22 SECTION 18 - CLUTCH - CHAPTER 1

Transcription

1 22 SECTION 8 - CLUTCH - CHAPTER PTO CLUTCH CONTROL SYSTEM ADJUSTMENT 43 See Section 3 PTO for details on PTO clutch servo control adjustment, and for the PTO engage switch adjustment.

2 SECTION 2 - TRANSMISSIONS - CHAPTER SECTION 2 - TRANSMISSIONS Chapter - Mechanical Transmission (6 x 6) Synchro-Command CONTENTS Section Description Page Main data... 2 Torque settings... 2 Tools... 4 Cross--sectional views... 8 Description and operation... 2 Troubleshooting Rear transmission/gearbox casing. Removal -- Installation Gearbox transmission casing. Disassembly -- Assembly Transmission--Gearbox Casing Gearbox control lever. Removal -- Installation Range gear control lever. Removal -- Installation... 36

3 2 SECTION 2 - TRANSMISSIONS - CHAPTER SHUTTLE UNIT MAIN DATA Type... mechanical type with spur gearing, located between the main clutch and the gearbox. Operating system... hand lever located on left--hand side of operator GEARBOX AND RANGE GEAR MAIN DATA Gearbox (Synchro-Command) speed constant mesh, synchronized on all gears with synchronized F/R shuttle shift. Gearingtype... helical Range gear (6 x 6)... ordinary gear train with 4 ranges for a total of 6 speeds. Thickness of gearbox driving shaft adjustment shim (4, page 8)... mm (in.) Thickness of gearbox driven shaft adjustment shim (2, page 8)... mm (in.) Springs for detent balls on gearbox and range gear control rods: -- spring free length... mm (in.) -- length of springs under load of 75.5 to 83.3 N (6.97to8.72ft.lbs.)... mm (in.) Springs (, page 0) for gearbox and range gear control levers: -- spring free length... mm (in.) -- length of springs under load of 3.4 to 35.3 N (7.05to7.943ft.lbs.)... mm (in.) ( ) ( ) 42 (.65) 35 (.37) 44 (.73) 35 (.37) TORQUE SETTINGS PART (Refer to Figure ) Thread Tightening torque Nm ft. lbs. Sleeve cover retaining nuts (C)... M8x to 25 5 to 9 Gearbox driving and driven shafts bearing cover screws (C 2 )... M 0 x to to 69 Retaining bolts securing creeper clutch casing to rear transmission/gearbox casing (C 3 )... M 2 x.25 7to29 87 to 96 Driven gear shaft locknut (C4)... M32x to to 228 Drive gear housing cover retaining screws (C5) to 5 32 to 38 Pressure switches (C6) to to 54 Parking brake inspection cover, gearbox and range control relay levers support cover retaining screws (C 7 )... M 0 x to 5 32 to 38 Bolts or nuts securing creeper clutch casing to the engine (C 8 ).. M 2 x.25 7to29 87 to 96

4 SECTION 2 - TRANSMISSIONS - CHAPTER 3 TORQUE SETTINGS C to 25 Nm C 3 --7to29Nm C to 309 Nm C to 5 Nm (5to9ft.lbs.) (87to96ft.lbs.) (206 to 228 ft. lbs.) (32 to 38 ft. lbs.) 2562 C to 93 Nm (62to69ft.lbs.) C to 72 Nm (38to54ft.lbs.) 2564 C 8 --7to29Nm (87to96ft.lbs.) C to 5 Nm (32to38ft.lbs.)

5 4 SECTION 2 - TRANSMISSIONS - CHAPTER TOOLS X Pliers for gearbox shafts circlips Driving shaft installation guide. Warning - The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Section Clutch casing lift hook Rotating stand for overhaul operations. X Tool for gearbox driving and driven shafts adjustment Driving shaft rod for lifting unit Driven shaft retaining tool Driven shaft installation guide Adjuster handle (with and ) Power take--off drive shaft seal splining tool (with ) Power take--off drive shaft roller bearings splining tool (with ) Tool for removal--installation final drives (see Section 27) Electronic Service Tool (use the Calibration and Diagnostic Unit as a substitute) Electronic Service Tool less lap top Calibration and Diagnostic Unit (use the Electronic Service Tool as a substitute) Guide pin for re -fitting the gearbox in the casing (Mark part with no Measurements in mm) Make in C 40 material. 2

6 SECTION 2 - TRANSMISSIONS - CHAPTER 5 (.57) (.96) (7.87) (9.84) (.8) (.57) (.787) (.787) (3.54) Tool to be made for lateral gear removal -installation, use with a part of (Mark tool No Measurement in mm [ins.]) Make in Fe 42 C material -- (*) Measurement according to hoist seat.

7 6 SECTION 2 - TRANSMISSIONS - CHAPTER 65 (24.2) () Bracket to be made for gearbox overhaul on rotating stand (Mark tool No Measurement in mm [ins.]). Rotating stand axis. Make in Fe 42C material.

8 SECTION 2 - TRANSMISSIONS - CHAPTER Bracket to be made for gearbox overhaul on rotating stand (Mark tool No Measurement in mm [ins.]) 5 Make in Fe 42C material.

9 8 SECTION 2 - TRANSMISSIONS - CHAPTER X X Longitudinal cross -sectional view of gearbox and gear range (6 + 6 Synchro-Command) 6. Seal. 2. Power take--off shaft support roller bearings. 3. Shuttle control synchronizer. 4. Gearbox driving gear clearance adjusting shim. 5. Power take--off shaft. 6. Gearbox driving gear. 7. Selector sleeve for high or medium--low speeds. 8. Bevel pinion shaft. 9. Selector sleeve for low or medium--high speeds. 0. Synchronizer for st and 2nd speed.. Synchronizer for 3rd and 4th speed. 2. Gearbox driven shaft gear clearance adjusting shim. 3. Gearbox driven shaft. NOTE: On assembly apply sealing compound to surfaces X as shown on page 34.

10 SECTION 2 - TRANSMISSIONS - CHAPTER 9 X Cross -sectional view of gearbox and range gear 7. Shuttle control external rod. 2. Gear control external rod spring. 3. Gear control external rod. 4. Gear selector internal rod. 5. Shuttle selector internal rod. NOTE: On assembly apply sealant to surfaces X as shown on page 34.

11 0 SECTION 2 - TRANSMISSIONS - CHAPTER Cross -sectional view of gearbox and range gear 8. Range gear control external rod spring. 2. Range gear control external rod. 3. Shuttle control fork. 4. Shuttle selector synchronizer. 5. Shuttle relay gear (reverse gear) 6. Detent ball and spring. 7. Lubricating oil external pipes. 8. Lubricating oil internal pipes. NOTE: On assembly apply sealant to surfaces X as shown on page 34.

12 SECTION 2 - TRANSMISSIONS - CHAPTER View of safety pin control 9. Gearbox clutch control pedal. 2. Gearbox clutch control cable. 3. Gearbox clutch control external lever. 4. Safety pin control cable.

13 2 SECTION 2 - TRANSMISSIONS - CHAPTER DESCRIPTION AND OPERATION Gearbox and Shuttle (Synchro-Command) 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade--type constant--mesh spur gears. The range gear provides 4 gears (6 x 6 version). The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The shuttle is a mechanical device making it possible to obtain 6 forward gears and 6 reverse gears. It is controlled by a lever located on the cab platform to the left of the operator. The shuttle is composed of a group of three spur gears: reverser driving gear, reverser driven gear and intermediate gear, engagement is by means of a synchronizer located in the gear unit. The shuttle is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox. GEARBOX, GEAR RANGE AND SHUTTLE TROUBLESHOOTING Problems Possible causes Remedies Spontaneous disengagement of gearbox.. Levers and relay rods incorrectly adjusted. Adjust correctly. 2. Control levers retaining springs damaged. Replace springs. 3. Synchronizer teeth or selection sleeves damaged. Remove the transmission--gearbox casing and replace the synchronizers or the sleeves. 4. Engagement stroke incomplete. Eliminate the cause and reset the complete stroke. (continued overleaf)

14 SECTION 2 - TRANSMISSIONS - CHAPTER 3 GEARBOX, GEAR RANGE AND SHUTTLE TROUBLESHOOTING (continued) Problems Possible causes Remedies Difficulty in engaging the gearbox.. External levers and relay rods incorrectly adjusted. Adjust correctly. 2. Stiffness and/or partial seizure of external levers and relay rods. Check rod pivots and lubricate. 3. Main clutch drag. See Section Synchronizers or selection sleeves damaged. Remove the transmission--gearbox casing and replace the synchronizers or the sleeves. 5. Internal control elements do not slide freely: rods, forks and sleeves. Overhaul the controls. Excessive noise in gearbox or shuttle.. Internal components worn or defective. Remove the transmission--gearbox casing and replace the damaged parts.

15 4 SECTION 2 - TRANSMISSIONS - CHAPTER Op REAR TRANSMISSION -GEARBOX CASING Removal -Installation WARNING Lift and handle all heavy parts using suitable lifting equipment Make sure that the units or parts are supported by means of suitable slings and hooks. Make sure that no--one is standing in the vicinity of the load to be lifted. In order to remove the rear transmission--gearbox the cab must be removed, following the instructions noted in Section 90, Chapter. Proceed as follows.. Position support stands under the rear transmission and remove the rear wheels. 2. Remove the HPL top link Remove the battery, unscrew the retaining bolts and remove the battery supports (, 2 and 3)

16 SECTION 2 - TRANSMISSIONS - CHAPTER 5 4. Disconnect and remove the lift auxiliary control valve control pipes () Unscrew the retaining bolts and extract the Lift-- O--Matic control lever ()

17 6 SECTION 2 - TRANSMISSIONS - CHAPTER 6. Unscrew the retaining bolts on the lift () and recover the trailer brake control pipes support bracket. Disconnect the power take--off speed sensor connections, if necessary. 7. Attach the lifting hook () to the lift (2) and, by means of the hoist, raise and remove the lift Unscrew the drainage plug on the drive gear housing and recover the oil in a suitably dimensioned container. 9. Disconnect all of the electrical connections, marking them (if necessary) to facilitate re--connection Remove the drainage plug () and recover the gas oil in a suitably dimensioned container

18 SECTION 2 - TRANSMISSIONS - CHAPTER 7. Loosen the clamp and detach the side tank sleeve () Unscrew the clamp and detach the gas oil intake pipes () Disconnect the electrical connections (), loosen the clamps and heat the pipes (2), using a heater (3), in order to facilitate the removal of the relative unions Position a hydraulic jack (2) under the side tank, unscrew the clamp retaining bolts ( and 3) and remove the tank

19 8 SECTION 2 - TRANSMISSIONS - CHAPTER 5. Detach the support bracket pipes ( and 2) from the cab right--hand support. Unscrew the unions on the pipes ( and 2) of the trailer brake and lift control Unscrew the clamp and detach the filter supply pipes (). Unscrew the bolts that secure the pipes () on the rear transmission casing and remove Unscrew the retaining bolts and detach the electrical leads clamp(), positioning the leads on the engine. 8. Disconnect the brake control pipes () from the brake block (2), the rear transmission casing and remove

20 SECTION 2 - TRANSMISSIONS - CHAPTER 9 9. Disconnect the unions ( and 2) of the services control oil delivery pipes Unscrew the retaining bolts and detach the rear guard () Position the bracket () and fix to the engine and axle Unscrew the two rear nuts () that retain the front guard