647027EN (27/07/2008)

GEAR BOX
SERIE PG 115
Repair manual

MANITOU BF
B.P 249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11
Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97
www.manitou.com
 647027EN 1st Date of Issue :
23 / 07 / 2008

DATE OF ISSUE OBSERVATION

23 / 07 / 2008 - 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED, EITHER PARTLY OR TOTALLY.
CONTENTS

– GEAR BOX AND CONVERTER ...................................................................... 5

– GEAR BOX ..................................................................................................... 6

(Details)

– GEAR BOX .................................................................................................... 8

(Mecanism details - gears)

– TRANSMISSION HYDRAULIC CIRCUIT ....................................................... 10

– TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT .................................. 11

– TRANSMISSION KINEMATICS ..................................................................... 12

– TRANSMISSION MAINTENANCE ................................................................. 14

– PRESSURE CHEKING ................................................................................... 16

– SPECIAL SERVICE TOOLS ........................................................................... 21

– TECHNICAL CHARACTERISTICS .................................................................. 22

– DIS-ASSEMBLY AND RE-ASSEMBLY ........................................................... 25

GENERAL INFORMATION ............................................................................... 26
1 - TRANSMISSION DISASSEMBLY ................................................................. 28
2 - INPUT SHAFT DISASSEMBLY AND RE-ASSEMBLY ...................................... 34
(Includes Forward High and Forward Low clutch packs)

3 - DISASSEMBLY AND RE-ASSEMBLY OF THE OUTPUT SHAFT ........................ 40

(Includes Speed Clutch 2 and Speed Clutch 3 packs)
4 - DISASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT ....................... 46
(Includes Speed Clutch 1 pack)
5 - REVERSE IDLER SHAFT ............................................................................ 52
6 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY ............. 58
10 - GEAR BOX RE-ASSEMBLY ....................................................................... 60

– ELECTRICITY ................................................................................................. 68

3
4
GEAR BOX AND CONVERTER

9 8

2
3

1
7
4
5

1 – Complete gear box

2 – Converter
3 – Intermediate plate
4 – Screw
5 – Washer
6 – Converter reinforcement plate
7 – Screw
8 – Screw
9 – Washer

5
 PPO
OC
DIC HCEH
J TT
JUOHITNUNEETDTE
E GS EJO
D
SEI GO TS DT 39
AC DE ATZ INE
SE L H K S
RIE ITTU JUNT
GU NGSAS 68
AR A
NIZ T Z
ION
E

64
38 70
LP 6 bar 24 33
FL
66 71 49
R 50
24 BP194 23
63 36
GEAR BOX (Details)

3 FH
21 1 8
LP 6 bar 22 BP195
2 51 7 35
17
55 37 7
25 26 75 18 51 34 7 5 4 3
27 56 7
27 8 8
9 15 20
7 8 7 52 54 8
65 9 8 8
32 16 16
30 57
7

6
31 69 19
59 58
67 15 6
60 16 16
62 14 8
13 47 53
7
46
11 7
48 29 8
12
27 10 28

27 52 45 74
26 bar 2
26 61 74
72
1 74 73
44
43
31 74
42 30
41 74
40 73
GEAR BOX (Details)

1 – Transmission housing 39 – Seal kit

2 – Transmission rear case 40 – Screw
3 – Screw 41 – Cover
4 – Washer 42 – "O" ring
5 – "O" ring 43 – Washer
6 – Seal 44 – Suction strainer
7 – Plug 45 to 48 - Valve start cold 26 bar
8 – "O" ring 45 – Plug
9 – Plug 46 – Spring
10 – Complete pump 47 – Ball
11 – Seal 48 – "O" ring
12 – "O" ring 49 – Sensor
13 – Screw 50 – Seal
14 – Washer 51 – "O" ring
15 – Hollow screw 52 – Plug
16 – Seal 53 – Screw
17 – Solenoid - Clutch N°1 (1) 54 – Stud-bolt
18 – Pipe (3rd and 4th gear) 55 – Oil temperature sensor
19 – Pipe (1st gear) 56 – "O" ring
20 – Screw 57 – Brake assy
21 – Valve - Clutch N°2 (2) and N°3 (3) 58 – Plug
22 – Complete electrical valve control 59 – "O" ring
- Forward gear low (LH)and high (FH) 60 – Filter housing
speed 61 – Oil filter
23 – Control valve - Reverse gear (R) 62 – Adaptor
24 – Screw 63 – Pipe
25 – Pipe 64 – Gauge
26 – Hollow screw 65 – Connection
27 – Seal 66 – Fastening plate
28 – Screw 67 – Screw
29 – Screw 68 – Wiring harness (gear box)
30 – Drain plug 69 – "O" ring
31 – "O" ring 70 – Screw
32 – Plug 71 – Screw
33 – Spacer 72 – Kit (Brake lining + Spring)
34 – Air breather 73 – Kit (Screw + Nut)
35 – Coupling flange 74 – Kit brake lining
36 – Valve (pressure regulation) 75 – Plug
- (LP) converter 6 bar 90 – Seal kit
37 – Plug 91 – Valve Kit
38 – Over pressure valve 92 - Pumpe kit
- (LP) principal 15 bar 93 – Seal kit
7
 2 15 22 23
10
21 18 9
9
10
GEAR BOX

8 26 42
16 36
20
11 19 41 43
21 36
T7 17 37
14 25
13
12 33 96 95
6 41
35 71 73
1 6 83
29 34 40
39 82 81
T9 6 32
12 66 81
13 6 38 84
14 T8 27 30 31 67
17
20 28 48
24 38 57
19 56
16 61 84
10 26 61 65
9 70
(mecanism details - gears)

8
3 53 56 47 83
7 52 59
7 62 60 54 85
51 90 55 80
T6 64 78
11 8 89
63 77
5 9 86
4 44 92 87
92 88
46 58 58 T10 79
45 106
48 89 107
49 94 99
78 68
50 92 97
77 99
90
80 101
91 76 79
88 98
69 91 93 T4 103
75
100
74 105 102
72 104
75 85
GEAR BOX (mecanism details - gears)
1 – Input shaft 56 – Bearing
2 – Gear (24 teeth) 57 – Washer
3 – Gear (32 teeth) 58 – Seal
4 – Bearing 59 – Washer
5 – Thrustwasher 60 – Circlips
6 – "O" ring 61 – Roller bearing
7 – Roller bearing 62 – Spring retainer
8 – Snap ring 63 – "O" ring
9 – Bearing 64 – Piston T6: Clutch N°1
10 – Washer 65 – Spacer
11 – Circlips 66 – Spacer
T7: Clutch forward gear low speed (FL) 67 – Shim
T9: Clutch forward gear high speed (FH) 68 – Out put shaft
12 – Seal 69 – Gear 4th gear (26 teeth)
13 – Piston 70 – Gear 3rd gear (38 teeth)
14 – "O" ring 71 – Gear (48 teeth)
15 – Bearing 72 – Bearing
16 – Plate 73 – Bearing
17 – Spring retainer 74 – Washer
18 – Spacer 75 – Bearing
19 – Clutch disc 76 – Washer
20 – Friction disc 77 – Clutch disc
21 – Roller bearing 78 – Friction disc
22 – Shim 79 – Piston T4: Clutch N°3
23 – Spacer T10: Clutch N°2
24 – Countershaft 80 – Plate
25 – Gear (24 teeth) 81 – Roller bearing
26 – Bearing 82 – Spacer
27 – Piston T8: Clutch reverse gear 83 – Bearing
28 – Seal 84 – Stop washer
29 – "O" ring 85 – Snap ring
30 – Spring retainer 86 – Circlips
31 – Clutch disc 87 – Spring plate
32 – Friction disc 88 – Spring
33 – Spacer 89 – "O" ring
34 – Circlips 90 – Seal
35 – Washer 91 – Roller bearing
36 – Bearing 92 – Seal
37 – Thrustwasher 93 – Spring plate
38 – Seal 94 – Circlips
39 – Plate 95 – Spacer
40 – Snap ring 96 – Shim
41 – Roller bearing 97 – Out put shaft
42 – Spacer 98 – Gear
43 – Shim 99 – Bearing
44 – Countershaft 100 – Spacer
45 – Gear (44 teeth) 101 – Seal
46 – Gear (38 teeth) 102 – End yoke
47 – Gear 1st and 2nd gear 103 – "O" ring
48 – Bearing 104 – Washer
49 – Washer 105 – Screw
50 – Screw 106 – Spacer
51 – Seal 107 – Shim
52 – Clutch disc
53 – Friction disc
54 – Snap ring
55 – Plate
9
TRANSMISSION HYDRAULIC CIRCUIT
Clutch - CRAWLER
Embrayage RAMPANTE(Option)
(OPTION)

Clutch - 1st
Embrayage 1ÈREGEAR

Clutch - FORWARD
Embrayage GEARBASSE
MARCHE AVANT LOW
SPEED

Clutch - FORWARD
Embrayage GEARHAUTE
MARCHE AVANT
HIGH SPEED

Clutch - REVERSE
Embrayage GEAR
MARCHE ARRIÈRE

Clutch - 2nd
Embrayage 2ÈME GEAR

REGULATEUR
PRESSURE REGULA-
DE PRESSION
TOR (14.5
(14,5 bar)
bars) Clutch - 3rd
Embrayage GEAR
3ÈME
PRISE DE PRESSION
Pressure test point
PUMP DE
PRISE
PRESSURE
PRESSION
CONVERTER PRESSURE TEST POINT
POMPE
PRISE DE PRESSION FILTRE
OIL
TEST POINT
CONVERTISSEUR AFILTER
HUILE

CONVER-
Converter
LIMITEUR DE
CONVERTER TISSEUR
PRESSION DU SOUPAPE DE
COLD STARTING
PRESSURE
CONVERTISSEUR LUBRICATION DEMARRAGE
VALVE
LIMITER (6.5 PRISE DE A FROID
(6,5 bar) PRESSURE TEST
PRESSION (26 bars)
bars) (26 bar)
POINT
LUBRIFICATION

PRISE DE
TEMPERATURE
TEMPERATURE POMPE
Pump
TEST POINT LUBRICATION
PRISE DE
PRESSURE
PRESSION
Suction CREPINE
strainer TEST POINT
LUBRIFICATION
D'ASPIRATION
TRANSMIS-
LUBRIFICATION
SION LUBRICA-
TRANSMISSION
TION
SUMP
CARTER

REFROIDISSEUR
OIL COOLER D'HUILE

10
TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT

Clutch - CRAWLER (Option)

Clutch - 1st GEAR

Clutch -
FORWARD
GEAR LOW
SPEED

Clutch -
FORWARD
GEAR HIGH
SPEED

Clutch - REVERSE GEAR

Clutch - 2nd GEAR

Clutch - 3rd GEAR

14,5 bar Pressure limiter

6,5 bar
Oil
filter
Pressure Converter
regulator
Cold starting 26 bar Pump
valve
Cooler

Suction
strainer

11
TRANSMISSION KINEMATICS

Gear FORWARD gear REVERSE gear

Clutch Clutch
1st FL+1 R+1
2nd FH+1 R+2
3rd FL+2 R+3
4th FH+2
5th FL+3 (Not used)
6th FH+3

R R

24 24

42 42
42 42
FH FL FH FL

24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

1st GEAR FORWARDS 2nd GEAR FORWARDS

12
 R R

24 24

42 42
42 42
FH FL FH FL

24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

3rd GEAR FORWARDS 4th GEAR FORWARDS

R R

24 24

42 42
42 42
FH FL FH FL

24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

5th GEAR FORWARDS

6th GEAR FORWARDS
(Not used)

13
TRANSMISSION MAINTENANCE

RECOMMANDED LUBRICANTS :

Oils used in this transmission must all meet the following specifications :

GRADE SPECIFICATION CLASSIFICATION

10W30 API GL 4 MIL-L-2105B

ALLISON C3

OPERATING TEMPERATURE : 85° - 90° C OIL LEVEL

In order to ensure a good lubrication and a good The level must be checked always with the oil
operating temperature it is important to use the gauge dipstick, with the engine idling.
specified oil and to maintain the correct level.
* Do not pour oil over the upper mark as this
could cause overheating due to oil splashing
OIL AND FILTER CHANGING through the pinions (emulsion and deterioration
of the oil). This could also cause external leaks.
It is recommanded to change the oil at the follo-
wing intervals : Oil changing is also necessary to eleminate the
metal particles of the transmission components.
After the first 50 hours of work. The particles result from a normal use.

Then every 800 hours maximum afterward.

Always clean the strainer when changing the oil.

Replace the filter after the first 50 hours of work PRECAUTION

and every 400 hours afterward.
To prevent a lack of lubrication in the trans-
mission when towing the machine on long dis-
Many factors having an influence on the oil chan-
tances, it is recommended to uncouple the
ging require to increase the oil changing frequen-
gear box out put shaft.
cy.

CAPACITY (GEAR BOX only) : 15,5 L

OIL USED BY MANITOU : MANITOU oil automatic

transmission shaft.

1 L - Ref 62 148
25 L - Ref. 487 655
56 L - Ref. 545 557
215 L - Ref. 490 207

14
15
PRESSURE CHECKING

PRESSURE CHECKING PROCEDURE

-Put fork lift truck on block.

-Connect pressure gauges (40 bars) to various test points.
-Engine running, allow the transmission temperature to warm up to 60 to 80 °C.
-With the engine at maximum speed, read the pressures for each gear engaged. Check the values obtai-
ned with the table below.
NOTA : The threads for the pump and converter pressure test points are 3/4" UNF. All others are 9/16"
UNF.

- Refer to the gauge box reference 547037 for the connections of the leads, valves and links.

PRESSURE TABLE IN BARS

Clutch - forward Clutch - forward

Clutch - reverse Clutch 1 Clutch 2 Clutch 3
gear low speed gear high speed
FORWARD GEAR gear
FL FH
(T8) (T6) (T10) (T4)
(T7) (T9)
1st gear 14,25 0 0 14,75 0 0
nd
2 gear 0 14,25 0 14,75 0 0
rd
3 gear 14,25 0 0 0 15,75 0
4th gear 0 14,25 0 0 15,75 0
5th gear 14,25 0 0 0 0 15,75
6th gear 0 14,25 0 0 0 15,75

Clutch - forward Clutch - forward

Clutch - reverse Clutch 1 Clutch 2 Clutch 3
gear low speed gear high speed
REVERSE GEAR gear
FL FH
(T8) (T6) (T10) (T4)
(T7) (T9)
1st gear 0 0 14,25 14,75 0 0
2nd gear 0 0 14,25 0 15,75 0
rd
3 gear 0 0 14,25 0 0 15,75

Pump (T3) 15 - 18
Converter (T1) 5-8
Lubrication (T5) 0,75 - 1,25

16
PRESSURE READING ON GEAR BOX "TURNER POWERSHIFT"

MACHINE TYPE and N° : .................................................. N° of HOURS : .........................................

GEAR BOX TYPE and N° : .................................................

Clutch - forward Clutch - forward

Clutch - reverse Clutch 1 Clutch 2 Clutch 3
gear low speed gear high speed
FORWARD GEAR gear
FL FH
(T8) (T6) (T10) (T4)
(T7) (T9)
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear

Clutch - forward Clutch - forward

Clutch - reverse Clutch 1 Clutch 2 Clutch 3
gear low speed gear high speed
REVERSE GEAR gear
FL FH
(T8) (T6) (T10) (T4)
(T7) (T9)
1st gear
2nd gear
3rd gear

Pump (T3)
Converter (T1)
Lubrication (T5)

COMMENTS : ....................................................................................................................................
.........................................................................................................................................................

.........................................................................................................................................................

* BREAKDOWN AT THE ORIGIN : .......................................................................................................

.........................................................................................................................................................

.........................................................................................................................................................

* DETERMINED CAUSE OF THE BREAKDOWN : .................................................................................

.........................................................................................................................................................

.........................................................................................................................................................

.........................................................................................................................................................

.........................................................................................................................................................

.........................................................................................................................................................

17
 T3

T1 T2

CONVERTER PRESSURE (T1)

PUMP OUTLET PRESSURE
NOT USED (T2)
PUMP PRESSURE AFTER FILTER (T3)

CLUTCH 3rd GEAR PRESSURE (T4) LUBRICATION PRESSURE (T5)

18
CLUTCH 1st GEAR PRESSURE (T6) CLUTCH - FORWARD GEAR SLOW SPEED FL
PRESSURE (T7)

CLUTCH - REVERSE GEAR PRESSURE (T8) CLUTCH - FORWARD GEAR HIGH SPEED FH
PRESSURE (T9)

CLUTCH 2nd GEAR PRESSURE (T10) CONVERTER PRESSURE

NOT USED (T11)

19
T5 T7 T9 T11 T10 T4 T2 T1 T3 T8 T6

20
SPECIAL SERVICE TOOLS

TOOL NUMBER DESCRIPTION

- 479307 Bearing Extractor, use with brg. removal collets.

- 600743 Piston seal sizing ring.
- 563390 4wd shaft front \ rear, Rev. Idler shaft front \ rear and Input shaft front brg. removal
collet.
- 563392 Countershaft, Output shaft and Crawler shaft, front \ rear brg. removal collet.
- 600744 Input shaft rear brg. removal collet.
- 563394 Output shaft and Crawler shaft front, bearing removal collet.
- 600745 Clutch pack spring compresser (Fits all shafts except output).
- 600746 Clutch pack spring compresser (Fits all shafts).
- 600747 Shimming Tool Kit.
- 600748 Shimming Tool.

RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS.

Ø INTERIOR Ø EXTERIOR

C/shaft, 4wd, Output shaft rear & Co-axial input shaft 41 mm 47 mm

front bearing.

Reverse idler,Output shaft front & input shaft bearing. 36 mm 41 mm

Output shaft 1st gear brg. sleeve and Co-axial input 50,5 mm 58 mm
shaft rear bearing.

The dummy plug for re-fitting inner detent spring & ball can be made using a piece of bar 18mm dia. x 25 mm
long.

21
TECHNICAL DATA

SHAFT END FLOATS

All shaft end floats should be 0,0254 to 0,0762 mm.

The following sized shims are available for each shaft : 0.06, 0.18, 0.07, and 0.05 mm.

GEAR END FLOATS

All free rotating gear end floats should be - 0.42 to 0.080 mm.

BOLT TORQUE'S

Strainer bolts 18 to 31 Nm.

Pump retaining bolts 18 to 31 Nm.
Output Yoke bolts 68 to 88 Nm.
O ring plugs 9/16" UNF 20 to 27 Nm.
O ring plugs 3/4" UNF 40 to 54 Nm.
Filler plug 1 5/16" UNF 68 to 80 Nm.
Main transmission case bolts 55 to 75 Nm.
Drain plug 34 to 54 Nm.
Converter relief valve 23 to 30 Nm.
Pressure regulator valve 45 to 64 Nm.
Cold start seating cap 45 to 64 Nm.
4WD solenoid valve spool 16 to 22 Nm.
4WD Solenoid coil retaining nut 2.7 to 5.4 Nm.
Control valve ret. capscrews 7 to 9 Nm.
Hydraulic pipe (internal) capscrews 10 to 18 Nm.
Hydraulic pipe (internal) banjo bolts 20 to 27 Nm.
Hydraulic pipe (external) banjo bolts 40 to 46 Nm.
Filter housing bolts 45 to 64 Nm.
Oil filter 7 to 10 Nm.
Temperature sender 20 to 27 Nm.
Countershaft front brg. ret. bolt 68 to 88 Nm.
Speed Probe lock nut 25.5 Nm.
Brake mounting bolt lock nuts 150 Nm.
Brake adjustment lock nut 61 to 75 Nm.
Dipstick bracket capscrews 7 to 9 Nm.
Dipstick tube capscrews 45 to 64 Nm.

RECOMMENDED SEALANTS

Transmission case joint Loctite 5203

Output shaft gear Loctite 638 spline lock.
4wd gear (Permanent 4wd assy) Loctite 638 spline lock.
Countershaft gears Loctite 638 spline lock.
Expansion plugs Loctite 574 or Omnifit FD10.
Speed probe lock nut Loctite 270.
Brake Calliper mounting lock nuts Loctite 542.

22
CLUTCH PACKS

Clutch Pack No. of Friction Plates No. of Plain Steel Plates Clutch Pack Thickness when new.
Forward High 6 6 22.48 to 24.06 mm
Forward Low 5 5 18.75 to 20.05 mm
Clutch 1 8 8 30 to 32.08 mm
Clutch 2 8 8 30 to 32.08 mm
Clutch 3 5 5 18.75 to 20.05 mm
Reverse 5 5 18.75 to 20.05 mm
4wd Hydraulic 8 8 30 to 32.08 mm

Clutch plate thickness when new :

• Friction Plate 1.97 to 2.13 mm
• Plain steel plate 1.78 to 1.88 mm

23
24
DIS-ASSEMBLY
RE-ASSEMBLY

25
GENERAL INFORMATION

We recommend that the procedures as outlined in BEARINGS

this manual be followed when performing mainte-
nance work on this transmission. When a transmission is removed at relativity low
mileage, bearings should be removed with pullers
designed for the purpose. Wrap the bearings to
TOOLS keep our dirt.

This transmission can be repaired with ordinary Clean, inspect and lubricate all bearings just prior
mechanics hand tools however this procedure is to reassembly. If accumulated mileage is over
not only slow but may damage otherwise servi- 1500 hours we suggest that all bearings be repla-
ceable parts. To reduce maintenance costs and ced.
vehicle downtime, we recommend that the special
tools listed in this manual be procured from a tool
manufacturer, as stated. REPLACEMENT PARTS

CLEANLINESS The exploded views of sub-assemblies which are

incorporated in this manuel are for the mecha-
Transmission should be steam cleaned externally nic’s convenience and show the latest material.
prior to disassembly. Seal all opening before clea- The parts are arranged in their correct order and
ning to prevent entry of dirt and water which can may also be used as a reference for assembly or
damage serviceable parts. Dirt is abravise and disassembly of this unit.
will cause premature wear and failure of clutch
plates, hydraulic valves and bearings.
SHIMS
* Due to the nature of opération of the hydraulic
system cleanliness is of prime importance and When inserting shim packs, it is essential that
the following guidelines should be observed : the thinnest shims are placed between the thicker
shims to prevent any possible damage to the
1 – Not lint or cotton rags should be used in order shims.
to prevent any possible clogging.

2 – When fitting new clutch plates they should be SEALS

soaked in clean new oil as recommended for
3 hours. The seals which have been removed on the disas-
sembly shall be replaced by new on reassembly.
3 – All parts should be thoroughly cleaned and
lubricated with new oil prior to reassembly.

26
27
1 - TRANSMISSION DIS-ASSEMBLY

1-1 1-2

Invert the transmission on a suitable bench . For Remove the 4 plastic plugs, cap screws and
convenience the bench top should have a hole spacers, (if fitted), and withdraw the forward
in it to accommodate the input shaft and pump. direction control valve.

1-3 1-4

Remove the 4 plastic plugs and cap screws and Remove the 4 plastic plugs and cap screws and
withdraw the reverse direction control valve. withdraw the Speed Clutch 2 and 3 control
valve.

1-5 1-6

Remove the Speed Clutch 1 soleniod coil retai- Unscrew and remove the Speed Clutch 1 sole-
ning nut and withdraw the coil. noid valve spool.

28
1-10 1-11

Remove the bolt, washer and O ring and with- Remove the bolt, washer and O ring and with-
draw the output yoke or flange. draw the 4 wheel drive yoke and spacer. (Not fit-
ted on 2 wheel drive models).

1-12 1-13

Undo the speed probe locknut and unscrew and Withdraw the 2 external hydraulic pipe banjo
withdraw the speed probe and sealing washer. bolts and washers and remove the lubrication
transfer pipe.

1-14 1-15

Remove 2 capscrews from the dipstick tube Withdraw the 2 capscrews and remove the dips-
bracket. tick tube assembly.

29
1-16 1-17

Remove the 17 screws and using suitable lifting Remove the 4 wheel drive shaft assembly (Not
equipment take off the rear transmission case. fitted on 2 wheel drive models).
Lever slots are provided to assist removal.
NOTE : The bearing cones and shims may fall
from the rear case during removal.

1-18 1-19

Lift the countershaft and input shaft assemblies Tilt the countershaft and withdraw the input
together by approximately 30 mm and get an shaft assembly.
assistant to simultaneously lift and remove the
output shaft assembly.

1-20 1-21

Remove the countershaft assembly. Remove the reverse idler shaft assembly.

30
1-22 1-23

Remove the bearing shells from the front case. Remove the 2 capscrews and 2 banjo bolts and
withdraw internal hydraulic pipe.

1-24 1-25

Remove and discard the expansion plug from Remove and discard the expansion plug from
the left side shimming access hole. the upper shimming access hole.

1-26 1-27

Remove 2 screws and withdraw the strainer Using a strap wrench remove and discard the oil
cover, O ring, spacer and strainer. filter.

31
1-28 1-29

Remove 2 bolts and take of the oil filter housing Remove the Converter Relief Valve.
and 2 O rings.

1-30 1-31

Remove the Pressure Regulator Valve. Remove the cold start housing, spring and ball.

1-32 1-33

Remove the temperature sender. Invert the case. Remove 4 screws and sealing
washers then withdraw the pump assembly and
sealing ring.

32
33
2 - INPUT SHAFT DISASSEMBLY AND RE-ASSEMBLY
(Includes Forward High and Forward Low clutch packs)

2-1 2-2

Remove and discard the 3 sealing rings. Using the appropriate bearing puller remove the
rear bearing.
(Tool No. 600744)

2-3 2-4

Remove the primary gear circlip. Remove the thrust washer and needle bearing.

2-5 2-6

Remove the primary gear. Remove the two bearings and spacer.
NOTE : There is no spacer fitted on the forward
high side.

34
 2-7 2-8

Remove the needle bearing and thrust washer. Remove the clutch pack spirol retaining ring.

2-9 2-10

Remove the clutch pack retaining plate. Remove the clutch pack.

2-11 2-12

Using the appropriate tool compress the piston Remove the circlip and spring pack assembly.
spring pack and release the circlip.
(Tool No. 600746)

35
2-13 2-14

Using pliers, as shown, pull the piston out of the Invert the shaft and remove the sealing ring.
drum.

2-15 2-16

Using the appropriate bearing puller remove the Remove and discard the piston sealing rings and
front bearing. O rings.
(Tool No. 563390) Re-assembly of the Input Shaft.
Repeat steps 2:4 to 2:13 to dismantle the for-
ward high clutch pack.

2-17 2-18

Re-new the piston sealing rings, to assist Using transmission fluid to lubricate the seals
assembly the seals may be warmed in lukewarm push the pistons into the sizing ring and leave
water prior to assembly. for approximately 30 minutes.
NOTE : The outer seal must be fitted with the open (Tool No. 600743)
edge facing away from the clutch pack.

36
2-19 2-20

Using transmission fluid to lubricate the seals Replace the spring pack assembly and circlip as
push the piston into the drum. shown.

2-21 2-22

Using the appropriate tool compress the spring Replace an externally splined ( plain ) disc and
pack and locate the circlip into its groove. then an internally splined (friction) disc alterna-
(Tool No. 600746) tely until six of each have been replaced.

2-23 2-24

Replace the clutch pack retaining plate and re-fit Replace the thrust washer and bearing.
the spirol retaining clip. NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

37
2-25 2-26

Replace the bearing , spacer and bearing. Line up the clutch plate splines and replace the
NOTE : There is no spacer fitted on the forward primary gear (see tips).
high side.

2-27 2-28

Replace the needle bearing and thrust washer Re-fit the primary gear circlip.
as shown. Check gear end float.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

2-29 2-30

Using an appropriately sized tube replace the Fit 3 new sealing rings to the rear of the shaft as
bearing as shown. shown.

38
2-31

Invert the shaft and repeat steps 2:17 to 2:27

and step 2:29 .Then fit a new sealing ring to the
front of the shaft.
NOTE : The Forward low clutch pack uses 5 fric-
tion and 5 plain plates.
(To avoid damage the sealing rings may be left
off until all shimming operations have been com-
pleted).

39
3 - DISASSEMBLY AND RE-ASSEMBLY OF THE OUTPUT SHAFT
(Includes Speed Clutch 2 and Speed Clutch 3 packs)

3-1 3-2

Position the shaft in a soft jawed vice as shown Using the appropriate bearing puller remove the
and remove and discard the 3 sealing rings. front bearing.
(Tool No. 563394)

3-3 3-4

Remove the thrust washer and needle bearing. Remove the primary gear.

3-5 3-6

Remove the two bearings. Remove the needle bearing and thrust washer.
NOTE : There is a spacer fitted between the bea-
rings on the Speed Clutch 2 side.

40
 3-7 3-8

Remove the clutch pack spirol retaining ring. Remove the clutch pack retaining plate.

3-9 3-10

Remove the clutch pack. Using the appropriate tool compress the piston
spring pack and release the circlip.
(Tool No. 600746)

3-11 3-12

Remove the circlip, retainer and spring. Using pliers, as shown, pull the piston out of the
drum.

41
3-13 3-14

Invert the shaft and using the appropriate bea- Remove the drive gear using suitable pullers.
ring puller remove the rear bearing. Then repeat steps 3:3 to 3:12.
(Tool No. 563392) NOTE : The Speed Clutch 2 assembly uses a
multi spring pack instead of a single
spring and retainer.

3-15 3-16

Remove and discard the piston sealing rings and Re-new the piston sealing rings.To assist
O rings. assembly the seals may be warmed in lukewarm
Re-assembly of the Output Shaft. water prior to assembly.
NOTE : The outer seal must be fitted with the open
edge facing away from the clutch pack.

3-17 3-18

Using transmission fluid to lubricate the seals Using transmission fluid to lubricate the seals
push the piston into the sizing ring and leave for push the piston into the drum.
approximately 30 minutes.
(Tool No. 600743)

42
3-19 3-20

Replace the spring and retainer and position cir- Using the appropriate tool compress the spring
clip as shown. and locate the circlip into its groove.
NOTE : The Speed Clutch 2 assembly uses a (Tool No. 600746)
multi spring pack instead of a single
spring and retainer.

3-21 3-22

Replace an externally splined (plain) disc and Replace the clutch pack retaining plate and re-
then an internally splined (friction) disc alterna- fit the spirol retaining clip.
tely until eight of each have been replaced.
NOTE : The Speed Clutch 3 pack uses 5 friction
and 5 plain plates.

3-23 3-24

Replace the thrust washer and bearing. Replace the 2 needle bearings.
NOTE : The needle bearing should be fitted with NOTE : There is a spacer fitted between the bea-
the closed side of its cage against the rings on the Speed Clutch 2 side.
gear.

43
3-25 3-26

Line up the clutch plate splines and replace the Replace the needle bearing and thrust washer
primary gear (see tips). as shown. Check gear end float.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

3-27 3-28

Using an appropriately sized tube replace the Invert the shaft and repeat steps 3:16 to 3:26.
bearing as shown. Then refit the drive gear using Loctite 638, or
equivalent on the shaft splines.

3-29 3-30

Using an appropriately sized tube replace the Finally fit 3 new sealing rings to the front of the
rear bearing as shown. shaft as shown.

44
45
4 - DISASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT
(Includes Speed Clutch 1 pack)

4-1 4-2

Position the shaft in a soft jawed vice as shown Using the appropriate bearing puller remove the
and remove and discard the 2 sealing rings. rear bearing.
(Tool No. 563392)

4-3 4-4

Remove the thrust washer and needle bearing. Remove the Speed Clutch 1 primary gear.

4-5 4-6

Remove the two bearings and spacer. Remove the needle bearing and thrust washer.

46
 4-7 4-8

Remove the clutch pack spirol retaining ring. Remove the clutch pack retaining plate.

4-9 4-10

Remove the clutch pack. Using the appropriate tool compress the piston
spring pack and release the circlip.
(Tool No. 600746)

4-11 4-12

Remove the circlip and spring pack assembly. Using pliers, as shown, pull the piston out of
the drum.

47
4-13 4-14

Remove and discard the piston sealing rings and Invert the shaft and remove the retaining bolt
O rings. and washer.

4-15 4-16

Using the appropriate bearing puller remove the Remove the 2 drive gears using suitable pullers
front bearing. or a press.
(Tool No. 563392)

48
RE-ASSEMBLY OF THE COUNTERSHAFT

4-17 4-18

Replace the 2 drive gears using Loctite 638, or Using an appropriately sized tube replace the
equivalent, on the shaft splines. front bearing as shown.

4-19 4-20

Replace the retaining washer and bolt then Re-new the piston sealing rings to assist assem-
torque to 68-88 Nm. bly the seals may be warmed in lukewarm water
prior to assembly.
NOTE : The outer seal must be fitted with the open
edge facing away from the clutch pack.

4-21 4-22

Using transmission fluid to lubricate the seals Using transmission fluid to lubricate the seals
push the pistons into the sizing ring and leave push the piston into the drum.
for approximately 30 minutes.
(Tool No. 600743)

49
4-23 4-24

Replace the spring pack assembly and circlip as Using the appropriate tool compress the spring
shown. pack and locate the circlip into its groove.
(Tool No. 600746)

4-25 4-26

Replace the thrust washer and bearing. Replace the bearing, spacer and bearing.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

4-27 4-28

Replace the Speed Clutch 1 gear. Replace the needle bearing and thrust washer
as shown. Check gear end float.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

50
4-29 4-30

Using an appropriately sized tube replace the Replace an externally splined (plain) disc and
bearing as shown. then an internally splined (friction) disc alterna-
tely until eight of each have been replaced.

4-31 4-32

Replace the clutch pack retaining plate and re-fit Fit 2 new sealing rings.
the spirol retaining clip.

51
5 - REVERSE IDLER SHAFT

5-1 5-2

Remove and discard the 2 sealing rings. Using the appropriate bearing puller remove the
rear bearing.
(Tool No. 563390)

5-3 5-4

Remove the thrust washer and needle bearing. Remove the reverse primary gear.

5-5 5-6

Remove the two bearings and spacer. Remove the needle bearing and thrust washer.

52
 5-7 5-8

Remove the clutch pack spirol retaining ring. Remove the clutch pack retaining plate.

5-9 5-10

Remove the clutch pack. Using the appropriate tool compress the piston
spring pack and release the circlip.
(Tool No. 600746)

5-11 5-12

Remove the circlip and spring pack assembly. Using pliers, as shown, pull the piston out of
the drum.

53
5-13 5-14

Remove and discard the piston sealing rings and Invert the shaft and using the appropriate bea-
O rings. ring puller remove the front bearing.
(Tool No. 563390)

RE-ASSEMBLY OF THE REVERSE SHAFT

5-15 5-16

Using an appropriately sized tube replace the Re-new the piston sealing rings to assist assem-
front bearing as shown. bly the seals may be warmed in lukewarm water
prior to assembly.
NOTE : The outer seal must be fitted with the open
edge facing away from the clutch pack.

5-17 5-18

Using transmission fluid to lubricate the seals Using transmission fluid to lubricate the seals
push the pistons into the sizing ring and leave push the piston into the drum.
for approximately 30 minutes.
(Tool No. 600743)

54
5-19 5-20

Replace the spring pack assembly and circlip as Using the appropriate tool compress the spring
shown. pack and locate the circlip into its groove.
(Tool No. 600746)

5-21 5-22

Replace an externally splined (plain) disc and Replace the retaining plate and re-fit the spirol
then an internally splined (friction) disc alterna- retaining clip.
tely until five of each have been replaced.

5-23 5-24

Replace the thrust washer and bearing. Replace the bearing, spacer and bearing.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

55
5-25 5-26

Line up the clutch plate splines and replace the Replace the needle bearing and thrust washer
reverse primary gear (see tips). as shown. Check gear end float.
NOTE : The needle bearing should be fitted with
the closed side of its cage against the
gear.

5-27 5-28

Using an appropriately sized tube replace the Fit 2 new sealing rings.
front bearing as shown. (To avoid damage the sealing rings should be
left off until all shimming operations have been
completed).

56
57
6 - PERMANENT 4 WHEEL SHAFT
DISASSEMBLY

6-1 6-2

The permanent 4 wheel drive shaft. Using the appropriate bearing puller remove the
front and rear bearings.
(Tool No. 563390)

6-3

Remove the 4 wheel drive gear using suitable

pullers or a press.

58
RE-ASSEMBLY

6-4 6-5

Replace the 4 wheel drive gear using Loctite Using a suitably sized tube re-fit the front and
(ref.: 548110), on the shaft splines. rear bearings.
Then using a suitably sized tube re-fit the front
and rear bearings.

59
10 - TRANSMISSION RE-ASSEMBLY
General Re-assembly Notes :
• All nylon patch bolts may be re-used 5 to 6 times provided a prevailing thread torque of 15 to 18 Nm. is recor-
ded.
• All shafts and bearings should be lubricated with transmission fluid prior to assembly.
• To prevent possible contamination of hydraulic parts lint or cotton rags should not be used.

10-1 10-2

Fit two new O rings to the internal hydraulic pipe. Invert the front case and fit the internal pipe
using 4 new sealing washers, one either side of
each banjo connection. Tighten the 2 banjo bolts
to 20 -27 Nm. and the two capscrews to 10 - 18
Nm.

10-3 10-4

Re-fit the bearing shells to the front case. Re-fit the reverse shaft assembly.

10-5 10-6

Re-fit the input shaft assembly. Lift the input shaft approximately 30mm and re-
fit the countershaft assembly.

60
10-7 10-8

Lift the input and countershaft assemblies toge- Re-fit the 4wd shaft assembly (Not used on 2wd
ther approximately 30mm and get an assistant models).
to simultaneously fit the output shaft assembly.
Take care not to damage the shaft sealing rings.

10-9 10-10

Fit a new O ring to the transmission case. Using a suitably sized tube fit new rear output
and 4wd oil seals into the front and rear cases.
The rear output seal should be fitted to a depth
of 6mm. Fill the seal lips with light grease.

10-11 10-12

Invert the rear case and replace the shim packs and Re-fit the internal pipe using 4 new sealing
bearing cups. The 2mm thick spacer shim should be washers, one either side of each banjo connec-
fitted into the case first , then fit the remaining tion. Tighten the 2 banjo bolts to 40 - 46 Nm.
shims followed by the bearing cup. A light grease
may be used to help hold the cups in the case.

61
10-13 10-14

Using suitable lifting equipment re-fit the rear Refit the flange retaining bolt and washer into the end of the
case, (without sealant at this stage), and secu- output shaft. Then position a D.T.I. as shown, and using a pry
re with at least 6 equally spaced bolts. When fit- bar lift the shaft, then measure and note the end float.
ting the rear case be careful to avoid damaging NOTE : All shaft assemblies should be rotated several times
any of the shaft sealing rings. to seat the bearings prior to measuring the end float.

10-15 10-16

Attach a suitable shimming tool, (with a 12mm thread), to the Fit tool (600747) into the countershaft shim-
end of the 4 wheel drive shaft. Position a D.T.I. as shown. Use ming hole and position a D.T.I. on the end of the
a pry bar lift the shaft, then measure and note the end float. tool as shown. Then using a suitable pry bar
(Tool No. 563395) through the side access hole, measure and note
(Not fitted on 2 wheel drive models). the shaft end float.

10-17 10-18

Fit tool (600747) into the input shaft shimming Fit tool (600747) into the reverse shaft shim-
hole and position a D.T.I. on the end of the tool ming hole and position a D.T.I. on the end of the
as shown. Then using a suitable pry bar through tool as shown. Then using a suitable pry bar
the upper access hole , measure and note the through the upper access hole, measure and
shaft end float. note the shaft end float.

Remove the rear case and add or remove shims as necessary to give .0,025mm to .0,076mm inches end float on
all shafts
Repeat steps 10:13 to 10:18 until all shaft end floats are correct. Then fit new sealing rings to the shafts.
62
10-19 10-20

Refit the rear case, using an approved liquid gasket Fit new expansion plugs to the shimming access
(Loctite 5203), taking care not to damage the shaft sealing holes using an approved sealant (Loctite 649).
rings. Tighten the 17 bolts to a torque of 55 to 75 Nm.
Then replace the shaft end plug and O ring assemblies.

10-21 10-22

Lubricate the seals with transmission fluid then Lubricate the seals with transmission fluid then
re-fit the pressure regulator valve and tighten to re-fit the converter regulator valve and tighten to
a torque of 45 to 64 Nm. a torque of 23 to 30 Nm.

10-23 10-24

Re-fit the cold start housing, spring and ball. Refit the filter housing using 2 new O rings.
Then tighten to a torque of 45 to 64 Nm. Tighten the two bolts to a torque of 45 to 64
Nm.

63
10-25 10-26

Lubricate the seal with a light grease and screw on Refit the strainer, spacer, O ring and cover plate.
a new oil filter. Tighten to a torque of 7 to 10 Nm. Then tighten the two screws to a torque of 18 to
31 Nm.

10-27 10-28

Refit the speed probe, sealing washer and lock- Re-fit the temperature sender. Then tighten to a
nut. Adjust. then tighten the locknut to a torque torque of 20 to 27 Nm.
of 25,5 Nm and seal with Loctite 542 (see notes
for correct adjustment).

10-29 10-30

Lubricate the seals with a light grease and re-fit Refit the external transfer pipe using 4 new cop-
the Speed Clutch 1 solenoid spool. Tighten to a per washers . Then tighten the 2 banjo bolts to
torque of 26 to 39 Nm. Then refit the solenoid a torque of 40 to 46 Nm.
coil and nut. Tighten to a torque of 2,7 to 5,4
Nm.

64
10-31 10-32

Refit the dipstick tube bracket and tighten the 2 Fit a new O ring to the dipstick tube assembly.
capscrews to a torque of 7 to 9 Nm.

10-33 10-34

Insert the dipstick tube assembly through the Re-fit the 4wd spacer and Yoke.
bracket and fit to the case. Tighten the 2 caps-
crews to a torque of 45 to 64 Nm.

10-35 10-36

Replace the 4wd O ring , washer and bolt. Then Replace the output flange, O ring , washer and
tighten to a torque of 68 to 88 Nm. bolt. Then tighten to a torque of 68 to 88 Nm.

65
10-37 10-38

Ensure the 4 O rings are in place then re-fit the Ensure the 4 O rings are in place then re-fit the
Speed Clutch 2 and 3 control valve assembly and Reverse control valve assembly and tighten the
tighten the 4 cap screws to a torque of 7 to 9 Nm. 4 cap screws to a torque of 7 to 9 Nm. Then re-
Then re-fit the 4 plastic caps to the capscrew fit the 4 plastic caps to the capscrew holes.
holes. NOTE : The valve can only be fitted one way
NOTE : The valve can only be fitted one way round round as it is located by a small dowel
as it is located by a small dowel pin. pin.

10-39

Ensure the 4 O rings are in place then re-fit the

Forward control valve assembly using 4 caps-
crews, and spacers if fitted. Then tighten the 4 cap
screws to a torque of 7 to 9 Nm. Then re-fit the 4
plastic caps to the capscrew holes.
NOTE : The valve can only be fitted one way round
as it is located by a small dowel pin.

66
67
ELECTRICITY
A - E.C.U.

The E.C.U (Electronic Control Unit) controls the transmission.

It controls several gearbox functions:
• gear changes
• kickdown function (according to model)
• diagnostics on the harness to the solenoid valves
• diagnostics of inputs.

Situated in the cab at the front right of the driver.

E.C.U operating process :

Information Information
from inverter from speed sensor
lever

Output to display on E.C.U. Information originating

control panel from handbrake / trans-
mission cut-off

Information originating from the switch

Solenoid valve sup- crawling speed (5th gear speed)
ply

68
 SERIAL COMM.

AMP 1
8 18
25 36 E.C.U. SUPPLY
36 13
24 KICK DOWN K
13 25 12

12 FORWARD GEAR F. F
1 1
28 A EV L
REVERSE GEAR R R
24
B
B - Wiring diagram

+12V AC GEAR N°1 29 EV H

2
30 C EV R
GEAR N°2
F8:15A 23
31 D EV 1
GEAR N°3
26

SWF MANIPULATOR
32 E EV 2
GEAR N°4
3
CRAWLER SWITCH 33 F EV 3
6

5TH GEAR LOCK

22 G
34 EV C

3 4
K18 5

ELECTRONIC CONTROL UNIT

REVERSING ALARM OUTPUT
2 1 15

TRANSMISSION CUT-OFF
F9:5A 21 14 BUZZER
(MLT --- 120 LSU POWERSHIFT Série B-E2)

TRNASMISSION CUT-OFF BRAKE ON INFO

20 B
HANDBRAKE ON 11
LED 9 6 DIAGNOSTIC 7
5
TRANSMISSION 35
RELAY CONTROL

CATCHER shint
CUT-OFF SWIT- 19

69
CH 0 1 17 16 9 10 + FUS.F8 RELAY K3 OUPUT
10 8 2 7 1
K2
3 5 : 20A
SPEED SEN- REVERSING LIGHTS
SOR SPEEDOMETER
DISTRIBUTOR BRAKE
HANDBRAKE LEVER PEDAL
SWITCH

BATTERY
CHARGING LED
RELAY CONTROL

INPUT RELAY K8 OUTPUT

1 STARTER MOTOR : 30A
+ IGNITION ON CONTROL
2 4 STARTER MOTOR
B+
D
3

- + Alt
IGNITION KEY D± W
BAT 12V

+ +
HR CT

R1
PREHEATING
 Prise test

SERIAL COMM.
+12V AC ALIM. E.C.U.

36 8 18
JSM up 13
down
kick_down K
25 12
F N R
B - Wiring diagram

marche AV F
1
28 A EV L
marche AR R
24
29 B EV H
vitesse AV n∞ 1
INFO 2
1 2 3 4 5 6 1 2 4 vitesse AR n∞ 1 C EV R
NEUTRE 30
vitesse AV n∞ 2
23
5 D
31 EV 1
vitesse AV n∞ 3
F8:15A 26
6 vitesse AR n∞ 2 E
32 EV 2
vitesse AV n∞ 4
3
12 vitesse AR n∞ 3 F
14 8 2 7 1 10 3 33 EV 3

9
(+) pour 5eme vitesse AV
22 G
13 34 EV C

MODULE INTERFACE 11 sortie alarme recul

15
shunt
inter crawler
6 Buzzer
K2
option 3 5 B
14
(MLT 735 120 LSU POWERSHIFT Série 2-E2)

coupure transmission
F9:5A 21 option
coupure transmission 11
20

70
lampe témoin
frein serré 9 6 5 5 9 7

ELECTRONIQUE CONTROL UNIT

35 RELAIS
inter de selection inter
19 K3:20A
coupure transm. suppr.5ème feux de recul
10 8 2 7 1 0 1 1 0 1 7 10 vitesse AV 17 16 9 10

contacteur
AFFICHEUR VITESSE
frein à main
(serré) pédale
de frein AMP 1

capteur 25 36
de vitesse 24 13 sécurité
1 12 démarrage
RELAIS
K8:30A

lampe témoin
de charge batterie

1
+ APRES CONTACT 4 CDE DEMARREUR
2 D DEMARREUR
B+
3

- + D±
Alt W
BAT 12V CLEF DE CONTACT
+ +
HR CT
PRECHAUFFAGE
R1
C - E.C.U. checking procedure

As soon as the ignition is switched on, the E.C.U checks the output harnesses (E.C.U to solenoid
valves) and input harnesses (from the inverter lever to E.C.U) in order to detect short circuits and
breaks in the harness.
The E.C.U starts by checking the output harnesses and, if the test is correct, the input harnesses
can be checked.

ECU output harness

When the ignition is switched on, if no problems are detected on the harnesses, the letter "n" is
shown on the display corresponding to the neutral position of the inverter lever.

If there is a fault on the outputs, the display shows lever "E" (error) for two seconds then reverts
to the letter "n".

The faulty harness can be identified.

1st case: assembly with SWF manipulator (Fig. 1):

Cross then restore the contact of the machine all while maintaining supported the button Kick
Down (Fig. 2).

Fig. 1 Fig. 2

2nd case: assembly with JSM manipulator (Fig. 3):

Cut the contact of the machine, schunt the diagnostic socket (fig. 4) then restore the contact.

Fig. 3 Fig. 4

X X

+
Schunt

71
The display then shows the letter "E" followed by a number corresponding to the faulty harness.

Example :

then

Errors codes on the output harness

- Fault on forward gear low FL solenoid valve

- Fault on forward gear high FH solenoid valve

- Fault on reverse gear solenoid valve

- Fault on 1st gear solenoid valve

- Fault on 2nd gear solenoid valve

- Fault on 3rd gear solenoid valve

- Fault on crawler solenoid valve

- Fault on microprocessor

72
E.C.U input harness
The input harnesses are only checked if there are no faults on the outputs and after having swit-
ched the ignition off and then back on again whilst pressing the kick down button.
The control panel display is used for the checking procedure. Each display segment corresponds
to an E.C.U input pin.

- Transmission cut-off pin

- Reverse gear on inverter pin

- Forward gear on inverter pin

- 4th gear on inverter pin

- 3rd gear on inverter pin

- 1st gear on inverter pin

- 2nd gear on inverter pin

- Neutral on inverter pin

- 5th gear locking switch

73
E.C.U connections

+ 12V igni-
tion on 0V

36 13
Forward gear input 1 12 0 V common
Forward gear low
Reverse gear input 24 28 solenoid valve
25 29 Forward gear high sole-
Kick down input
noid valve

E.C.U.
1st gear input 2 30 Reverse gear solenoid
valve
2nd gear input 23 31 1st gear solenoid valve
2nd gear solenoid
3rd gear input 26 32
valve
4th gear input 3 33 3rd gear solenoid valve

5th gear cut-off input

22 34 Crawler solenoid valve
(trailer switch)
OK to start in neutral
Not used 27 35
output
Not used 4

Cut-off by handbrake 21 15 Reversing alarm output

Not used 5 11 Not used

Cut-off by brake pedal
20 14 Not used
or control valve
Crawler input 6 16 5 V - display

Speed sensor earth 19 10 0V display

9 Clock - display
Speed sensor
7 18 8 17 Data - display
return F<10KHz

Communication
port

74
D - Additional information about the forward speed sensor mounted on the PG 115 TURNER
powershift gearbox

- The speed sensor analyses the rotational speed of the transmission output shaft.
- It informs the E.C.U in order to authorise the automatic gear change from 4th to 5th gear (1112
Hz, approximately 16.5 kph).
- It also protects the gearbox when changing down gears and changing the direction of travel in
accordance with the following values:

Gear change down Max frequency in Hz Speed in kph

2 1 578 Approx. 8,5
3 2 933 Approx. 14
4 3 1230 Approx. 18.4
5 4 1986 Approx. 29,5 for kick down
1032 Approx. 15,4 Auto

Change of direction Speed in kph

5 4 Forward If V < 29,5
Then 3 Reverse If V < 18,4
3 2 Forward If V < 14
Then 2 Reverse

Sensor assembly :

Speed gear
Gearbox out-
sensor
put

0.4 mm or tighten fully

then undo by 3/4 of a turn

75
76