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• EFREN SANCHEZ ROBLES

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Beschnitt

Beschnitt

S1057

DEUTZ AG Service-Technik Instandhaltungstechnik Motoren Deutz-Mülheimer Str. 147-149 D-51057 Köln Tel.: ++49 (0)2 21-8 22-0 U4_Impr_2012_9957

Fax: ++49 (0)2 21-8 22-53 58

Beschnitt

http: //www.deutz.de

Printed in Germany All rights reserved 1st Edition, © 11/02

We move your world.

MAGENTA = HKS 14K

Order No.: 0312 0836

SCHWARZ

Beschnitt

F1012

F1012

F1012

F1012

DEUTZ 2012 FUEL & OIL FILTERS

13715 Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

1

44238

ENGINE OIL FILTER ELEMENT (SPIN ON)

1

2

44235

PRE FILTER ASSEMBLY (FUEL/WATER SEPARATOR)

1

3

44236

CARTRIDGE ONLY FOR 44235 (ITEM 2)

1

4

44239

GASKET SET ONLY FOR 44235 (ITEM 2)

1

5

44237

FUEL FILTER ELEMENT (SPIN ON)

2

6*

44252

FAN BELT (DEUTZ 2012)

1

*ITEMS NOT SHOWN

Updated: 03/08/07

RADIATOR INSTALLATION

*ITEMS NOT SHOWN

17096 Page 1 of 2

Updated: 08/22/07

RADIATOR INSTALLATION

17096 Page 2 of 2

ITEM PART #

DESCRIPTION

QTY.

1

465112

RADIATOR ASSEMBLY

1

2

43GH250

CLAMP

6

4

43GH400

CLAMP

4

5

12567-05

HUMP HOSE

2

6

19125-13

CHARGE AIR TUBE (RH)

1

7

12567-07

HUMP HOSE

1

8

43GH300

CLAMP

2

9

NA

HOSE 2 ¾” ID

A/R

11

605726

TUBE (COOLANT)

A/R

12

12350-01

CHARGE AIR TUBE (LH)

1

15

605726

TUBE (COOLANT)

A/R

16*

1185-09

WASHER (MOUNTING)

8

17*

84229

PRESSURE CAP

1

18*

10592-07

FLANGE (ADAPTER)

1

19*

465271

FAN (BLOWER)

1

20*

534606

SIGHT GAUGE

1

22*

18483-01

TANK (SURGE)

1

23*

12457-05

TUBE, SURGE TANK (OPTIONAL)

1

*ITEMS NOT SHOWN

Updated: 08/22/07

AIR INTAKE & EXHAUST SYSTEMS

13753 Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

1

94653

HOSE (3” ID)

1

2

12457-09

TUBE WELDMENT

1

3

12346-01

TUBE WELDMENT

1

4

604117

AIR INLET HOOD

1

5

604116

AIR CLEANER (10”)

1

6

604119

RUBBER ELBOW REDUCER (5” – 4”)

1

7

12456-01

EXHAUST FLANGE WELDMENT

1

8

19188-08

ELBOW (4”)

1

9

19188-07

EXHAUST TUBE WELDMENT

1

10

594993

PURIFIER

1

11

594570

SILENCER

1

12

15951-01

DIFFUSER WELDMENT

1

Updated: 01/03/07

AIR CLEANER

ITEM PART #

11968 Page 1 of 1

DESCRIPTION

QTY.

604116

AIR CLEANER (INCLUDES ITEMS 1-8)

1

1

604795

CUP/ASSEMBLY

1

2

604796

CLAMP ASSEMBLY

1

3

604797

PRIMARY ELEMENT

1

4

284052

SAFETY ELEMENT

1

5

604264

VACUATOR VALVE

1

6

604798

BAFFLE ASSEMBLY

1

7

604708

NUT ASSEMBLY

1

8

604799

O-RING

1

9

10

604464 605505 605512 604117

INDICATOR 20 (DEUTZ 912W) INDICATOR 30 (3304, 3006 PCT) INDICATOR 25 (3304, 3306 PCNA) INLET HOOD

1 1 1 1

11

604687

PRECLEANER

1

12

604118

MOUNTING BAND

2

*ITEMS NOT SHOWN

Updated: 05/25/07

S1020

S1020

MANUAL INDEX A-64 DUNBAR ANFO MINERA BISMARK S/N 6964 11/02/07 5.

DRIVE TRAIN 17055 16922 S1036 17101

TRANSMISSION TRANSMISSION MOUNTS TRANSMISSION MAINTENANCE & SERVICE MANUAL DRIVELINE INSTALLATION

TRANSMISSION ASSEMBLY

17055 Page 1 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

DESCRIPTION

17055 Page 2 of 35 QTY.

CONVERTER HOUSING GROUP 465425

TRANSMISSION ASSEMBLY

1

1

244451

CONVERTER HOUSING ASSEMBLY

1

2

244452

SLEEVE (CONVERTER HOUSING)

2

3

244314

PIPE PLUG

1

4

244453

PIPE PLUG

1

5

244454

GASKET (CONVERTER HOUSING)

1

6

244455

SCREW (CONVERTER HOUSING)

18

7

244321

LOCKWASHER

18

8

244456

PIN (CONVERTER HOUSING)

1

9

244457

CLIP

2

10

24474

SCREW (CLIP)

2

11

244458

LOCKWASHER (CLIP)

2

12

24240

AIR BREATHER

1

13

244312

PLUG (INCLUDES ITEM 14)

5

14

24830

O-RING

5

15

244459

PIPE PLUG

1

16

244460

O-RING

1

17

244461

SCREW

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 3 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

DESCRIPTION

17055 Page 4 of 35 QTY.

CASE & REAR GROUP 1

244462

TRANSMISSION CASE (INCLUDES ITEMS 2-9)

1

2

244463

SUCTION TUBE (INCLUDES ITEM 7)

1

3

244464

O-RING (SUCTION TUBE)

1

4

24245

TUBE (LOW SPEED)

1

5

24337

SLEEVE

4

6

244465

TUBE (3RD)

1

7

244466

CLIP

1

8

24436

SCREW

1

9

244321

LOCKWASHER

1

10

244312

PLUG (INCLUDES ITEM 11)

1

11

24461

O-RING

1

12

244467

PLUG (INCLUDES ITEM 13)

1

13

244402

O-RING

1

14

244468

REAR COVER ASSEMBLY (INCLUDES ITEM 15)

1

15

244312

PLUG (INCLUDES ITEM 16)

1

16

24461

O-RING

1

17

244469

OIL BAFFLE

1

18

244470

GASKET (TRANSMISSION CASE)

1

19

24467

O-RING (CLUTCH PRESSURE TUBE)

4

20

24080

O-RING (CLUTCH PRESSURE)

1

21

244456

PIN (TRANSMISSION CASE)

2

22

244195

SCREW (REAR COVER)

20

23

244321

LOCKWASHER (REAR COVER)

20

24

24339

PLUG (MAGNETIC DRAIN)

2

25

23033

PLUG (DRAIN)

1

26

244459

PLUG (SPEED PORT)

2

27

244460

O-RING (SPEED PORT)

2

28

244461

SCREW (SPEED PORT)

2

30

244471

COVER

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 5 of 35

31

244472

GASKET (COVER)

1

32

24191

SCREW (COVER)

2

33

244154

LOCKWASHER (COVER)

2

34

24255

DIPSTICK TUBE

1

35

24256

DIPSTICK

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 6 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 7 of 35

DESCRIPTION

QTY.

TURBINE SHAFT GROUP 1

244473

TURBINE SHAFT ASSEMBLY (INCLUDES ITEM 2)

1

2

24497

RETAINER RING

1

3

244474

BEARING

1

4

24258

SNAP RING

1

5

24257

WASHER

1

6

24086

RING

1

7

244475

RING (PISTON)

1

8

244476

SUPPORT (STATOR)

1

9

244477

SCREW (STATOR SUPPORT)

6

10

244478

RING (PISTON)

1

11

244669

OIL BAFFLE ASSEMBLY (INCLUDES ITEM 12)

1

12

244480

SEAL (OIL BAFFLE)

1

13

244481

RING (OIL BAFFLE SEAL)

1

14

244128

RING (OIL BAFFLE RETAINING)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

17055 Page 8 of 35

DESCRIPTION

QTY.

DRIVE PLATE GROUP 1

244443

DRIVE PLATE ASSEMBLY KIT (INCLUDES ITEMS 1-4)

1

2

NSS

DRIVE PLATE

5

3

NSS

DRIVE PLATE BACKING RING

1

4

NSS

DRIVE PLATE MOUNTING SCREW & LOCKWASHER

10

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 9 of 35

QTY.

TORQUE CONVERTER 1

244482

TORQUE CONVERTER ASSEMBLY

1

2

24265

BEARING

1

3

244483

RING

1

4

24342

PLUG (TORQUE CONVERTER)

1

5

24077

O-RING

1

6

24524

RING (SNAP)

1

7

244484

RING (RETAINING)

2

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 10 of 35

QTY.

GEAR GROUP 1

244485

GEAR (REVERSE)

1

2

244670

GEAR (1ST)

1

3

244487

GEAR (LOW)

1

4

244488

GEAR (IDLER REAR)

1

5

244489

GEAR (IDLER FRONT)

1

6

244490

GEAR (OUTPUT)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 11 of 35

QTY.

AUXILIARY PUMP DRIVE 1

244491

PUMP DRIVE BEARING SUPPORT

1

2

244492

BEARING SUPPORT SCREW

1

3

244493

PIN (BEARING)

1

4

244494

BEARING

1

5

24083

DRIVE GEAR BEARING RETAINING RING

1

6

244495

GEAR (AUX PUMP DRIVE)

1

7

244496

COVER (PUMP)

1

8

244497

GASKET (COVER)

1

9

244270

SCREW (COVER)

2

10

244498

LOCKWASHER (COVER)

2

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 12 of 35

QTY.

PUMP DRIVE GROUP 1

244491

PUMP DRIVE BEARING SUPPORT

1

2

244492

PIN (BEARING)

1

3

244493

SCREW (BEARING)

1

4

244494

BEARING

1

5

24083

RING (DRIVE GEAR)

1

6

244499

GEAR (CHARGING)

1

7

244500

GEAR (PUMP DRIVE)

1

8

24767

SHAFT (IDLER GEAR)

1

9

244501

BALL

1

10

24540

BEARING

1

11

24081

RING (BEARING LOCATING)

2

12

24227

RING (BEARING RETAINING)

2

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 13 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 14 of 35

DESCRIPTION

QTY.

FORWARD SHAFT GROUP 1

244502

FORWARD SHAFT DRUM ASSEMBLY

1

2

24280

CLUTCH PISTON (INCLUDES ITEMS 3, 4)

1

3

24206

CLUTCH PISTON SEAL (OUTER)

1

4

24207

CLUTCH PISTON SEAL (INNER)

1

5

24208

CLUTCH INNER DISC

8

6

24209

CLUTCH OUTER DISC

8

7

24277

SPACER (PISTON)

1

8

24279

CLUTCH DISC BACKING PLATE

1

9

24278

SNAP RING (BACKING PLATE)

1

10

24523

DISC SPRING ASSEMBLY (INCLUDES 5 WASHER)

1

11

24276

SNAP RING (SPRING RETAINING)

1

12

24347

FORWARD SHAFT PISTON RING

2

13

24275

FORWARD SHAFT PILOT BEARING

1

14

244503

BEARING

1

15

24283

GEAR RETAINING RING

1

16

244504

BEARING RETAINING RING

1

17

244670

GEAR (1ST DRIVE)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 15 of 35

QTY.

REVERSE IDLER GROUP 1

244505

REVERSE IDLER SHAFT

1

2

24090

REVERSE IDLER GEAR BEARING

1

3

244506

WASHER

1

4

244507

NUT (BEARING RETAINER)

1

5

244508

WASHER (BEARING)

1

6

24872

LOCKBALL (IDLER SHAFT)

1

7

244509

GEAR (REVERSE)

1

8

244510

O-RING (SHAFT)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 16 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 17 of 35

DESCRIPTION

QTY.

ND

SHAFT GROUP

ND

SHAFT DRUM ASSEMBLY

REVERSE & 2 1

244511

REVERSE & 2

1

2

24280

CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3 & 4)

1

3

24206

OUTER CLUTCH PISTON SEAL

1

4

24207

INNER CLUTCH PISTON SEAL

1

5

244331

CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 6 & 7)

1

6

24206

OUTER CLUTCH PISTON SEAL

1

7

24207

INNER CLUTCH PISTON SEAL

1

8

24208

CLUTCH INNER DISC

8

9

24208

CLUTCH INNER DISC

6

10

24209

CLUTCH OUTER DISC

8

11

24209

CLUTCH OUTER DISC

6

12

24277

PISTON RETURN SPRING SPACER

1

13

24279

CLUTCH DISC BACKING PLATE

2

14

24278

BACKING PLATE SNAP RING

2

15

24296

PISTON RETURN SPRING

1

16

24297

RETAINER (SPRING)

1

17

24523

DISC SPRING ASSEMBLY (INCLUDING 5 WASHER)

1

18

24298

SNAP RING (SPRING)

1

19

24293

BEARING (GEAR)

1

20

24291

BEARING (GEAR)

1

21

24292

RING (GEAR)

2

22

244512

BEARING

1

23

244190

RING (RETAINING)

1

24

24290

SNAP RING

1

25

24347

RING (PISTON)

3

26

24276

SNAP RING

1

27

244513

HUB (2ND CLUTCH)

1

28

24298

RING (2ND CLUTCH)

1

29

244514

BEARING

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 18 of 35

30

244515

RETAINER (RING)

1

31

244516

RING (LOCATING)

1

32

244517

SPACER

1

33

244485

GEAR (REVERSE)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 19 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 20 of 35

DESCRIPTION

QTY.

LOW SPEED SHAFT GROUP 1

244518

LOW SHAFT HUB DRUM ASSEMBLY

1

2

24280

CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4)

1

3

24206

SEAL (CLUTCH PISTON OUTER)

1

4

24207

SEAL (CLUTCH PISTON INNER)

1

5

24304

CLUTCH INNER DISC

8

6

24209

CLUTCH OUTER DISC

8

7

24279

CLUTCH DISC BACKING PLATE

1

8

24300

BACKING PLATE RETAINING RING

1

9

24278

DISC SPRING ASSEMBLY (INCLUDES 7 WASHER)

1

10

24298

SNAP RING (SPRING RETAINER)

1

11

244520

SPACER (WASHER)

1

12

24302

BEARING (GEAR)

1

13

244521

BEARING (GEAR)

1

14

244522

RING (GEAR BEARING)

2

15

244523

RING (PISTON)

1

16

244524

BEARING

1

17

244525

SPACER (GEAR)

1

18

244526

BEARING

1

19

24259

SNAP RING

1

20

244527

RETAINER (WASHER)

1

21

244487

GEAR (LOW CLUTCH)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 21 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 22 of 35

DESCRIPTION RD

SHAFT CLUTCH GROUP

RD

3

QTY.

1

244529

3

CLUTCH SHAFT, DRUM & PLUG ASSEMBLY

1

2

244331

CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4)

1

3

24206

OUTER CLUTCH PISTON SEAL

1

4

24207

INNER CLUTCH PISTON SEAL

1

5

24208

CLUTCH INNER DISC

6

6

24209

CLUTCH OUTER DISC

6

7

24279

DISC BACKING PLATE

1

8

24278

BACKING PLATE SNAP RING

1

9

24296

PISTON RETURN SPRING

1

10

24297

SPRING RETAINER

1

11

24298

SPRING RETAINER SNAP RING

1

12

244190

FRONT BEARING RETAINING RING

1

13

244512

BEARING

1

14

24290

FRONT BEARING SNAP RING

1

15

24517

RING (PISTON)

2

16

24347

RD

HUB (3

CLUTCH)

RD

17

24300

RING (3

18

244514

BEARING

DISC HUB)

1 1 1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 23 of 35

QTY.

IDLER SHAFT GROUP 1

244524

SHAFT (IDLER)

1

2

244474

BEARING

1

3

24258

SNAP RING (BEARING)

1

4

244530

BEARING

1

5

24064

NUT

1

6

24063

WASHER

1

7

24321

SPACER

1

8

24556

SNAP RING

1

9

244488

GEAR

1

10

244489

GEAR

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 24 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 25 of 35

DESCRIPTION

QTY.

OUTPUT SHAFT GROUP 1

244531

SHAFT OUTPUT

1

2

244532

BEARING OUTPUT SHAFT REAR

1

3

244533

BEARING OUTPUT SHAFT FRONT

1

4

244534

RING OUTPUT SHAFT REAR BEARING

1

5

24575

RING OUTPUT SHAFT REAR BEARING RETAINING

2

6

244235

SEAL OUTPUT SHAFT

2

7

24318

STUD BEARING CAP

4

8

244536

LOCKWASHER

4

9

24488

NUT STUD

4

10

244537

CAP OUTPUT SHAFT REAR BEARING

1

11

24491

O-RING OUTPUT SHAFT REAR BEARING

1

12

24490

O-RING OUTPUT SHAFT REAR BEARING

1

13

244538

SPACER GEAR

1

14

24321

SPACER GEAR

1

15

24489

O-RING FLANGE

1

16

24063

WASHER FLANGE

1

17

24064

NUT WASHER

1

18

24324

SPACER BEARING TO FLANGE

1

19

244490

GEAR OUTPUT

1

20

244450

FLANGE FRONT

1

21

24062

FLANGE REAR

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

17055 Page 26 of 35

DESCRIPTION

QTY.

CHARGING PUMP GROUP 1

244539

CHARGING PUMP

1

2

24079

GASKET- PUMP ASSEMBLY TO CONVERTER HOUSING

1

3

24080

O-RING

1

4

244540

PUMP MOUNTING SCREW

1

4A

244541

PUMP MOUNTING SCREW

4

5

244321

PUMP MOUNTING SCREW LOCKWASHER

5

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

DESCRIPTION

17055 Page 27 of 35

QTY.

OUTPUT FLANGE GROUP 1

24106

OUTPUT FLANGE (FRONT)

1

2

24062

OUTPUT FLANGE (REAR)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

ITEM PART #

17055 Page 28 of 35

DESCRIPTION

QTY.

REMOTE FILTER GROUP 244447

FILTER & ADAPTOR ASSEMBLY (INCLUDES ITEMS 1, 2)

1

1

244449

FILTER ADAPTOR

1

2

244448

FILTER (ELEMENT)

1

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 29 of 35

ITEM PART #

DESCRIPTION

QTY.

1

244671

CONTROL VALVE GROUP (BEFORE TRANSMISSION S/N HBEA235758) ELECTRIC CONTROL VALVE ASSEMBLY

1

2

244335

GASKET

1

3

244334

SCREW

9

4

244154

LOCKWASHER

9

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 30 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART #

17055 Page 31 of 35

DESCRIPTION

QTY.

1

244672

CONTROL VALVE ASSEMBLY (BEFORE TRANSMISSION S/N HBEA235758) CONTROL VALVE ASSEMBLY ELECTRIC (12 VOLT) (INCLUDES ITEMS 1-32) CONTROL VALVE ASSEMBLY ELECTRIC (24 VOLT) (INCLUDES ITEMS 1-32) CONTROL VALVE HOUSING ASSEMBLY

2

244354

COVER CONTROL VALVE

1

3

244355

GASKET CONTROL VALVE COVER

1

4

244338

SPOOL FWD. & REV. SHIFT

2

5

244339

SPRING

2

244671 244722

RD

1 1 1

6

244361

SPOOL RANGE (3 )

1

7

244467

VALVE HOUSING PLUG (INCLUDES ITEM 8)

2

8

244402

O-RING

2

9

244358

STOP SPOOL

1

10

244673

PIN

1

11

244360

PLUG STOP

1

12

244356

SPOOL RANGE (1ST & 2ND)

1

13

244339

SPRING

1

14

244542

PIPE PLUG

8

15

244453

PLUG

1

16

244674

SCREW

1

17

24495

SCREW

2

18

244154

LOCKWASHER

3

19

244675

SPOOL STOP

1

20

244676

FORWARD & REVERSE DECLUTCH SPOOL

1

21

244677

SPRING DECLUTCH

1

22

244164

PLUG (INCLUDES ITEM 23)

1

23

244159

O-RING

1

24

244139

CARTRIDGE BALL VALVE (INCLUDES ITEMS 25-27)

4

25

244682

O-RING

4

26

244406

O-RING

4 Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 32 of 35

27

244172

O-RING

4

28 29

244678 244408 244679

COIL (12 VOLT) COIL (24 VOLT) NUT

4 4 4

30

244407

O-RING

8

31

244680

COVER SOLENOID

1

32

244681

SPACER COVER

2

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 33 of 35

ITEM PART #

DESCRIPTION

QTY.

1

244778

1

2

244778-01

CONTROL VALVE ASSEMBLY (STARTING WITH TRANSMISSION S/N HBEA235758) GASKET

1

3

244674

CAPSCREW

4

4

244289

CAPSCREW

3

5

244150

CAPSCREW

2

6

244154

LOCKWASHER

9

Updated: 05/25/07

TRANSMISSION ASSEMBLY

17055 Page 34 of 35

Updated: 05/25/07

TRANSMISSION ASSEMBLY ITEM PART # 244778

17055 Page 35 of 35

DESCRIPTION

QTY. 1 4

1

244776

CONTROL VALVE ASSEMBLY (STARTING WITH TRANSMISSION S/N HBEA235758) DEUTSCH SOLENOID 24V (INCLUDES ITEMS 1A-1D)

1A

244776-01

O-RING

4

1B

244776-02

O-RING

4

1C

244776-03

O-RING

4

1D

244776-04

O-RING

4

2

244453

PLUG

8

3

NSS

BODY

1

4

244778-02

SOLENOID COVER

1

5

244778-03

CAPSCREW

10

6

NSS

EXPANSION PLUG

9

Updated: 05/25/07

TRANSMISSION MOUNTS

16922 Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

1

16954-03

TRANSMISSION MOUNT

1

2

16954-02

TRANSMISSION MOUNT

1

3

01GC10056

BOLT

4

4

02GE12

WASHER

8

5

01GC120128

BOLT

8

6

34014

RUBBER MOUNT

4

7

1185-08

WASHER

4

8

68GD10

NUT

4

Updated: 03/08/07

S1036

S1036

FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF-HIGHWA Y PRODUCTS product. Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated wiii be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and adjustments, it is urged that the mechanic studies the instructions in this manuai carefuiiy and uses it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAYPRODUCTS approved parts as listed in the applicable parts manual should be used. Use of "wiii-fit" or non-approved parts may endanger proper operation and performance of the equipment. SPICER OFF-HIGHWA YPRODUCTS does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by SPICER OFF-HIGHWA Y PRODUCTS.

IMPORTANT ALWAYS FURNiSH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.

When checking the difference between a 6-speed with range shift, a 3-speed standard ratio and a 3-speed deep ratio, you would notice that the difference is only on the idler and the output shaft. .. ---"-'-A-3'~spe-e-c:r-'iIa'ncia-rdrs--si"iTlnaf-to-a--o-iweErd-Witlrrange-·shift·-w he n-- h igh--ran g e.. 1s-s el ected. While a 3-speed deep ratio is similar to a 6-speed with range shift when low range is selected. For this reason, we wiii use the 6-speed with range shift in most cases to explain the function of the 3 different transmissions.

I

._._.

S1036

3-SPEED STANDARD RATIO

S1036

3-SPEED DEEP RATIO

S1036

6-SPEED RANGE SHIFT

S1036

Table of Contents 1. SAFETY PRECAUTIONS

2. CLEANING, INSPECTION AND LEGEND SYMBOLS 2.1

CLEANING

2-1

2.1.1 Bearings 2.1.2 Housings 2.2 INSPECTION

2-1 2-1 2-1

2.2.1 Bearings 2.2.2 Oil Seals, Gaskets, Etc 2.2.3 Gears and Shafts 2.2.4 Housing, Covers, etc 2.3 LEGEND SYMBOLS

2-1 2-2 2-2 2-2 2-2

3. TECHNICAL SPECIFICATIONS 3.1

IDENTIFICATION OFTHE UNIT

3.2 WEIGHT, DIMENSIONS, OIL CAPACITY ~~

3-1 3-1

.... _..... ~:J....ILG!:JIJ:J'!LN.G.I..QggI,JJ=..§..""'~.=••c".c,'c,,.c".c,.c,•.c"."c",,,,,,=,,,,,,,'c,,,,,,.c,:c.c,,,"c,,,,,,•.,,,,,,:3~~ ....._

3.4

3.3.1 Torque specifications for lubricated or plated screw threads 3.3.2 Elastic stop nut torque 3.3.3 "0" ring port plug torque chart 3.3.4 Pipe plug torque chart 3.3.5 Permanent metric plug torque chart 3.3.5 Coil and cartridge torque PRESSURE AND TEMPERATURE SPECIFICATIONS

3·2 3·3 3·3 3-3 3·3 3-4 3·5

3.5

ELECTRICAL SPECIFICATIONS

3-6

3.6

HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS

3-6

4. MAINTENANCE 4.1

OIL SPECIFICATION

4-1

4.1.1 Recommended lubricants 4.2 MAINTENANCE INTERVALS

4-1 4-3

4.2.1 Daily 4.2.2 Normal drain period 4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL

4-3 4-3 4-4

S1036

5. INSTALLATION DETAILS 5.1

CONVERTER DRIVE COUPLING

5-1

5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

5-2

5.3 EXTERNAL PLUMBING

5-3

5.3.1 Optional: remote filter 5.3.2 Cooler & filter lines specifications 5.4 SPEED SENSOR INSTALLATION

5-3 5-3 5-4

6. OPERATION OF THE TRANSMISSION 6.1

THE TRANSMISSION ASSEMBLY

6.1.1 The converter, pump drive section and pressure regulating valve 6.1.2 The input shaft and directional clutches 6.1.3 The range clutches 6.1.4 The output section 6.1.5 The transmission controls (refer to hydraulic diagram) 6.2 ELECTRIC SOLENOID CONTROLS

6-1 6-2 6-3 6-4 6-4 6-5 6-6

6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.4 GEAR 6.4.1 6.4.2 6.4.2

Neutral, 3rd clutch engaged and high range selected Forward 1st speed and high range selected Forward 2nd speed and high range selected Forward 3rd speed and high range selected Reverse 1st speed and high range selected Forward 1st speed and low range selected AND CLUTCH LAY-OUT 3-Speed with standard ratio 3-Speed with deep ratio 6-Speed with range shift

6-7 6-9 6-11 6-13 6-15 6-17 6-19 6-19 6-20 6-21

7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION 7.1

T20000 TRANSMISSION

7-1

7.2 TROUBLESHOOTING PROCEDURES

7-1

7.2.1 Stall Test 7.2.2 Transmission pressure checks 7.2.3 Mechanical and electrical checks 7.2.4 Hydraulic checks 7.3 TROUBLESHOOTING GUIDE

7-1 7-2 7-2 7-2 7-3

7.3.1 Low clutch pressure 7.3.2 Low charging pump output 7.3.3 Overheating 7.3.4 Noisy converter 7.3.5 Lack of power 7.4 CHECK POINTS

7-3 7-3 7-3 7-3 7-3 7-4

7.5 SPEED SENSOR - STATIC STANDALONE TEST

7-7

S1036

8. SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP - CONVERTER HOUSING

8-2

GROUP - TRANSMISSION CASE AND REAR COVER

8-4

GROUP - TURBINE SHAFT

8-6

GROUP - DRIVE PLATE

8-8

GROUP - TORQUE CONVERTER

8-1 0

GROUP - AUXILIARY PUMP DRIVE

8-12

GROUP - PUMP DRIVE

8-14

GROUP - FORWARD SHAFT

8-16

GROUP - REVERSE AND 2ND SHAFT

8-18

GROUP - REVERSE IDLER

8-20

GROUP - LOW SPEED SHAFT

8-22

GROUP - 3RD SHAFT

8-24

GROUP - IDLER SHAFT {USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO}

8-26

GROUP - IDLER SHAFT {USED IN 3 SPEED STANDARD RATIO}

8·28

GROUP - OUTPUT SHAFT {6 SPEED}

8-30

GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)

11-32

GROUP - OUTPUT SHAFT ( 3 SPEED DEEP RATIO)

11-34

GROUP - HI & LOW RANGE SHIFT CONTROL

11-36

GROUP - CHARGING PUMP & FILTER

8·38

GROUP - ELECTRIC CONTROL VALVE MOUNTING

8·40

GROUP - ELECTRIC CONTROL VALVE ASSEMBLy

8-42

9. ASSEMBLY INSTRUCTIONS

10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION

11. OPTIONS 11.1 HYDRAULIC ACTUATED AXLE DISCONNECT 11.1.1 Seclional views and parts identificalion 11.1.2 Assembly instructions 11.1.3 Disassembly of output shall with axle disconnect 11. 1.4 Rea ssem bly of output sha II with axl e discon nect 11.1.5 Disassembly of axle disconnect 11.1.6 Reassembly of axle disconnect 11.2 PARKING BRAKES 11.2.1 Mechanical Brake 11.2. 1. 1 Section al views and pa rts id entification 11.2.1.2 Adjustment and rebuild criteria 11.2.1.3 Replacing friction pads 11.2.1.4 Disassembly 11.2.1.5 Cleaning and inspection 11.2.1.6 Assembly 11.2.1.7 Replacing mount bushings 11.2.1.8 Servicing rolor assembly

11-1 11-1 11·4 11·5 11-8 11-11 11-14 11-18 11-18 11-18 11-23 11-23 11-24 11-24 11·25 11-25 11-25

S1036

11. OPTIONS (Continued)

11.2.2 Spring applied hydraulic released brake (high pressure) 11.2.2.1 Seclionat views and pa rts identificalion 11.2.2.2 Operation 11.2.2.3 Adjustment and rebuild criteria 11.2.2.4 Replacing friction pads 11.2.2.5 Disassembly 11.2.2.6 Cleaning and inspection 11.2.2.7 Assembly 11.2.2.8 Inslallalion 11.2.2.9 Torque specs 11.2.3 Spring applied hydraulic released brake (low pressure) 11.2.3.1 Sectional views and parts identification 11.2.3.2 Operation 11.2.3.3 Adjustment and rebuild criteria 11.2.3.4 Replacing friction pads 11.2.3.5 Disassembly 11.2.3.6 Cleaning and inspection 11.2.3.7 Assembly 11.2.3.8 Installation 11.2.3.9 Torque specs 12. SERVICE TOOLS

12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304-54)

.»

11-26 11-26 11-31 11-31 11-31 11-31 11-32 11-32 11-33 11-33 11-34 11-34 11-39 11-39 11-39 11-39 11-40 11-40 11-41 11-41

S1036

1. SAFETY PRECAUTIONS To reduce the chance of personal injury and/or property damage, the following instruction must be carefully observed. Proper service and repair are important 10 the safety of tine service technician and the safe. reliable operation of the machine. If replaceme nt parts are required the part mu st be repla ced by a spare pa rt wh ich has the same part number or with an equlvalenl part. Do not use a spare part of lesser qualily. The service procedures recommended in this manual are effective methods for performing service and repa ir. Some of these proced ures req uire the use of tools specifi cally design ed for tine purpose. Accordingly, anyone whD inlends 10 use a spare part, service procedure or 1001, which is not recommended by SPICER OFF-HIGHWA YPRODUCTS, must first detemrine Ihal neitine r his safely no r the safe operation of tine machine will be jeopardized by the spare part, service procedure or tool selected.

IMPORTANT IT IS IMr:rrITA."lT TO llOTE TH.....T THIS M~Jm~L corfI~rjS V.o.\RiOUS CAREFUllY

OBS~"iED I rl

ORDE R TO REDtKE TH E RI SK OF

00 TH E POSSI 81 LIT'{ l"H.A.T I',l PROPER EERvrcE OR REPA1R MAY

IT lS AlSO IMPORTAhl" TO urm:::RS-T.l.J..'O THAT T;-1ES:::: BEC...'ill Sf: IT" IS I Pol POSS BLE TO ,....N~N ABC UT

~ll

'CAUTtONS' u.;-D 'NOTICES' TH.A.T MUST BE

FERSOU~ DA.~.t!J,GE

INJURY OU RING SERVlCE OR REPAJ R,

THE Url fT OR REJ.'DER IT UN SAF E.

'CAUTIONS' J.1m 'NOTICES' A~E

~jOT EXHAUSTIVE,

ill E POSS IoLE HAZ..ARDa US CON S=:0 UENe ES TH.....T III GHT RESULT

i=ROM F/OJlURE TO FOlta'"'' THESE 1N5TRucnorlS.

S1036

2. CLEANING, INSPECTION AND LEGEND SYMBOLS 2.1 CLEANING Clean all parts th orou ghly usi ng solvent type cle aning II uid. II is re commen ded th at pa rts be imm ersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are tho roughly clea ned.

CAUTION CARE SHOULD BE EXERCiSED TO AvmD SKIN- RASHES~ FIRE H.AL.!JR.DS, N~D tNHA1ATlm-i Or VAPour:;:s "','t+EN USL",IG

:sOl.. .'Et~T TYPE ClEMl ERS.

2.1.1 Bearings Rem ove beari ng s from c1ea ni ng lIu id and strike lIat ag ain st a block of wood to dislodge so Ii dill ed pa rticles of lubricant immerse again in cleaning fluid to lIush out particies. Repeat above operation until bearings are thoTOu ghly ciea n. 0 ry bea ri ng s using moi sture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. 00 not spin bearings when drying. Bearings may be rotated slowly by hand to fa cilitate drying pTOces s. 2.1.2 Housings Clean interior and exterior of housings. bearing caps, etc..., thoroughly. Cast paris may be cieaned in hot solution tanks with mild alkali solutions providing these paris do not have ground or polished surfaces. Parts sh ou Id rem ain in solution Ion g enough to be tho roughly clean ed and heated. Th is vliIi aid the eva po ration of the c1ea ning solution and ri nse water. Pa rts c1ea ned in solu tion tan ks mu st be th oroughIy rinsed with clean water to remove aII traces 01 aIka11. Cast pa rls may also be cI ea ned with steam c1ea ner.

CAUTION C~'\RE SHOULD BE EXE RC IS EO TO AVO: D IN:-tALATlorl OF VAPOU RS AND SKIN R.!I,S HES .....~EN US ING Al.J{II,L1 ClE.'JRERS.

All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soli, Iintless absorbent \~;ping rags free of abrasive materials such as metalllliings. contaminated oil, or lapping compound.

2.2 INSPECTION The importance 01 carelul and thorough inspection of all parts cannot be overstressed. Replacement 01 all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. 2.2.1 Bea rings Carefully inspect all rollers: cages and cups lor wear, chipping, or nicks to detemnine fitness 01 bearings for further use. 00 not replace a bearing cone or cup indiVidually without replacing the mating cup or cone at the same lime. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect th emu ntil installed.

Cleaning, inspection and legend symbols

S1036

2.2.2 Oil Seals, Gaskets, Etc. Replacement of spring load oil seals, "O"-rings, metal sealing rings, gaskets, and snap rings Is more economical when unit is disassembled than premature overhaul to replace these parts at a luture time. Further loss of lubricanl through a worn seal may result in failure of other more expensive parls 01 the assembly. Sealing members shoutd be handled carefully, parlculariy when being installed. Culling, scratching, or curlin gun der 0111p of seat seriously Impa Irs lIs elfid ency. When ass em bl ing new mela I type sea ling ring 5, these should be lubricated with coat of chassis grease to stabilize rings In their grooves lor ease 01 assembly of mating members. Lubricate all "O"-rings and seals wllh recommended type Automatic Transmission Fluid before assem bl y. 2.2.3 Gears an d Sh afts If magna-flux process is available, use process to check parts. 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, replace wHh new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make cerla In th ey are not sprung, be nt, or splin es twisted, and lh at sh ails are true. 2.2-4 H0 us in g, Covers, etc. Inspect housings, covers and bearing caps to ensure lhatthey are thoroughly clean and thai mating surfaces, bearing bores, etc ..., are free from nicks or burrs. Check all parls carefUlly for evidence 01 cracks or conditions which would cause subsequent oil leaks or failures.

2.3 LEGEND SYMBOLS -Srrn-".3ggD di [}~:;aUBTl-ti

~

~,.:.'1...."·gn:q:::l

of n

".

•• _~~lO!lI)l ....

2J

I

~

""

~Im

l;LllDIClIO

Ih'.IlA5~

flLTUl

VALVE !.5,1.1bJf

II

E~IIQIO

I

' ,

• ,-

T

""{

l~t

.;r ronWAIlD o

eOmlQl1l

""

AI~ DREATHEA

l]

.,

( __)

@ ,,,

'" ~J r.r....::~ r £l.>.1 ""..";i "-'.'.

in~o

disconnect Musing. shift hub and fork in. n.::::u8ing. align srjf( fork and actu atm Distcn. fnse rt piston in ~ hift fa rk.

TightEn securejy and lock ,.,,'ire to pre-vent toc-s-ening.

Figure 29 !nstall ·O"·,ing and g1yd ring (88" figure 29).

Figure 32

Figure 28

H~ld

Figure 30

G~

actuator piston

Align splines on discGnnect shaft \'"ith splines in stci(t h:Jb.

Figure 33 Tap s1aft and bearing in pfacE.

Reassembly 01 axle disconnect

S1036

Figure 34

Figure 37

Install shaft bearing ollter wlainer ling.

Sc-cLJre bme plug wilh retairr'ng ring.

Figure 35

Figure 38

Press seal in

disconnec~

J1c.JJsing \ViUl lip of seal in.

Figure 36 PositicH twa new "G"-rings e-n piston bore plug. Al'g~ t1O!e rn p!ug"ith ho!e in he-using. install plug.

/l.pply a iight coat of loctite 577 te- the outer diamelm of Ihe housing plug. Tap plug into posilioo in housing.

Figure 39 Install disconnect housing ·O"-rings in housing.

Reassembly of axle disconnect

S1036

Figure 40

Figure 43

Insert the actJator pislon in.oar and cuter return springs irt piston.

Install output flange ·O"-ring, wasner artd flartge nut

FIgure 41

Figure 44

Use new UO"-rjngs Oil assemb~l_ Posi:iDfl disconnect assembly 0'1 discoo'lect m01Jnti'lg studs. Irtsta'i stud nuts and lock'Nashe's.

Bleck flange to prevenl turning. Tightert flange nut to specified torque (see elastic step nu~ chart}.

Figure 42 The actuatc-r p:stGn sprin-gs must be comprEssed against the rear cover ~o start the stud nuts and lock'.'iasller. TightEn stud nuts to speci'fBd torque (see torque chart).

S1036

11.2 PARKING BRAKES 11.2.1

MechanIcal Brake

11.2.1.1 seclional views and paris Idenliflcatlon

S1036

GROUP - DISC BRAKE (MECHANICAL BRAKE)

1

S1036

GROUP - DISC BRAKE (MECHANICAL BRAKE) Item

1 2

3

4 5 6 7 8

Description

Calipe r - Par king brake Disc - Brake Assem bly - Mo unti ng bracket Screw - Bracket asse mbly 10 b rg cap mtg Washer - Bracket assembly 10 brg cap mtg fiat screw Screw - Flange Screw - Caiiper 10 mounting bracket Spacer

Quantity

1 1 1

4 4 6 2 2

S1036

GROUP - MECHANICAL BR AKE

16

.

",

~:.~ .