Manual Template.T65 - Dieci Telehandlers Ltd
Contents
1. 039 1 gt Tighten 250 300 Lbs ft 339 407 Nm 3 amp 4 Shaft Drop Box 04 01 7 3 8 DISASSEMBLY AND REASSEMBLY 3 amp 4 SHAFT DROP BOX Note This SECTION SHOWS DISASSEMBLY AND REASSEMBLY OF A 4 SHAFT DROP BOX THE PROCEDURE IS A ALSO VALID FOR THE 3 SHAFT DROP BOX AS IT HAS ONLY ONE IDLER GEAR AND SHAFT WHEREAS THE 4 SHAFT DROP BOX HAS TWO Transmission 09 00 1 1 Disassembly of 4 shaft drop box Figure 1 Figure 4 Front view of 4 shaft drop box Remove coupling sleeve Figure 2 Figure 5 Support box with chain hoist Remove drop box Remove output shaft front bearing retaining ring mounting screws and lockwashers Figure 3 Figure 6 Pry box from transmission housing Remove output gear retaining ring 3 amp 4 Shaft Drop Box 04 01 8 2 Disassembly of 4 shaft drop box Figure 7 Figure 10 From2. 1 8 DISASSEMBLY AND REASSEMBLY amp 4 SHAFT DROP BOX 1 3 amp 4 Shaft Drop Box 04 01 1 SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine if replacement parts are required the parts must be replaced by spare parts which have the same part number or with an equivalent part DO NOT USE SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use spare part service procedure or tool which is not recommended by SPICER OFF HIGHWAY PRODUCTS must first determine that neither his safety nor the safe operation of the machine will be jeopardised by the spare part service procedure or tool selected A IMPORTANT IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTICES THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE EXHAUSTIVE
3. Port 71 temperature check port converter out Port 44 check port 4th clutch pressure 3750 24 UNF 2B ring port 1 4 18 mounting holes M12 x 1 75 THD Port 43 25 4 mm 1 00 deep check port 3rd clutch pressure 3750 24 UNF 2B SAE ring port RIGHT SIDE VIEW 3 amp 4 Shaft Drop Box 04 01 5 2 Troubleshooting guide 5 1 CHECK POINTS coNriNUED 5 1 3 Transmission with a 3 shaft drop box Port 12 from cooler Port 33 1 0625 12 UNF 2B pressure check port from cooler SAE O ring port 3750 24 UNF 2B SAE ring port lifting eye location M12 x 1 75 THD 22 4 mm 0 880 deep clutch pressure 1 8 27 Port 31 clutch pressure Engine speed sensor TOP VIEW 3750 24 UNF 2B provision SAE ring port 3 amp 4 Shaft Drop Box 04 01 5 3 Troubleshooting guide 5 1 CHECK POINTS CoONTINUED 5 2 1 Transmission with a 4 shaft drop box Engine speed sensor provision oil filler hole drop box M22 X 1 5 THD breather drop box FRONT VIEW Port 32 Port 11 pressure check port to cooler to cooler 1 8 27 NPTF 8750 14 UNF 2B SAE ring port 1 IN 7 turbine speed sensor W ur provision Jii s Port 31 d ID clutch pressure H RA eos y Port 45 1 8 27 NPTF Hd m Mes S A F check port forward
4. 16 20 e 16 22 26 29 23 25 31 34 41 45 5 37 41 50 56 64 70 57 63 77 85 91 123 82 90 111 122 128 141 174 113 124 153 168 223 245 200 220 271 298 GRADE 8 FINE THREAD COARSE THREAD N m 9 11 12 15 26 30 35 41 33 36 45 49 52 57 71 77 80 88 108 119 115 127 156 172 159 175 216 237 282 310 382 420 GRADE 8 8 or 9 8 GRADE 10 9 COARSE THREAD COARSE THREAD N m N m 40 50 60 65 65 75 100 110 170 190 240 275 3 amp 4 Shaft Drop Box 04 01 3 3 Technical specifications 3 3 2 Pipe plug torque chart THREAD NPTF TORQUE LBF FT IN m 57 7 9 7 10 9 14 15 20 20 27 25 30 94 41 30 35 41 47 40 45 54 61 3 3 3 Permanent metric plug torque chart THREAD SIZE TORQUE LBF FT M18 x 1 5 6H 25 30 M26 x 1 5 6H 45 50 3 amp 4 Shaft Drop Box 04 01 3 4 4 MAINTENANCE 4 1 OIL SPECIFICATIONS Both transmission and Drop Box use the same type of oil 4 1 1Recommended lubricants 1 Caterpillar TO4 2 John Deere J20C D 3 Military MIL PRF 2104G 4 Allison 4 5 Dexron Equivalent See note below A Note Dexron EQUIVALENT IS ACCEPTABLE HOWEVER IT IS NOT COMPATIBLE WITH TORQUE CONVERTERS OR TRANSMISSIONS EQUIPED WITH GRAPHITIC FRICTION MATERIAL CLUTCH PLATES A Caution ENGINE OIL OR GL 5
5. from rear cover Figure 21 Figure 24 Output flange front ring washer and nut removed Front cover removed Figure 22 Figure 25 Remove front to rear cover screws and lockwashers Remove idler shaft and gear 3 amp 4 Shaft Drop Box 04 01 8 6 Disassembly of 4 shaft drop box Figure 26 Figure 29 t Remove idler shaft and gear Output shaft assembly removed L Y Figure 27 4 Figure 30 Pry input assembly from cover If bearing outer have to be replaced remove outer races Figure 2 t Figure 31 Input shaft assembly removed L Remove seal sleeve retaining ring 3 amp 4 Shaft Drop Box 04 01 8 7 Disassembly of 4 shaft drop box Figure 32 Tap seal sleeve from cover Figure 33 Seal sleeve removed 3 amp 4 Shaft Drop Box 04 01 Reassembly of 4 shaft drop box Refer to Cleaning amp Inspection pages Figure 34 Figure 37 E Install two new oil seals in the seal sleeve ES With new O rings installed Tap center sleeve oQ See assembly instructions page 7 2 and 7 3 into position Figure 35 Figure 38 Install two new out
6. 1 3 amp 4 Shaft Drop Box 04 01 6 5 4 SHAFT DROP BOX GROUP 30 8 m 5 31 N b e 2 f 2 6 6 04 01 3 amp 4 Shaft Drop Box 4 SHAFT DROP BOX GROUP Item Description Qty 1 Cover Drop boxr ar 5 ea ad ERR EE DUO ehe 1 2 Cover Drop DOX core t eterna H 1 3 Gasket Rear to front CoVer e t gi e Eege cr egi a phd a 1 4 Shaft Drop box IMPIES deo ded de e E a P Weed d 1 5 Shaft Dap boxIdler se ettet ete eR d e b 1 6 Shat Drop 010 4 EEN 1 7 Shaft Drop boxoutput yuan derre ER Sto 1 8 Bearing Drop box input shaft rrr nennen 2 9 Bearing Drop box output shaft e eee 2 10 Bearing Drop box idler Shaft 4 eene 4 11 Dowel a Peete 2 12 Screw Rear cover to front cover inii eee ener nee nnns 13 13 Lockwasher Rear cover to front cover screw eene 13 14 Seal Drop box output eme eene 2 15 Flange Output ot pter teg de ee es DUE 2 16 ring Output flange 2 17 Washer en keen 2 18 Nut Qutputflange 5 dete ec rtr rd tet 2 19 OE ELA 1 20 DO ting sleeve ee dE eder dei re oed tell 1 21 Seal Qll se
7. BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS 3 amp 4 Shaft Drop Box 04 01 1 1 2 CLEANING INSPECTION AND LEGEND SYMBOLS 2 1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned A CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES FIRE HAZARDS AND INHALATION OF VAPOURS WHEN USING SOLVENT TYPE CLEANERS 2 1 1 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 drying process 2 1 2 Housings Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts
8. OILS NOT RECOMMENDED PREFERRED OIL VISCOSITY It is recommended that the highest viscosity monograde lubricant available be used for the anticipated ambient temperature Typically this will be a CAT TO 4 qualified lubricant When large swings in ambient temerature are possible J20 C D multigrades are recommended Multigrade lubricants should be applied at the lower viscosity rating for the prevailing ambient temperature i e a 10W20 should be used where 10W monograde is used If a C 4 multigrade is used instead of J20 lubricant it is recommended that the viscosity spans no more than 10 points i e 10W20 A Caution SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OF THE ABOVE SPECIFICATIONS OIL VISCOSITY GUIDELINES APPLY BUT SYNTHETIC MULTIGRADES MAY SPAN MORE THAN 10 POINTS FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER OFF HIGHWAY PRODUCTS Recommended SAE J300 Viscosity Grade Based on Prevailing Ambient Temperature SAE OW20 Dexron Il or equivalent T T T SAE 10W SAE 20 SAE 30 40 Celsius 40 30 20 10 0 10 20 30 40 50 Fahrenheit 40 22 4 14 32 50 68 88 104 122 3 amp 4 Shaft Drop Box 04 01 4 1 Maintenance NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hours of average environmental and duty cycle conditions Severe or sustained high operating temperature or very
9. cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner A CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS All parts cleaned must be thoroughly dried immediately by using moistere free compressed air or soft lintless absorbant wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound 2 2 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 2 2 1 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 dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed 3 amp 4 Shaft Drop Box 04 01 2 1 Cleaning Inspection and Legend symbols 2 2 2 Oil seals gaskets etc Replacement of spring load oils seals rings metal sealing rings gaskets and snap rings is more economi cal when the unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a wo
10. dusty atmospheric conditions will result in accelerated deterio ration or contamination Judgement must be used to determine the required change intervals for extreme conditions EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine baseline Wear metal analysis can provide useful information but a transmission should not be removed from service based solely on this analysis Dexron is a registered trademark of GENERAL MOTORS CORPORATION 3 amp 4 Shaft Drop Box 04 01 4 2 Maintenance 4 2 MAINTENANCE INTERVALS FOR THE TRANSMISSION DRAIN THE TRANSMISSION BOTH DRAIN PLUGS amp NEED TO REMOVED 3 shaft drop box 6 e 9 5 lt 1 9 o el o D REAR VIEW LEFT VIEW 4 shaft drop box REAR VIEW LEFT VIEW 4 3 MAINTENANCE INTERVALS FOR THE 3 amp 4 SHAFT DROP BOX 4 3 1 Daily Check oil level daily Maintain oil level at full mark Middle of oil level glass 4 3 2 Normal drain period Normal drain period is every 1000 hours for average environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination
11. 2 3 TECHNICAL SPECIFICATIONS lt gt SPICER OFF HIGHWAY TEN BRIELE 3 8200 See MODEL SERIAL 3 1 IDENTIFICATION OF THE UNIT 1 Model and Type of the unit 2 Serial number 04 01 3 amp 4 Shaft Drop Box 3 1 Technical specifications 3 2 WEIGHT DIMENSIONS OIL CAPACITY 3 2 1 Transmission with 3 shaft Drop Box Weight dry 255 kg 562 Lbs Max lenght 529 3 mm 20 84 Max Width 872 0 mm 34 33 Max Heigth 619 2 24 38 Oil Capacity Transmission 13 5 3 6 US gallon without cooler and hydraulic lines Consult Operator s Manual on applicable machine for system capacity Drop Box 0 751 0 2 US gallon 3 2 2 Transmission with a 4 shaft Drop Box Weight dry 272 kg 600 Lbs Max lenght 529 3 mm 20 84 Max Width 1007 2 mm 39 66 Max Heigth 619 2 mm 24 387 Oil Capacity Transmission 13 5 3 6 US gallon without cooler and hydraulic lines Consult Operator s Manual on applicable machine for system capacity Drop Box 1 0 0 26 US gallon vore THE OIL OF THE DROP BOX IS COMPLETELY SEPARATED FROM THE OIL OF THE TRANSMISSION 3 amp 4 Shaft Drop Box 04 01 Technical specifications 3 3 TIGHTENING TORQUES 3 3 1 Torque specifications for lubricated or plated screw treads GRADES FINE THREAD COARSE THREAD LBF FT N m 9 11 8 10 11 14
12. 3 4 3 MAINTENANCE INTERVALS FOR THE 3 amp 4 SHAFT DROP BOX eene 3 4 3 11 EE 3 4 3 2 Normal drain period 2 kann 3 5 TROUBLESHOOTING GUIDE ees 1 5 1 CHECK POINTS 3 SHAFT DROP BOX msvvnnnnnvvnnrnvvnnnnevnnnnnvnnnnnvvnnnnnvnnnnnennnnnnnnnnnnvnnnnnnnnnnnnnnnnnnvnnnnner 1 5 1 1 Transmission with a 3 shaft drop box evrrnrnnnnnnvennnnnnnnnvnnnnnnnnnnvnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnennenr 1 5 1 2 Transmission with a 3 shaft drop box essen 2 5 1 3 Transmission with a 3 shaft drop box essen enne nnn 3 5 2 CHECK POINTS 4 SHAFT DROP BOX vvnnnnnvvnnnnvvnnnnnvnnnnnvnnnnnvnnnnnnvnnnnnennnnnnnnnnnnvnsnnnnnnnnnennnnnnnnnnnnenr 4 5 2 1 Transmission with a 4 shaft drop box sseeerrrnnnnnvvnrennnnnnvvnnennnnnnnennnnnnnnnnvnnnnnnnnnnennnnnnnnnvenennr 4 5 2 2 Transmission with a 4 shaft drop box seeerrrnnnnnvvnnnnnnnnnvnnnnnnnnnnnvnnnnnnnnnnennnnnnnnnnennnnnnnnnnenennr 5 5 2 3 Transmission with a 4 shaft drop box sseeerrrnnnnnvvnnnnnnnnnvnnnnnnnnnnnennnnnnnnnnennnnnnnnnnennnnnnnnnnennenr 6 6 SECTIONAL VIEWS AND PARTS IDENTIFICATION 1 7 ASSEMBLY INSTRUCTIONS nay Rn
13. AUTIONS nassen 1 2 CLEANING INSPECTION AND LEGEND SYMBOLS 1 2 1 CLEANING ike 1 PANMICIILIE E 1 2 1 2 HOUSINGS ETENEE ARRA AAA 1 2 2 INSPEGTION Eed Eege EEN 1 2 2 1 2 2 1 2 2 2 Oil seals gaskets EE 2 2 2 3 Gears and E E ai TAARA KE KANANA 2 2 2 4 Housing Covers E 2 2 3 LEGEND SYMBOL E 2 3 TECHNICAL SPECIFICATIONS i rrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenvnnnnnevever 1 3 1 IDENTIFICATION OF THE UNIT 1 3 2 1 Transmission with a 3 shaft Drop BOX eese nennen nnns 2 3 2 2 Transmission with a 4 shaft Drop BOX nennen nennt 2 3 3 TIGHTENING TORQUE O c 3 3 3 1 Torque specifications for lubricated or plated screw treads 3 3 3 2 Pipe plug torque 4 3 3 3 Permanent metric plug torque 4 4 MAINTENANCE RII Ra NAI Bee Ehe dE eee 1 4 1 O1IL SPECIFICATIONS 2 2 1 4 1 1 Recommended lubricants eese nennen nennen nennen nnn nnns n nennen nnn 1 4 2 MAINTENANCE INTERVALS FOR THE TRANSMISSION cerent
14. For extreme conditions judgement must be used to determine the required change intervals 3 amp 4 Shaft Drop Box 04 01 4 3 5 TROUBLESHOOTING GUIDE 5 1 CHECK POINTS 5 1 1 Transmission with a 3 shaft drop box Engine speed sensor provision FRONT VIEW Port 32 pressure check port to cooler 1 8 27 Port 11 to cooler 8750 14 UNF 2B ring port turbine speed sensor provision Port 31 clutch pressure Port 45 1 8 27 check port forward clutch pressure 3750 24 UNF 2B Port 46 check port reverse clutch transmission pressure oil filler hole 3750 24 UNF 2B mounting holes M12x 1 75 THD 25 4 mm 1 007 deep magnetic drain plug transmission 3 4 14 NPTF THD LEFT SIDE VIEW 3 amp 4 Shaft Drop Box 04 01 5 1 Troubleshooting guide 5 1 CHECK POINTS CoONTINUED 5 1 2 Transmission with a 3 shaft drop box breather transmission breather drop box oil filler hole fni drop box dipstick M22 x 1 5 THD transmission oil level glass drop box magnetic drain plug Me magnetic drain plu transmission g p ug drop box 3 4 14 NPTF THD REAR VIEW M22 x 1 5 THD Port 41 engine speed sensor check port 1st clutch pressure provision 3750 24 UNF 2B SAE ring port Port 42 check port 2nd clutch pressure 3750 24 UNF 2B breather SAE ring port transmission
15. SUPPLEMENT 3 amp 4 SHAFT DROP BOX To be used in conjunction with the T12000 3 4 amp 6 Speed Intermediate Drop SPICER OFF HIGHWAY COMPONENTS CD ROM 8100038 MANUAL 8100039 NOTICE All information mentioned in the maintenance and service manual T12000 powershift transmission 3 4 amp 6 speed Intermediate Drop is valid unless otherwise specified in this 3 amp 4 shaft drop box supplement for the T12000 Intermediate Drop Copyright DANA CORPORATION 1990 Unpublished material All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION 3 amp 4 Shaft Drop Box 04 01 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 HIGWAY 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 will 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 manual care
16. al sleeve olsen 1 22 Lockwasher Drop box mounting SCrew nennen nennen 8 23 Screw Drop box mounting a ae e e nn 8 24 Plug Magnetic draln nach 1 25 Glass 01 tet ose aged ride 1 26 et 1 27 SIGEVE MM 1 28 KO ar dE E 2 29 Ringe 1 30 EIE ee en Blei da deed detest esd ner 1 31 Fitting Elbow 90 Street an arena ee adu ez teer eund ed nad 1 32 cM en 1 3 amp 4 Shaft Drop Box 04 01 6 7 7 ASSEMBLY INSTRUCTIONS 3 amp 4 Shaft Drop Box 04 01 7 1 7 ASSEMBLY INSTRUCTIONS 3 Shaft Drop Box 0 435 11 3 amp 4 Shaft Drop Box 0 435 11 04 01 ze 039 1 gt Tighten 250 300 Lbs ft 339 407 Nm 7 2 Assembly Instructions 7 ASSEMBLY INSTRUCTIONS CONTINUED 4 Shaft Drop Box
17. clutch HD res UN 3750 24 UNF 28 1 i Dt oy d IB d M Port 46 Ch check port reverse clutch transmission pressure oil filler hole 3750 24 UNF 2B FU mounting holes M12 x 1 75 THD 25 4 mm 1 00 deep LEFT SIDE VIEW 3 amp 4 Shaft Drop Box 04 01 magnetic drain plug transmission 3 4 14 NPTF THD 5 4 Troubleshooting guide 5 1 CHECK POINTS coNrINUED 5 2 2 Transmission with a 4 shaft drop box breather transmission dipstick transmission oil level glass drop box PAW C _ Cy S Oct magnetic drain plug 22 magnetic transmission dro Box E 3 4 14 NPTF THD REAR VIEW M22 x15 THD Port 41 engins Sues sonst check port 1st clutch pressure provision 3750 24 UNF 2B SAE ring port Port 42 check port 2nd clutch pressure 3750 24 UNF 2B breather SAE ring port transmission Port71 temperature check port converter out Port 44 check port 4th clutch pressure 3750 24 UNF 2B SAE ring port 1 4 18 mounting holes M12 x 1 75 THD Port 43 25 4 mm 1 00 deep check port 3rd clutch pressure 3750 24 UNF 28 SAE ring port RIGHT SIDE VIEW 3 amp 4 Shaft Drop Box 04 01 5 5 Troubleshooting guide 5 1 CHECK POINTS CONTINUED 5 2 3 Transmission with a 4 shaft drop box Por
18. eat ete t HR eden 1 13 poppet Converter safety valve emere rne 1 14 Spring Converter safety valve cecidere ent i en 1 15 Washer Puppet retaining nenne nennen nnns 1 16 lao 1 17 ali i dee tene buet sta 3 18 SO ring Plug nt ae A ve 3 19 Screw Plate to transmission Case 7 20 Screw Plate to transmission Case 2 21 Lockwasher Plate to transmission eene 9 22 Assembly Tube amp uec e etie d e e t dettes 1 23 eire ade 1 24 la per DLE DERE PE 1 25 ele Test Fra ds ce Te So oe o cs tti Ti ctt tio 1 26 Assembly Dipstick Tuben ee ee ai 1 27 1 28 Plug Speed sensor port cett pde uini epo ta teg ple de doe eens 2 29 ring Speed sensor port plug rennen nnns 2 30 Screw Speed sensor port plug nnne 2 3 amp 4 Shaft Drop Box 04 01 6 3 3 SHAFT DROP BOX GROUP 6 4 04 01 3 amp 4 Shaft Drop Box 3 SHAFT DROP BOX GROUP Item Description Qty 1 Cover Drop LEE 1 2 Cover Drop eet H 1 3 Gasket Rearto front Cover tegi E 1 4 Shaft Dropbox Input ss ted edd p e DE a m Wein 1 5 Gear Drop box
19. fully and uses it as reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAY PRODUCTS approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment SPICER OFF HIGHWAY PRODUCTS does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied or approved by SPICER OFF HIGHWAY PRODUCTS IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS 3 amp 4 Shaft Drop Box 04 01 Table of Content 1 SAFETY PREC
20. idler ar me Er nein reihen 1 6 Shaft Drop box output 1 7 Bearing Drop box input shaft 2 8 Bearing Drop box output sbatt e eere 2 9 Bearing Drop boxidler shaft oot eese een Hess ba p ud 2 10 t 2 11 Screw Rear cover to front cover 10 12 Lockwasher Rear cover to front cover screw 10 13 Seal Drop box output shaft oil rece p a og i tene eee tee 2 14 Fange EE 2 15 Oring Output flange drusere 2 16 Washers eege eee REA RR en E Bee 2 17 Nut Qutputflarnige na se E RR be casera Tod kasse damn cbe E rodeo nt 2 18 Sleeve aS 1 19 ring Ollseal sleeve uie Rte b te e eo Pe Zeie 1 20 Seal Oil seal sleeve ol 2 21 Lockwasher Drop box mounting Screw 8 22 Screw Drop box mountmg 4 8 23 Glass Oil l velz a ET 1 24 Plug Magnetic drain eea ee emm rr ener nnne 1 25 1 26 POP GING SEE 1 27 Sl eve PIloE E 1 28 EE ere ka add 2 29 Ringe RETAINING 1 30 Breather D de ak faer EE 1 31 Fitting Elbow 90 Street an arena ee adu e hz teer Eun ode nad 1 32 cM en
21. mettere la sicura Reassemble to from assembly group Unlock lock e g split pin locking plate etc rta Smontaggio di particollari ingombranti Mettere la sicura incollare mastice liquido ty Remove obstruction parts Lock adhere liquid sealant ria Montaggio di particollari ingombranti Evitare danni ai materiali danni ai pezzi AS Reinstall remount parts which had obstructed disassembly Guard against material damage damage to parts Attention important notice Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc lt Mark before disassembly observe marks when reasembl Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc T Attrezzature speciali P Pagina Scarricare olio lubrificante 2 Attenzione indicazione importante HH Marchiari prima dello smontaggio per il montaggio M V T Special tool Page Drain off oil lubricant Rispettare direzione di montaggio Note direction of installation Tighten clamp tightening clamping device Controllare esaminare controllo visuale Insere pressione nel circuito idraulico Visual inspection Apply pressure into hydraulic circuit M G d Eventualimente riutilizzable sostituire se necessario Pulire lt D Possibly still serviceable renew if necessary To clean 3 amp 4 Shaft Drop Box 04 01 2
22. put shaft oil seals in front and rear With new ring installed Install seal sleeve 0 cover See assembly instructions page 7 2 and 7 3 Figure 36 Figure 39 Install seal sleeve retaining ring Install input shaft into rear cover oQ Use caution as not to damage oil seals 3 amp 4 Shaft Drop Box 04 01 8 9 Reassembly of 4 shaft drop box Figure 40 Figure 43 nstall output shaft into rear cover osition new gasket on rear cover Install output shaft int pa Positi ket QQ Use caution as not to damage oil seal Figure 41 Figure 44 If bearing outer races have been removed Position drop box front cover on rear cover install bearing outer Use caution as not to damage oil seal Figure 42 4 Install idler shafts and gears p Install capscrews and lockwashers Figure 45 3 amp 4 Shaft Drop Box 04 01 8 10 Reassembly of 4 shaft drop box Figure 46 Tighten screws to specified torque See torque chart Figure 47 Install coupling sleeve retaining ring 3 amp 4 Shaft Drop Box 04 01 Reassembly of 4 shaft drop box Figure 48 Figure 51 Install output shaf
23. rn 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 of lips of seals seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with a coat of chassis grease to stabilise rings in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recommended type Automatic Transmission Fluid before assembly 2 2 3 Gears and Shafts 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 with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or spline twisted and that shafts are true 2 2 4 Housing Covers etc Inspect housings covers and bearing caps 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 which would cause subsequent oil leaks or failures 2 3 LEGEND SYMBOLS Big Smontaggio di sottogruppi Sostituire con ogni montaggio db Disassembly of assembly groups SEN Renew at each reassembly Ee Montaggio di sottogruppi Togliere
24. t 33 pressure check port from cooler 3750 24 UNF 2B SAE ring port Port 12 from cooler 1 0625 12 UNF 2B ring port lifting eye location M12 x 1 75 THD 22 4 mm 0 880 deep 4S A U EN m SEI lt Port 31 r 1 i 188 clutch pressure L 1 8 27 N UL uf Port 31 clutch pressure 3750 24 UNF 2B SAE ring port TOP VIEW Engine speed sensor provision 3 amp 4 Shaft Drop Box 04 01 6 SECTIONAL VIEWS AND PARTS IDENTIFICATION 3 amp 4 Shaft Drop Box 04 01 6 1 TRANSMISSION CASE amp PLATE GROUP Von a Pal Per 6 2 04 01 3 amp 4 Shaft Drop Box TRANSMISSION CASE amp PLATE GROUP Item Description Qty 1 Case Transmission eet edle fee frede ede 1 2 Breather All ed ae Dale 1 3 MPPE PIDE aa 1 4 Coupling s PIPE ie pe EI bei E Fehn 1 5 Pitting EIBOW EE 1 6 tire o met te rt ein 2 7 Pin Plate to transmission case dowel eee 2 8 Gasket Plate to transmission Case eere 1 9 Ring Oil supply tube seal e eer rennen 1 10 Plate Spacer teie erre ee FR de 1 11 Seat Safetyvalve eie 1 12 Snapring e S
25. t rear bearing locating ring Install output shaft rear bearing in case against locating ring Figure 49 Figure 52 Install output shaft front bearing locating ring Position output shaft Align splines on shaft with splines in output gear Tap shaft into position Figure 50 Figure 53 From the front of transmission case position Install new bore plug 0 output gear with long hub of gear towards the front 3 amp 4 Shaft Drop Box 04 01 8 12 Reassembly of 4 shaft drop box Figure 54 Figure 57 Install output shaft gear retaining ring Install coupling sleeve Figure 55 Figure 58 Install output shaft front bearing in case against Install drop box assembly ba locating ring Figure 56 Figure 59 Install front bearing retaining ring Install drop box mounting screws and lockwashers Tighten to specified torque See torque chart 3 amp 4 Shaft Drop Box 04 01 8 13 Reassembly of 4 shaft drop box NW Figure 60 Figure 63 Install front and rear output flanges Install breather Figure 61 Install flange rings washers and nuts Figure 62 Block flanges to prevent turning Tighten flange nuts to specified torque See assembly instructions page 7 4 3 amp 4 Shaft Drop Box 04 01 8 14
26. the rear remove output shaft bore plug Remove output shaft gear and retaining ring Figure 8 Figure 11 From the front tap output shaft and rear bearing from Remove output shaft front bearing housing Figure 9 1 Figure 12 Output shaft and rear bearing removed Remove output shaft front bearing retaining ring 3 amp 4 Shaft Drop Box 04 01 8 3 Disassembly of 4 shaft drop box Figure 13 From the rear remove rear bearing retaining ring 3 amp 4 Shaft Drop Box 04 01 8 4 Disassembly of 4 shaft drop box Figure 14 Use an impact wrench to loosen flange nut Figure 17 Use gear puller to remove pilot sleeve Figure 15 Output flange rear ring washer and nut removed Figure 16 Remove sleeve outer ring 3 amp 4 Shaft Drop Box Figure 18 Pilot sleeve and inner ring removed x Figure 19 Remove coupling sleeve retaining ring 04 01 8 5 Disassembly of 4 shaft drop box Figure 20 Figure 23 Use an impact wrench to loosen flange nut Support front cover with a chain hoist Pry front cover
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