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BV 12 H PDF
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Arrêter SIS
Ecran précédent
Montage et démontage
12H, 140H and 160H Motor Graders Power Train
Numéro d'imprimé -SENR8548-13 Date de publication -01/11/2008 Date de mise à jour -19/11/2008
i03337320
Transmission - Assemble
SMCS - 3030-016
Assembly Procedure
Table 1
Required Tools
C 6V-5221 Bolt 1
E 6V-3918 Bolt 1
J 5P-7970 Nut 1
5F-7353 Washer 1
L
5F-7369 Puller Leg 2
5P-4808 Cap 2
1U-9895 Crossblock 1
9S-9151 Block 2
M 1B-4206 Nut 4
P 6V-8149 Nut 1
1P-2325 Head 1
R 3H-0462 Bolt 4
8H-0709 Strap 4
5F-7373 Jaw 3
S 3E-3882 Eyebolt 1
T 6V-5765 Sealant 1
Illustration 1 g00623302
1. Lower the temperature of bearing outer races (130) . Install bearing outer races (130) to the original locations
in both transmission case assembly (3) (not shown) and the transmission cover assembly (11) until bearing
outer races (130) are seated.
Illustration 2 g00623301
3. Heat ball bearing (127) to a maximum of 135 °C (275 °F). Install ball bearing (127) to the original location
on gear assembly (126) .
4. Use Tooling (Q) in order to install snap ring (129) to the original location on gear assembly (126) .
Illustration 3 g00623300
5. Install gear assembly (126) to the original location in the transmission cover assembly (11) .
7. Install four bolts (125) in the gear assembly (126) . Tighten bolts (125) to a torque of 28 ± 7 N·m (21 ± 5 lb
ft).
Illustration 4 g00623299
8. Install the cup plug (not shown) in input shaft assembly (65) .
10. Heat inner bearing (123) to a maximum of 135 °C (275 °F). Install inner bearing (123) on Input shaft
assembly (65) until inner bearing (123) is seated. Gear (124) should be tight on input shaft assembly (65) .
11. Install two seal rings (122) to the original locations on Input shaft assembly (65) .
Illustration 5 g01024466
12. Install Tooling (S) to Input shaft assembly (65) . Use a hoist in order to position Input shaft assembly (65) to
the original location in the transmission case assembly (11) . Install Input shaft assembly (65) in the
transmission case assembly (11) . Remove Tooling (S) from Input shaft assembly (65) .
Illustration 6 g00623297
Illustration 7 g00623294
13. Install seal rings (121) on piston (120) . Install both seal rings (121) with the sealing lips facing toward the
small diameter of piston (120) .
14. Place Forward shaft assembly (95) in the modified work bench or on blocks. Apply a light coat of clean
hydraulic oil on seal rings (121) . Install piston (120) at the original location on Forward shaft assembly
(95) . Slightly rotate piston (120) while the seal is being installed. Ensure that the seal rings (121) are
installed properly.
15. Install valve assembly (119) to the original location on Forward shaft assembly (95) .
Illustration 8 g00623292
16. Install six clutch plates (117) and seven friction discs (118) in the original order on hub assembly (115) . The
splines on hub assembly (115) must align with the splines on the friction discs (118) .
17. Install spring (116) in the original location on Forward shaft assembly (95) .
18. As one unit, install hub assembly (115) , six clutch plates (117) and seven friction discs (118) to the original
location on Forward shaft assembly (95) .
Illustration 9 g00623291
19. Use a second person in order to manually compress clutch assembly (113) on spring (116) .
20. Install two half rings (114) in the Forward shaft assembly (95) .
Illustration 10 g00623665
21. Install the washer and thrust disc (112) to the original locations on Forward shaft assembly (95) .
Illustration 11 g00623672
22. Install gear assembly (110) on Forward shaft assembly (95) and over clutch assembly (113) . Align the spline
teeth on the outer diameter of the clutch plates (117) with the splines on the inside of gear assembly (110) .
Ensure that gear assembly (110) is completely down over the clutch assembly (113) .
Illustration 12 g00623673
23. Install roller bearing (111) to the original location on Forward shaft assembly (95) .
Illustration 13 g00623736
24. Install two thrust discs (131) and thrust race (132) on Forward shaft assembly (95) . The thrust discs (131)
should not spin the thrust race (132) .
Illustration 14 g00623738
25. Heat inner bearing (109) to a maximum of 132 °C (270 °F). Install inner bearing (109) on Forward shaft
assembly (95) until inner bearing (109) contacts the bearing race.
26. Position Forward shaft assembly (95) , as shown. The weight of Forward shaft assembly (95) is
approximately 43 kg (95 lb). Place Forward shaft assembly (95) in the modified work bench or blocks.
Illustration 15 g00623287
27. Install lip seals (108) in piston (107) . Install lip seals (108) with the sealing lip toward the small diameter of
piston (107) .
28. Apply a light coat of clean hydraulic oil on lip seals (108) .
Illustration 16 g00623285
29. Install piston (107) to the original location on Forward shaft assembly (95) . Rotate the piston slightly while
the seal is being installed. Ensure that the lip seals are installed properly.
30. Install valve assembly (106) to the original location on Forward shaft assembly (95) .
Illustration 17 g00623284
Note: Friction discs 1 and 7 are different from the remaining discs. Assemble friction discs (1) and (7) with
the grooved pattern toward the center of the clutch pack.
31. Install six clutch plates (105) and seven friction discs (103) in the original order on hub assembly (102) . The
splines on hub assembly (102) must align with the splines on the friction plates.
32. Install spring (104) to the original location on Forward shaft assembly (95) .
33. As one unit, install hub assembly (102) , six clutch plates (105) , and seven friction discs (103) to the original
location on Forward shaft assembly (95) .
Illustration 18 g00623281
34. Use two people to manually compress hub assembly (100) on spring (94) . Install two half rings (101) in
Forward shaft assembly (95) .
Illustration 19 g00623746
35. Install thrust disc and washer (99) on Forward shaft assembly (95) . The thrust disc should not spin the
washer.
Illustration 20 g00623747
Illustration 21 g00634016
36. Install gear assembly (97) on Forward shaft assembly (95) and over clutch assembly (100) . Align the spline
teeth on the outer diameter of the clutch plates with the splines on the inside of gear assembly (97) . Ensure
that the gear assembly (97) is completely down over hub assembly (102) .
37. Install roller bearing (98) to the original location on Forward shaft assembly (95) .
38. Install the two thrust discs on Forward shaft assembly (95) .
Illustration 22 g00623756
39. Heat bearing (96) to a maximum of 132 °C (270 °F). Install bearing (96) on Forward shaft assembly (95)
until bearing (96) contacts the bearing race.
Illustration 23 g01024454
40. Install Tooling (S) in Forward shaft assembly (95) . Install Forward shaft assembly (95) to the original
location in the transmission cover assembly (11) . The weight of Forward shaft assembly (95) is
approximately 63.6 kg (140 lb). Remove Tooling (S) .
Illustration 24 g00623276
41. Install the cup plug (not shown) from Reverse/Second shaft assembly (68) .
42. Install seals (93) and (94) with the sealing lip toward the small diameter of piston (92) .
Illustration 25 g00623270
43. Place Reverse/Second shaft assembly (68) in the modified work bench, or on blocks. Apply a light coat of
clean hydraulic oil on the lip seals. Install piston (92) to the original location on Reverse/Second shaft
assembly (68) . Rotate the piston slightly while the seal is being installed. Ensure that the lip seals are
installed properly.
44. Install valve assembly (91) to the original location on Reverse/Second shaft assembly (68) .
Illustration 26 g00623269
45. Install six clutch plates (88) and seven friction disc (90) in the original order on hub assembly (87) . The
splines on the hub assembly (87) must align with the splines on the friction discs (90) .
46. Install spring (89) in the original location on Reverse/Second shaft assembly (68) .
47. As one unit, install hub assembly (87) , six clutch plates (88) , and seven friction discs (90) to the original
location on Reverse/Second shaft assembly (68) .
Illustration 27 g00623265
48. Use two people to manually compress clutch plate (85) on spring (89) . Install two half rings (86) in Reverse/
Second shaft assembly.
Illustration 28 g00623760
49. Install the washer and thrust disc (84) to the original locations on Reverse/Second shaft assembly (68) . The
thrust disc should not spin the washer.
50. Install gear assembly (82) on Reverse/Second shaft assembly (68) . Align the spline teeth on the outer
diameter of the clutch plates with the splines on the inside of gear assembly (82) . Ensure that the gear
assembly (82) is completely down over the clutch assembly (85) .
Illustration 29 g00634018
51. Install roller bearing (83) to the original location on Reverse/Second shaft assembly (68) .
Illustration 30 g00634020
52. Install two thrust discs and one thrust race (133) .
Illustration 31 g00634021
53. Heat inner bearing (81) to a maximum of 132 °C (270 °F). Install inner bearing (81) on Reverse/Second shaft
assembly (68) until inner bearing (81) contacts the bearing race. The thrust disc should not spin.
Illustration 32 g00623260
Illustration 33 g00623261
54. Position Reverse/Second shaft assembly (68) , as shown. The weight of Reverse/Second shaft assembly (68)
is approximately 41 kg (90 lb). Place Reverse/Second shaft assembly (68) in the modified work bench or on
blocks.
55. Apply a light coat of clean hydraulic oil on the lip seals. Install lip seals (79) and (80) in piston (78) . Install
lip seals (79) and (80) with the sealing lip toward the small diameter of the piston (78) . Rotate the piston
slightly while the seal is being installed.
56. Install piston (78) to the original location on Reverse/Second shaft assembly (68) . Ensure that the lip seals
are installed properly.
Illustration 34 g00623259
58. Install clutch assembly (74) on Reverse/Second shaft assembly (68) . Position the three clutch plates, the four
friction disc, and the hub assembly in the original locations on Reverse/Second shaft assembly (68) .
59. Install Tooling (K) and Tooling (H) on Reverse/Second shaft assembly (68) . Tighten Tooling (J) on Tooling
(H) in order to compress clutch assembly (74) . Install two half rings (75) and two lock rings (76) in Reverse/
Second shaft assembly (68) .
60. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (74) . Remove
Tooling (H) and Tooling (K) from clutch assembly (74) .
Illustration 35 g00623258
61. Install the thrust disc and the washer on Reverse/Second shaft assembly (68) .
62. Install the sleeve bearing (not shown) on Reverse/Second shaft assembly (68) .
63. Install gear assembly (73) on Reverse/Second shaft assembly (68) . Align the spline teeth on the outer
diameter of the clutch plates with the splines on the inside of gear assembly (73) . Ensure that gear assembly
(73) is down over the clutch assembly completely.
64. Install the thrust disc (not shown) and spacer (72) to the original locations on Reverse/Second shaft assembly
(68) .
Illustration 36 g00623761
67. Heat bearing (69) to a maximum of 132 °C (270 °F). Install bearing (69) on Reverse/Second shaft assembly
(68) until bearing (69) contacts spacer (70) . Spacer (70) should not spin.
Illustration 37 g01024451
68. Install Tooling (S) in Reverse/Second shaft assembly (68) . Place Reverse/Second shaft assembly (68) to the
original location in the transmission case assembly (11) . The weight of Reverse/Second shaft assembly (68)
is approximately 64 kg (141 lb). Remove Tooling (S) .
Illustration 38 g00623801
69. Install gear (67) to the original location on Input shaft assembly (65) .
70. Heat inner bearing (66) to a maximum of 132 °C (270 °F). Install inner bearing (66) on Input shaft assembly
(65) until inner bearing (66) contacts gear (67) . Gear (67) should be tight on input shaft assembly (65) .
Illustration 39 g00623250
71. Install seal extension ring (63) and seal ring (64) on piston (62) . Install seal (63) and seal (64) with the
sealing lips toward the small diameter of the piston (62) . Apply a light coat of clean hydraulic oil on the lip
seals of piston (62) .
Illustration 40 g00623249
72. Place First/Third shaft assembly (14) in the modified work bench, or on blocks. Install piston (62) to the
original location on First/Third shaft assembly (14) . Rotate the piston (62) slightly while the seal is being
installed. Ensure that the lip seals are installed properly.
73. Install wave spring (61) to the original location on First/Third shaft assembly (14) .
Illustration 41 g00623248
74. As you install clutch assembly (58) to First/Third shaft assembly (14) , position the three clutch plates, four
friction disc and the hub assembly to the original locations on First/Third shaft assembly (14) .
75. Install Tooling (K) and Tooling (H) on First/Third shaft assembly (14) . Tighten Tooling (J) on Tooling (H)
in order to compress clutch assembly (58) . Install two half rings (59) and two lock rings (60) to First/Third
shaft assembly (14) .
76. Carefully loosen the nut on Tooling (J) in order to relieve pressure from clutch assembly (58) . Remove
Tooling (K) and Tooling (H) .
Illustration 42 g00634025
77. Install the washer, the thrust disc, and the bearing sleeve to the original locations on First/Third shaft
assembly (14) .
78. Install gear assembly (57) in the original location on First/Third shaft assembly (14) and over clutch
assembly (58) . Align the spline teeth on the outer diameter of the clutch plates with the splines on the inside
of gear assembly (57) . Ensure that the gear assembly (57) is completely down over clutch assembly (58) .
79. Install the thrust disc that was under gear (56) to the original location on First/Third shaft assembly (14) .
80. Install gear (56) to the original location on First/Third shaft assembly (14) . Install the thrust disc that was on
top of gear (56) .
81. Heat inner bearing (55) to a maximum of 132 °C (270 °F). Install inner bearing (55) on First/Third shaft
assembly (14) until inner bearing (55) contacts gear (56) . The thrust disc that is under inner bearing (55)
should not spin.
Illustration 43 g00623245
82. Install seal extension ring (53) and seal ring (54) on piston (52) . Install seal extension ring (53) and seal ring
(54) with the sealing lips toward the small diameter of the piston (52) . Apply a light coat of hydraulic oil on
the lip seals.
Illustration 44 g00623242
83. Rotate First/Third shaft assembly (14) in order to assemble the other end. The weight of First/Third shaft
assembly (14) is approximately 55 kg (121 lb). Place the First/Third shaft assembly (14) on the modified
work bench, or on blocks. Install piston (52) to the original location on First/Third shaft assembly (14) .
Rotate the piston slightly while the seal is being installed. Ensure that the lip seals are installed properly.
84. Install wave spring (51) to the original location on First/Third shaft assembly (14) .
Illustration 45 g00623241
85. As you install clutch assembly (48) to First/Third shaft assembly (14) , position the five clutch plates, six
friction disc and the hub assembly to the original locations on First/Third shaft assembly (14) .
86. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (14) . Tighten Tooling (J) on Tooling (H)
in order to compress clutch assembly (48) . Install two half rings (49) and two lock rings (50) on First/Third
shaft assembly (14) .
87. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (48) . Remove
Tooling (K) and Tooling (H) .
Illustration 46 g00623240
88. Install washer (47) and thrust disc (46) to the original locations on First/Third shaft assembly (14) .
Illustration 47 g00623154
90. Install gear assembly (45) in the original location on First/Third shaft assembly (14) . Install gear assembly
(45) on First/Third shaft assembly (14) . Align the spline teeth on the outer diameter of the clutch plates with
the splines on the inside of gear assembly (45) . Ensure that the gear assembly (45) is completely down over
the clutch assembly.
Illustration 48 g00623802
93. Install the thrust disc that was under bearing (42) on First/Third shaft assembly (14) . Heat bearing (42) to a
maximum of 132 °C (270 °F). Install bearing (42) on First/Third shaft assembly (14) until bearing (42)
contacts gear assembly (43) . Thrust disc should not spin.
94. Install Tooling (S) (not shown) in First/Third shaft assembly (14) and place First/Third shaft assembly (14)
aside. The weight of First/Third shaft assembly (14) is approximately 89 kg (196 lb).
Illustration 49 g00623150
Illustration 50 g00623149
95. Install seal ring (40) and seal extension ring (41) on piston (39) . Install seal ring (40) and seal extension ring
(41) with the sealing lip toward the small diameter of piston (39) .
96. Place High/Low shaft assembly (15) in the modified work bench or on blocks. Apply a light coat of
hydraulic oil on the lip seals. Install piston (39) to the original location on High/Low shaft assembly (15) .
Ensure that seal ring (40) , and seal extension ring (41) are installed properly.
99. Install balance piston (35) on High/Low shaft assembly (15) and in piston (39) . Ensure that the guides that
are located on balance piston (35) are placed in the center of each spring (38) .
Illustration 51 g00623148
100. Install Tooling (K) and Tooling (N) on High/Low shaft assembly (15) and balance piston (35) . Tighten
Tooling (P) on Tooling (N) in order to compress balance piston (35) . Rotate balance piston (35) slightly
while the seal is being installed.
101. Use Tooling (Q) in order to install retaining ring (36) to High/Low shaft assembly (15) .
102. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston (35) . Remove
Tooling (B) from balance piston (35) and High/Low shaft assembly (15) .
Illustration 52 g00623145
Illustration 53 g00623141
103. Install the clutch assembly (32) to the original locations on High/Low shaft assembly (15) . The clutch
assembly (32) includes seven friction discs, eight clutch plates, and the hub assembly.
104. Install Tooling (K) and Tooling (N) on High/Low shaft assembly (15) and clutch assembly (32) . Tighten
Tooling (P) on Tooling (N) in order to compress clutch assembly (32) .
105. Install two lock rings (34) and two half rings (33) to High/Low shaft assembly (15) .
106. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch assembly (32) . Remove
Tool (K) and Tooling (N) from High/Low shaft assembly (15) and clutch assembly (32) .
107. Install thrust disc and washer (31) to the original locations on High/Low shaft assembly (15) .
Illustration 54 g00623805
108. Install gear assembly (30) in the original location on High/Low shaft assembly (15) . Install gear assembly
(30) on High/Low shaft assembly (15) . Align the spline teeth on the outer diameter of the clutch plates with
the splines on the inside of gear assembly (30) . Ensure that gear assembly (30) is completely down over
clutch assembly.
109. Install two thrust discs (29) and the two bearing sleeves on High/Low shaft assembly (15) .
110. Heat inner bearing (28) to a maximum of 132 °C (270 °F). Install inner bearing (28) on the High/Low shaft
assembly (15) until the inner bearing (28) contacts the thrust disc.
Illustration 55 g00623134
Illustration 56 g00623132
112. Install seal extension ring (27) and seal ring (26) on piston (24) . Install seal extension ring (27) and seal ring
(26) with the sealing lips toward the small diameter of the piston (24) . Apply a light coat of hydraulic oil on
seal extension ring (27) and seal ring (26) .
113. Position High/Low shaft assembly (15) , as shown. The weight of the High/Low shaft assembly (15) is 50 kg
(110 lb). Place High/Low shaft assembly (15) on the modified work bench, or on blocks. Install piston (24)
to the original location on High/Low shaft assembly (15) . Rotate the piston (24) slightly while the seal is
being installed. Ensure that the seal extension ring (27) and seal ring (26) are installed properly.
114. Install wave spring (25) to the original location on High/Low shaft assembly (15) .
Illustration 57 g00623131
115. As you install clutch assembly (21) to High/Low shaft assembly (15) , position the five clutch plates, six
friction discs, and the hub assembly to the original locations on High/Low shaft assembly (15) .
116. Install Tooling (K) and Tooling (H) on High/Low shaft assembly (15) and clutch assembly (21) . Tighten
Tooling (J) on Tooling (H) in order to compress clutch assembly (21) .
117. Install two half rings (22) and two lock rings (23) to High/Low shaft assembly (15) .
118. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (21) . Remove
Tooling (H) and Tooling (K) from High/Low shaft assembly (15) and clutch assembly (21) .
Illustration 58 g00623129
119. Install the thrust disc, the two sleeve bearings and washer (20) to the original locations on High/Low shaft
assembly (15) .
Illustration 59 g00623806
Illustration 60 g00623126
120. Install gear assembly (18) in the original location on High/Low shaft assembly (15) . Ensure that gear
assembly (18) is completely down over clutch assembly (23) . Install rotor (17) in High/Low shaft assembly
(15) and clutch assembly (23) . Align the spline teeth on the outer diameter of the rotor (17) with the splines
on the inside of gear assembly (18) .
121. Install thrust disc (19) that was under rotor (17) to High/Low shaft assembly (15) . Heat rotor (17) to a
maximum of 135 °C (275 °F). Install rotor (17) to High/Low shaft assembly (15) until rotor (17) makes
contact with the shoulder of shaft assembly (15) . Ensure that rotor (17) is completely down against the
shoulder of shaft assembly (15) . Thrust disc (19) should spin freely.
Illustration 61 g00623807
122. Heat bearing (16) to a maximum of 135 °C (275 °F). Install bearing (16) to High/Low shaft assembly (15)
until bearing (16) makes contact with rotor (17) .
Illustration 62 g00634111
123. Install Tooling (F) in High/Low shaft assembly (15) and place High/Low shaft assembly (15) next to First/
Third shaft assembly (14) and in Tooling (F) . The weight of High/Low shaft assembly (15) is approximately
89 kg (195 lb). The use of Tooling (F) will hold First/Third shaft assembly (14) and High/Low shaft
assembly (15) to the proper height of the gear mesh. This will allow Tooling (D) to be installed properly.
Slide the two shafts together until the gear mesh is obtained.
Illustration 63 g00849491
124. Use Tooling (C) and Tooling (E) to install Tooling (D) on First/Third shaft assembly (14) and High/Low
shaft assembly (15) . First/Third shaft assembly (14) and High/Low shaft assembly (15) must be installed in
the transmission cover assembly (11) together.
125. Attach a suitable lifting device to Tooling (D) . Carefully install First/Third shaft assembly (14) and High/
Low shaft assembly (15) to the original locations in the transmission case assembly. The weight of the two
shaft assemblies is 177 kg (390 lb).
Illustration 64 g00623113
126. Position tube assembly (13) and the O-ring (not shown) to the original locations in the transmission case
assembly. Install three bolts (12) to secure tube assembly (13) to the transmission case assembly. Tighten
bolts (12) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
127. Clean the flanges of both halves of the transmission cover assembly (11) and the transmission case assembly
(3) . Apply a 3.0 mm (0.12 inch) bead of Tooling (T) to the joint between transmission case assembly (3) and
transmission cover assembly (11) .
Illustration 65 g00623110
128. Attach Tooling (A) and a suitable lifting device to the transmission cover assembly (11) . Carefully install
the transmission cover assembly (11) to the transmission case assembly (3) . Be careful not to bind on the
locating pins during the installation.
Illustration 66 g00623108
Illustration 67 g00623105
Illustration 68 g00636998
132. Install Tooling (A) (not shown) in seal carrier (5) . Carefully install seal carrier (5) in the original
transmission case assembly bore (7) . Ensure that spring pin (10) is installed in the proper location in the
shaft assembly.
133. Install two bolts (6) to secure seal carrier (5) to the shaft assembly. Tighten bolts (6) to a torque of 55 ± 10
N·m (41 ± 7 lb ft).
134. Repeat Steps 132 and 133 in order to install the remaining three seal carriers to the original locations in the
transmission case assembly (11) .
Illustration 69 g00623100
135. Install 41 bolts (4) in transmission case assembly (3) . Tighten bolts (4) to a torque of 55 ± 10 N·m (41 ± 7 lb
ft).
136. Install four covers and the O-ring seals to the transmission case assembly (3) .
137. Install 12 bolts (2) in the four covers. Tighten bolts (2) to a torque of 28 ± 7 N·m (20 ± 5 lb ft).
End By:
a. Install the transmission magnetic screen base. Refer to Disassembly and Assembly, "Magnetic Screen -
Remove and Install".
b. Install the transmission oil pump. Refer to Disassembly and Assembly, "Gear Pump (Transmission Charging
and Scavenge) - Install".
c. Install the transmission speed sensor.
d. Install the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Install".
e. Install the transmission control valve. Refer to Disassembly and Assembly, "Transmission Control Valve -
Install".
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