Shim 0.5mm

7

Thrust washer

8

Belleville washer

9

Spacer

10

O-ring

11

Clutch piston

12

O-ring

13

Brake plate

14

4WD shaft kit

15

Brake pin

16

O-ring

17

Rivet D6

18

Clutch kit (4WD)

19

Lockring

20

Lockring

21

Gear Z41

22

Needle bearing bush

23

Thrust washer

24

Bearing

25

Seal ring D45

26

Flange

27

Seal ring

N13–07–104

DRIVETRAIN AND BRAKES Disassembly 1. Using a suitable bearing puller remove the bearing.

2. Using a suitable press release the pressure on the belleville washers (1) and remove the snap ring (2) from the shaft.

3. Remove the washer (1) and the shimming (2).

Note: • The orientation of the belleville washers 4. Remove the Belleville washers.

N13–07–105

DRIVETRAIN AND BRAKES 5. Remove the sleeve.

6. Using a suitable bearing puller remove the bearing.

7. Remove the spacer.

8. Remove the gear.

N13–07–106

DRIVETRAIN AND BRAKES 9. Remove the snap ring.

10. Remove the retaining plate.

Note: • Note the plate orientation. 11. Remove the clutch pack.

12. Remove the spacer. When the spacer is removed push the dowels down releasing the piston.

N13–07–107

DRIVETRAIN AND BRAKES 13. Remove the dowels.

14. Remove the clutch piston seals.

Assembly

•

Caution: Take care not to damage the sealing rings.

Note: • Install new seals. Note: Soak new friction discs in transmission oil before assembly.

•

1. To assemble, reverse the disassembly procedure. Note: • The clutch piston inner and outer seals must be re-sized. Sizing is best accomplished by rotating the piston while holding a round object against the new sealing ring. Re-size untill the new seal is flush with the outer diameter of the piston. 2. Using a suitable steel straight edge, check the flatness of both the drive plates and the friction plates from the clutch pack.

N13–07–108

DRIVETRAIN AND BRAKES Note: • Any plates found to be warped, damaged or worn must be replaced

TV051295

3. Ensure dowels are fitted into the piston

4. Using suitable snap ring pliers, install the snap ring. Note: • Make sure the snap ring is correctly located in the groove.

TV040284

N13–07–109

DRIVETRAIN AND BRAKES Note: • Alternate the friction and steel discs until the correct amount of discs are installed.

TV040295

N13–07–110

DRIVETRAIN AND BRAKES

•

•

Caution: Make sure the clutch gear splines are fully installed. Failure to follow this instruction may result in damage to the transmission. Caution: Do not force this operation. Failure to follow this instruction may result in damage to the transmission.

Note: Align the splines on the clutch gear with the internal teeth of the friction discs.

•

5. When the circlip has been installed on the output shaft a measurement must be taken and shimmed.

Using a thickness gauge measure quote X between the washer and the lock ring Subtract from quote X fixed quote S1( S1=1.80mm) The result S is the thickness of shims which has to be inserted between the washer and the lock ring. S = X _ S1 = X (1.80mm) Selection of shims

Shims Range Thickness mm

0.1

0.3

Select the shim of thickness value S from the range of available shims.

0.5

Note: • Choose a shim so that a guaranteed stroke of 1.70 — 1.90 is achieved

N13–07–111

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–07–112

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT HYDRAULIC PUMP DRIVE SHAFT Operation: Disassembly and Assembly of the Hydraulic Pump Drive Shaft

BHN1307DJ

Job Code: xx xx xx xx

None

Standard tools, Suitable puller

4 3 2

1

TV040569

1

Charging Pump drive shaft

2

Sealing ring

3

Charging Pump drive shaft bearing

4

Charging Pump drive shaft bearing circlip

Disassembly 1. Using suitable circlip pliers, remove the charging pump drive shaft bearing circlip.

TV040343

N13–07–113

DRIVETRAIN AND BRAKES 2. Using a suitable puller, remove the hydraulic pump drive shaft bearing.

TV040344

3. Remove and discard the seals from the hydraulic pump drive shaft.

TV040345

N13–07–114

DRIVETRAIN AND BRAKES Assembly 1. Install the seals on the hydraulic pump drive shaft.

TV040345

2. Using a suitable press, install the hydraulic pump drive shaft bearing.

TV040346

3. Using suitable circlip pliers, install the charging pump drive shaft bearing circlip.

TV040343

N13–07–115

DRIVETRAIN AND BRAKES

Note: This page intentionally left blank.

N13–07–116

DRIVETRAIN AND BRAKES DISASSEMBLY AND ASSEMBLY — CARRARO POWERSHIFT TRANSMISSION CONTROL VALVE

1

Plug

2

Bolt m8x90

3

Plug

4

Control valve

5

On-off valve

6

Proportional valve

7

Valve block

8

Ramp valve

9

Gasket

Disassembly Note: • The position of the hydraulic control valves.

N13–07–117

BHN1307DL

DRIVETRAIN AND BRAKES 1. Remove the 8 hydraulic control valves.

2. Remove the plug.

3. Remove the boom lock outlet port plug (P).

4. Remove the hydraulic differential lock union (HDL).

N13–07–118

DRIVETRAIN AND BRAKES 5. Remove the brake outlet port (X).

6. Remove the ramp valve.

7. Remove the supply and gear pressure check port plugs.

Assembly Note: • Always fit new O-ring seals and gaskets 8. To assemble, reverse the disassembly procedure.

N13–07–119

DRIVETRAIN AND BRAKES

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N13–07–120

DRIVETRAIN AND BRAKES GENERAL PROCEDURE — CARRARO POWERSHIFT CLEANING AND INSPECTION AFTER TRANSMISSION REPAIR After the repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed. The following are considered the minimum steps to be taken: 1. Drain the entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from the machine for cleaning. 3. Replace oil filter elements cleaning out filter cases thoroughly. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow

BHN1307GB

will not adequately clean the cooler. If necessary, the cooler assembly should be removed from the machine for cleaning, using oil, compressed air, and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes. 5. Reassemble all components and use only the specified type of oil. Fill the transmission through the filler opening until fluid comes up to the oil level check port. Run the engine for 2 minutes at low RPM to prime the torque converter and hydraulic lines. Check the transmission oil with the engine running at idle RPM and add oil as necessary. Check the transmission oil level when the transmission is at the operating temperature 80 °C (176°F). 6. Check all drain plugs, lines, connections, etc. for leaks and tighten where necessary.

N13–07–121

DRIVETRAIN AND BRAKES

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N13–07–122

DRIVETRAIN AND BRAKES SPECIFICATIONS — CARRARO POWERSHIFT TRANSMISSION

BHN1307SA

Special Tools Special Tool Number

Description

CA119033

Handle

CA715004

Driver

CA715046

Driver

CA715149

Driver

CA715356

Gauger

CA715358

Clutch assembly / disassembly

CA715409

Driver

CA715494

Check

CA715495

Protection shims

CA715497

Pusher

CA715499

Protection

CA715501

Driver

CA715623

Driver

CA715732

Shaft B,C,E raising tool

CA715743

Protection shims

CA715744

Protection shims

CA715745

Gauger

CA715748

Pusher

CA716009

Gauger

CA716010

Protection

CA716018

Protection shims

CA716019

Pusher

CA716020

Gauger

CA716021

Extractor

N13–07–123

DRIVETRAIN AND BRAKES General Information Transmission

Power Shift

Make

Carraro

Model

TLB2

Power rating

85KW at 2200 RPM

Max, input torque Nm

800

Max, speed RPM

2400

TC pump drive configuration

W300

Flywheel HSG dimensions

SAE 3 STD

Output yokes

1410 Half round type

Front output yoke from engine CL drop

340 mm

Rear output yoke from engine CL drop

170 mm

Coaxial pump drive

SAE C 2 & 4 bolts — spline B/B

Pump drive torque capacity

Full engine torque

Solenoid electric voltage (V)

12

Modulation FWD / REV

Proportional hydraulic, electrically controlled

Gear shifting

Proportional hydraulic, electrically controlled

Speed gears

4 FWD — 3 REV

Dipstick port

Left hand side Right hand side

Cooler in / out port MFD sizing

Capable to hold 1st gear @ stall

Capacity System Powershift Transmission

Temperatures ALL

Viscocity 10W

Specification ATF

Temperature Specifications

• •

Normal operating temperature 80° (176°F). Maximum allowed transmission temperature 120°C (248°F).

N13–07–124

Capacity 23 (Total System)

Notes Check oil level with engine running at idle. Approved oils: Chevron Texaco textran 7045 Total Fina HY-Tran

DRIVETRAIN AND BRAKES Torque Values Note: • All threads assembly.

must

be

lubricated

before

Description

Nm

Lb.ft

Transmission Bell Housing

71

52

Torque Converter

41

30

Propeller Shaft

47

35

Hydraulic Pump

98

72

Transmission/Converter Housing

45

33

Output Flange

380

280

Transmission Housing Plug

17

13

Four-wheel Drive Flange

380

280

Charging Pump

23

17

Torque Converter Drive Plates

37

27

Transmission Oil Filter Adapter

23

17

Transmission Oil Filter

34

25

Transmission Control Valve

22

16

Transmission Control Valve Cover

6

4

Wiring Harness Connector Mounting Nut

7

5

Transmission Air Breather

38

28

N13–07–125

DRIVETRAIN AND BRAKES Torque Chart (Bolts) Note: • (Based in VDI 2230, µ = 0,14 and CCI standard) Metric

Inch Torque

Class 8,8 M5 x 0,8 M8 x 1,25 M10 x 1,5

Torque

Grade 5

Nm

lbft

5 — 6 20 — 25 40 — 50

3,7 — 4,4 14,7 — 18,4 29,5 — 36,8

0,5000

Nm

lbft

87 — 95

64,1 — 70,0

Torque Chart (O-Ring Port Plugs) Metric

Inch Torque

Size M10 x 1 M22 x 1,5 M33 x 2

Torque

Size

Nm

lbft

8 — 10 48 — 60 112 — 140

5,9 — 7,4 35,4 — 44,2 82,5 — 103,2

1,3125 — UN

Nm

lbft

112 — 140

82,5 — 103,2

Torque Chart (Pipe Plugs) Metric

Inch Torque

Size M22 x 1,5 UNI 7707

Torque

Size

Nm

lbft

48 — 60

35,4 — 44,2

0,1250 — 27 NPTF

N13–07–126

Nm

lbft

9 — 13

6,6 — 9,6

DRIVETRAIN AND BRAKES

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N13–07–127

ENGINE

P14 SECTION

DESCRIPTION AND OPERATION — ENGINE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . P14–01–1 REMOVAL AND INSTALLATION — ENGINE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . P14–01–3 REMOVAL AND INSTALLATION — ENGINE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–15 REMOVAL AND INSTALLATION — RADIATOR .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–27 REMOVAL AND INSTALLATION — FUEL TANK . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–31 REMOVAL AND INSTALLATION — AIR CLEANER .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–33 REMOVAL AND INSTALLATION — EXHAUST PIPE. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–35 REMOVAL AND INSTALLATION — EXHAUST SILENCER . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–37 GENERAL PROCEDURE — THROTTLE ADJUSTMENT .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–39 GENERAL PROCEDURE — DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM .. .. ..P14–01–41 SPECIFICATIONS — ENGINE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..P14–01–43

ENGINE DESCRIPTION AND OPERATION — ENGINE

BHP1401OA

For additional information, refer to the Perkins Engine Manual.

P14–01–1

ENGINE

Note: This page intentionally left blank.

P14–01–2

ENGINE REMOVAL AND INSTALLATION — ENGINE

BHP1401RA

Operation: Removing and Installing the Engine Suitable lifting equipment, Suitable jack

Job Code: 14 10 13 xx Standard tools

Vehicles with Air Conditioning Vehicles without Air Conditioning

Removal All vehicles 1. Remove the front tool box. For additional information, refer to Section K10-01 HARDNOSE/TOOLBOX, PAGE K10–01–3 . 2. Remove the hood. For additional information, refer to Section K10-01 HOOD, PAGE K10–01–5 . 3. Drain the cooling system. For additional information, refer to DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM, PAGE P14–01–41 in this section. 4. Remove the air cleaner. For additional information, refer to AIR CLEANER, PAGE P14–01–33 in this section. 5. Detach the exhaust stack spring and remove the exhaust stack.

TV040070

6. Loosen the exhaust silencer clamp (1). 7. Remove the exhaust silencer (2).

TV040071

Vehicles with Air Conditioning (A/C) 8. Evacuate the A/C system. For additional information, refer to Section H08-01 AIR CONDITIONING RECOVERY AND CHARGING, PAGE H08–01–45 .

P14–01–3

ENGINE Note: • Install blanking contamination.

plugs

to

avoid

9. Disconnect the A/C pipes from the A/C compressor (1). Note: • Remove and discard the O-ring seals. 10. Disconnect the A/C electro–magnetic clutch and glow plug wire electrical connectors (2). 11. Disconnect the engine coolant hose (3).

TV040072

12. Loosen the A/C accessory drive belt tensioner adjustment bolt and remove the accessory drive belt from the A/C compressor (1). 13. Remove the A/C compressor bracket retaining bolts (2).

TV040073

14. Remove the A/C compressor and mounting bracket.

TV040074

15. Disconnect the A/C inlet hose from the condensor (1). 16. Disconnect the A/C outlet hose from the condensor (2).

P14–01–4

ENGINE Note: • Install blanking plugs to avoid contamination. Note: • Remove and discard the O-ring seals.

TV040075

17. Remove the A/C condensor lower retaining bolts.

TV040078

All Vehicles 18. Disconnect the horn electrical connectors.

TV040076

19. Remove the radiator support bracket (1). 20. Remove the A/C condensor (if equipped) (2).

TV040077

P14–01–5

ENGINE Note: • Install blanking contamination.

plugs

to

avoid

21. Disconnect the oil cooler pipes from the oil cooler.

TV040079

22. Remove the oil cooler.

TV040080

23. Disconnect the radiator bottom coolant hose from the water pump.

TV040081

24. Disconnect the radiator top hose from the thermostat housing (1). 25. Detach the windshield washer bottle from the cooling fan shroud and position it to one side (2).

TV040082

P14–01–6

ENGINE 26. Remove the radiator assembly.

TV040083

27. Disconnect the fuel filter fuel supply and return lines (1). 28. Remove the fuel filter assembly (2).

TV040084

29. Loosen the throttle cable adjuster nut and disconnect the throttle cable from the fuel injection pump.

TV040691

Vehicles with Air Conditioning (A/C) Note: Install blanking contamination.

•

plugs

to

avoid

30. Disconnect the A/C pipe from the A/C filter/drier (1). 31. Disconnect the A/C filter/drier electrical connectors (2).

P14–01–7

ENGINE 32. Detach the A/C filter/drier and position it to one side.

All Vehicles 33. Disconnect the fuel pump electrical connectors (1). Note: Install blanking contamination.

•

plugs

to

avoid

34. Disconnect the fuel pipe from the fuel pump (2).

35. Remove the cab heater ducting. For additional information, refer to Section H08-01 CAB HEATER AIR DUCTING, PAGE H08–01–13 .

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: Remove and discard the retaining bolts.

•

36. Remove the front propeller shaft (1) and secure it to one side. 37. Remove the access cover (2).

TV040091

P14–01–8

ENGINE 38. Using the access hole, remove the torque converter retaining bolts.

TV040166

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

39. Attach the engine lifting eyes to the engine.

Note: • To aid removal of the engine, it is necessary to raise the front of the engine approximately 80mm higher than the rear . 40. Attach the suitable lifting equipment to the engine lifting eyes and support the engine.

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

41. Using a suitable transmission jack, support the transmission.

P14–01–9

ENGINE 42. Cut the cable ties and position the wiring harness to one side.

TV040138

43. Remove the transmission retaining bolts.

TV040361

44. Loosen the brake master cylinder.

TV040653

45. Remove the turbocharger outlet tube retaining bolts. 46. Disconnect the turbocharger outlet tube from the turbocharger.

TV040652

P14–01–10

ENGINE 47. Disconnect the coolant hose from the rear of the engine.

TV040655

48. Remove the engine mount retaining bolts. (right-hand side shown, left-hand side similar).

49. Remove the oil filter housing.

TV040651

50. Remove the engine mounting brackets from the engine. (left-hand side shown, right-hand side similar).

TV040692

P14–01–11

ENGINE

•

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury. Caution: Ensure the torque converter is remains with the transmission.

51. Remove the engine.

Installation Note: • Install new O-ring seals. 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

TV040692

3. Tighten to 25Nm (18 lb.ft).

TV040651

4. Tighten to 56Nm (41 lb.ft).

P14–01–12

ENGINE Note: • Install new retaining bolts. 5. Tighten to (1) 47Nm (34 lb.ft).

TV040091

6. Tighten to 41Nm (30 lb.ft).

TV040166

7. Tighten to 98Nm (72 lb.ft).

TV040083

P14–01–13

ENGINE

Note: This page intentionally left blank.

P14–01–14

ENGINE REMOVAL AND INSTALLATION — ENGINE

BHP1401RE

Operation: Removing and Installing the Engine

Job Code: 14 10 13 xx

Suitable lifting equipment, Suitable jack

Standard tools

Vehicles with Air Conditioning Vehicles without Air Conditioning

Removal All vehicles 1. Remove the front tool box. For additional information, refer to Section K10-01 HARDNOSE/TOOLBOX, PAGE K10–01–3 . 2. Remove the hood. For additional information, refer to Section K10-01 HOOD, PAGE K10–01–5 . 3. Drain the cooling system. For additional information, refer to DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM, PAGE P14–01–41 in this section. 4. Remove the air cleaner. For additional information, refer to AIR CLEANER, PAGE P14–01–33 in this section. 5. Remove the exhaust silencer. For additional information, refer to EXHAUST SILENCER REMOVAL AND INSTALLATION, PAGE P14–01–37 in this section. Vehicles with Air Conditioning (A/C) 6. Evacuate the A/C system. For additional information, refer to Section H08-01 AIR CONDITIONING RECOVERY AND CHARGING, PAGE H08–01–45 . Note: • Install blanking contamination.

plugs

to

avoid

7. Disconnect the A/C pipes from the A/C compressor (1). Note: • Remove and discard the O-ring seals. 8. Disconnect the A/C electro–magnetic clutch and glow plug wire electrical connectors (2). 9. Disconnect the engine coolant hose (3).

TV040072

P14–01–15

ENGINE 10. Loosen the A/C accessory drive belt tensioner adjustment bolt and remove the accessory drive belt from the A/C compressor (1). 11. Remove the A/C compressor bracket retaining bolts (2).

TV040073

12. Remove the A/C compressor and mounting bracket.

TV040074

13. Disconnect the A/C inlet hose from the condensor (1). 14. Disconnect the A/C outlet hose from the condensor (2). Note: Install blanking plugs to avoid contamination.

•

Note: • Remove and discard the O-ring seals.

TV040075

P14–01–16

ENGINE 15. Remove the A/C condensor lower retaining bolts.

TV040078

All Vehicles 16. Disconnect the horn electrical connectors.

TV040076

17. Remove the radiator support bracket (1). 18. Remove the A/C condensor (if equipped) (2).

TV040077

Note: • Install blanking contamination.

plugs

to

avoid

19. Disconnect the oil cooler pipes from the oil cooler.

TV040079

P14–01–17

ENGINE 20. Remove the oil cooler.

TV040080

21. Disconnect the radiator bottom coolant hose from the water pump.

TV040081

22. Disconnect the radiator top hose from the thermostat housing (1). 23. Detach the windshield washer bottle from the cooling fan shroud and position it to one side (2).

TV040082

24. Remove the radiator assembly.

TV040083

25. Disconnect the fuel filter fuel supply and return lines (1).

P14–01–18

ENGINE 26. Remove the fuel filter assembly (2).

TV040084

27. Loosen the throttle cable adjuster nut and disconnect the throttle cable from the fuel injection pump.

TV040691

Vehicles with Air Conditioning (A/C) Note: • Install blanking contamination.

plugs

to

avoid

28. Disconnect the A/C pipe from the A/C filter/drier (1). 29. Disconnect the A/C filter/drier electrical connectors (2). 30. Detach the A/C filter/drier and position it to one side.

All Vehicles 31. Disconnect the fuel pump electrical connectors (1).

P14–01–19

ENGINE Note: • Install blanking contamination.

plugs

to

avoid

32. Disconnect the fuel pipe from the fuel pump (2).

33. Remove the cab heater ducting. For additional information, refer to Section H08-01 CAB HEATER AIR DUCTING, PAGE H08–01–13 .

•

Caution: Secure the universal joint bearing cups to prevent contamination or damage.

Note: • Remove and discard the retaining bolts. 34. Remove the front propeller shaft (1) and secure it to one side. 35. Remove the access cover (2).

TV040091

36. Using the access hole, remove the torque converter retaining bolts.

TV040166

P14–01–20

ENGINE

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

37. Attach the engine lifting eyes to the engine.

Note: • To aid removal of the engine, it is necessary to raise the front of the engine approximately 80mm higher than the rear . 38. Attach the suitable lifting equipment to the engine lifting eyes and support the engine.

•

Warning: Secure the transmission to the transmission jack. Failure to follow this instruction may result in personal injury.

39. Using a suitable transmission jack, support the transmission. 40. Cut the cable ties and position the wiring harness to one side.

TV040138

41. Remove the transmission retaining bolts.

TV040361

P14–01–21

ENGINE 42. Loosen the brake master cylinder.

TV040653

43. Remove the turbocharger outlet tube retaining bolts. 44. Disconnect the turbocharger outlet tube from the turbocharger.

TV040652

45. Disconnect the coolant hose from the rear of the engine.

TV040655

46. Remove the engine mount retaining bolts. (right-hand side shown, left-hand side similar).

P14–01–22

ENGINE 47. Remove the oil filter housing.

TV040651

48. Remove the engine mounting brackets from the engine. (left-hand side shown, right-hand side similar).

TV040692

•

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury. Caution: Ensure the torque converter is remains with the transmission.

49. Remove the engine.

Installation Note: • Install new O-ring seals. 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

TV040692

P14–01–23

ENGINE 3. Tighten to 25Nm (18 lb.ft).

TV040651

4. Tighten to 56Nm (41 lb.ft).

Note: • Install new retaining bolts. 5. Tighten to (1) 47Nm (34 lb.ft).

TV040091

6. Tighten to 41Nm (30 lb.ft).

TV040166

P14–01–24

ENGINE 7. Tighten to 98Nm (72 lb.ft).

TV040083

P14–01–25

ENGINE

Note: This page intentionally left blank.

P14–01–26

ENGINE REMOVAL AND INSTALLATION — RADIATOR

BHP1401RB

Operation: Removing and Installing the Radiator

Job Code: 14 04 13 xx

Suitable container

Standard tools

Vehicles with air conditioning Vehicles without air conditioning

Removal All Vehicles 1. Drain the cooling system. For additional information, refer to DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM in this section. Vehicles with Air Conditioning (A/C) 2. Remove the A/C condensor lower retaining bolts and position to one side.

TV040078

All Vehicles 3. Disconnect the horn electrical connectors.

TV040076

4. Remove the radiator support bracket (1). 5. Detach the A/C condensor (2) (if equipped).

1

1 1 2

TV040584

P14–01–27

ENGINE 6. Detach the oil cooler.

TV040080

7. Disconnect the radiator lower coolant hose from the water pump.

TV040081

8. Disconnect the radiator upper coolant hose from the water pump (1). 9. Detach the windshield washer bottle from the cooling fan shroud and position it to one side (2).

TV040082

10. Remove the radiator.

TV040083

11. Remove the cooling fan shroud from the radiator.

Installation 1. To install, reverse the removal procedure.

P14–01–28

ENGINE 2. Tighten to 98Nm (72 lb.ft).

TV040083

P14–01–29

ENGINE

Note: This page intentionally left blank.

P14–01–30

ENGINE REMOVAL AND INSTALLATION — FUEL TANK

BHP1401RC

Operation: Removing and Installing the Fuel Tank Suitable trolley jack

Job Code: 14 28 13 xx Standard tools, Suitable container

Removal

•

•

Warning: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury. Warning: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

1. Isolate the battery ground cable. For additional information, refer to Section J09-01 BATTERY ISOLATION, PAGE J09–01–33 . 2. Drain the fuel tank into a suitable container. 3. Detach the hydraulic hoses from the fuel tank.

TV040180

Note: • Make a note of the position of the fuel lines prior to disconnection to aid installation. Install blanking contamination.

plugs

to

avoid

4. Disconnect the fuel supply and fuel return lines (1) from the fuel tank sender unit.

P14–01–31

ENGINE 5. Disconnect the fuel tank sender unit electrical connector (2).

TV040179

•

Warning: This component is very heavy. Ensure the lifting equipment is adequate. Failure to follow this instruction may result in personal injury.

6. Using a suitable trolley jack, support the fuel tank. 7. Remove the fuel tank.

TV040181

Installation 1. To install, reverse the removal procedure. 2. Tighten to 98Nm (72 lb.ft).

TV040181

P14–01–32

ENGINE REMOVAL AND INSTALLATION — AIR CLEANER

BHP1401RD

Operation: Removing and Installing the Air Cleaner None

Job Code: 14 33 13 xx Standard tools

Removal 1. Open the hood. 2. Remove the air cleaner pre cleaner.

TV040035

3. Remove the air cleaner assembly retaining bolts (1). 4. Detach the turbocharger inlet tube (2) and reposition the air cleaner.

TV040034

5. Disconnect the air cleaner vacuum electrical connectors and remove the air cleaner.

TV040178

Installation 1. To install, reverse the removal procedure.

P14–01–33

ENGINE

Note: This page intentionally left blank.

P14–01–34

ENGINE REMOVAL AND INSTALLATION — EXHAUST PIPE

BHP1401RF

Operation: Removing and Installing the Exhaust Pipe None

Job Code: XX XX XXxx Standard tools

Removal 1. Open the hood. 2. Remove the exhaust pipe retaining bolts.

3. Remove the exhaust pipe.

Installation 1. To install, reverse the removal procedure.

P14–01–35

ENGINE

Note: This page intentionally left blank.

P14–01–36

ENGINE REMOVAL AND INSTALLATION — EXHAUST SILENCER

BHP1401RG

Operation: Removing and Installing the Exhaust Silencer

Job Code: XX XX XXxx

None

Standard tools

Removal 1. Remove the exhaust pipe. For additional information, refer to EXHAUST PIPE REMOVAL AND INSTALLATION, PAGE P14–01–35 in this section. 2. loosen the silence r rear mounting bracket retaining bolts (1). 3. Remove the silencer rear retaining bolts (2).

1 2

4. Loosen the exhaust silencer clamp (1). 5. Remove the silencer front retaining bolts (2).

6. Remove the silencer.

Installation 1. To install, reverse the removal procedure.

P14–01–37

ENGINE

Note: This page intentionally left blank.

P14–01–38

ENGINE GENERAL PROCEDURE — THROTTLE ADJUSTMENT

BHP1401GA

1. Park the machine on firm level ground. 2. Switch off the engine. 3. Move the hand throttle lever to the max. rpm position 4. Check that the throttle linkage on the fuel injection pump is in contact with the stop screw (1). 5. If the throttle linkage is not in contact with the stop screw (1), adjust the length of the cable using the locknuts at the throttle bracket (2).

6. Set the throttle pedal to the max. rpm position and hold it there. 7. Check the gap between the throttle pedal and the stop bolt on the mounting bracket is less than 0 to 0.5mm. 8. If the gap between the throttle pedal and the stop bolt is greater than 0 to 0.5mm adjust the length of the stop bolt to bring the gap within limits. 9. Move the hand throttle lever to the min rpm position. 10. Start the engine. 11. Check that the engine idle RPM is between 700 — 900rpm. Maximum engine rpm is 2350rpm. 12. If the engine rpm is incorrect, adjust the stop screw on the fuel injection pump to bring the rpm within limits. 13. Make sure that the hand throttle lever is in contact with the stop on the hand throttle assembly.

P14–01–39

ENGINE

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P14–01–40

ENGINE GENERAL PROCEDURE — DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM Operation: General Procedure — Draining, Filling and Bleeding the Cooling System None

Job Code: 14 04 09 xx Standard tools, Suitable container

Draining

•

•

Warning: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury. Warning: Do not allow anti-freeze to contact skin. Adhere to instructions detailed on the antifreeze container. Failure to follow this instruction may result in personal injury.

1. Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. 2. Remove the coolant drain plug from the right-hand side of the cylinder block and drain the cooling system. Note: • Drain the coolant into a suitable container.

TV040620

3. Install the cylinder block drain plug.

Filling and Bleeding 1. Make sure the correct grade, and quality of antifreeze is added to the water. Recommended content mixture is 50% water, with 50% antifreeze. 2. Refill the cooling system through the radiator cap until completely full. Re-install the radiator cap and refill the coolant expansion tank to the full mark. 3. Start the engine and run until the normal engine operating temperature is achieved. Check for leaks, allow to cool then recheck the coolant level.

P14–01–41

BHP1401GB

ENGINE

Note: This page intentionally left blank.

P14–01–42

ENGINE SPECIFICATIONS — ENGINE

BHP1401SA

General Information Engine

Low Power (820)

High Power (860 – 970)

Make

Perkins

Model

1104C–44T

Bore and Stroke

105x127mm 4400 cc

Capacity

16.5:1

Compression Ratio Firing Order

1 3 4 2

Type

2164/2200

2166/2200

Build List (With Air Con)

RG38043

RG38044

Build List (Without Air Con)

RG38100

RG38099

Power @ 2200rpm

68.5kW (92 HP)

74.5kW (100 HP)

Torque @ 1400rpm

395Nm

415Nm

Turbocharger

Garrett GT 25, with wastegate 2674A226

Perkins P/N Wastegate beginning to operate pressure

1.0 +/- 0.05bar

Injection Pump

Delphi

Model

DP210

Type

1398/2644H013

1405/2644H023

Setting Code

XR/2/2350

DT/2/2350

Perkins Type

9320A212G

9320A342G

Perkins P/N

2644H002

2644H003

Injection Advance

0.5° BTDC

Timing

Pin Timed 0° ATDC

Speed at which cut off starts under full load

2200 +/- 25rpm

Maximum No Load Speed

2350 +/- 25rpm

Idle Speed

700 – 1200rpm Injectors

Delphi

Type

LJBX6921101 2645K611

Perkins P/N (Nozzle) Opening Pressure

290 +/- 8bar Yellow

Colour Code Fuel Feed Pump Pressure

0.1 – 0.7bar

Valve Lash (Cold) – Inlet

0.20mm

Valve Lash (Cold) – Exhaust

0.45mm

P14–01–43

ENGINE Valve Arrangement

IE IE IE IE

Cold Start System

Glow Plugs (4)

Make

Beru

Perkins P/N

2666A016

Initial Current

30A Immediately Reduced to 21A

After 8 sec

14A

After 20 sec

10A

After 60 sec

9A

Cold Start Sensor

Normally Open

Perkins P/N

2848A127

Closes at

50 +/- 3°C

Re–opens at

40 +/- 3°C

Radiator Cap Pressure

110kPa

Thermostat

Wax Element By-pass Blanking

Perkins P/N

2485C041P

Nominal Temperature Stamped on Thermostat

82°C

Start to Open Temperature

79 – 84°C

Fully Open Temperature

93°C

Minimum Valve Lift Fully Open

10mm

Lubrication

Rotor Pump

Minimum Oil Pressure at Max rpm

3.0bar

Capacity System

Engine Turbocharged – 1100 Series 820/860/970

Temperatures

Viscosity

Specifications

Capacities (Litres)

Notes

EMA DHD-1 or CH-4 API CH-4 ACEA E3 or E5

7.3

If sulphur content in fuel is above 0.2% of mass (2000ppm), change oil and filter every 250 hours)

From

To

-40°C

+40°C

0W – 40

-30°C

+40°C

5W – 40

-10°C

+50°C

15W – 40

For additional information, refer to the Perkins Engine Manual.

P14–01–44