Professional Documents
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0349 859 0 Sys RHB en 144
0349 859 0 Sys RHB en 144
REPAIR
AXLES AND STEERING
ENGINE
TRANSMISSION
BOOM
CHASSIS
TECHNICAL DATA
CL
CLAA AS TTARGO
ARGO C Series
08/2003 349859.0
The machines in this handbook are designed essentially for agricultural and associated applications. This is
their intended use.
Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in
any way contrary to the intended use or if the machine is not properly driven or maintained then the Company
will not accept any liability whatsoever for any damage or injury (whether direct or consequential).
The method of operation and maintenance specified in this handbook should be strictly adhered to.
For your parts requirements, it is essential that only genuine CLAAS parts are fitted. Any resultant damage
from non-genuine parts will invalidate your machine warranty.
CLAAS operates a policy of continuous improvement to its products and reserve the right to change specifica-
tions and equipment without notice. Therefore some information within this handbook may differ from your
machine.
SECTION 1
AXLES AND STEERING
AXLES 1.1
Description 1.1
Front Axle 1.1
Removal 1.1
Installation 1.2
Rear Axle 1.3
Removal 1.3
Installation 1.4
Dismantling and Assembly 1.5
Dismantling 1.6
Transmission box 1.6
Trunnions (rear axle only) 1.8
Steering cylinder (front and rear axle) 1.9
Epicyclic reduction gear (front and rear axle) 1.10
Wheel hub (front and rear axle) 1.11
Axle beam trumpet (front and rear axle) 1.13
Axle beam removal 1.14
Brake group (front axle only) 1.14
Differential support group (rear axle) 1.17
Differential group (front and rear axle) 1.18
Assembly 1.20
Pinion group (front axle) 1.20
Pinion group (rear axle) 1.24
Differential group (front and rear axle) 1.26
Brake and differential housing (front axle only) 1.27
Differential carrier group assembly 1.32
Brake control group assembly (front axle) 1.36
Generic information 1.37
Brake and axle beam assembly (front axle) 1.38
Wheel hub (front and rear axles) 1.41
Epicyclic reduction gear (front and rear axles) 1.43
Steering cylinder (front and rear axles) 1.44
Toe-in adjustment 1.45
Steering angle adjustment 1.46
Transmission box assembly 1.47
Trunnion assemblies 1.49
Testing after installation 1.50
Trouble shooting 1.51
Operating problems 1.51
Axle problems 1.52
Axle noise problems and diagnosis 1.53
Special tools 1.54
Steering 1.63
Description 1.63
Operation 1.63
Checking the steering system 1.66
Steering cylinder 1.66
Steering unit (OSPF) 1.66
Servicing 1.66
Steering valve assembly 1.67
Removal 1.67
Installation 1.67
Dismantling 1.68
Assembly 1.68
CONTENTS
SECTION 1 (continued)
AXLES AND STEERING
AXLES (continued)
Brake system bleeding 1.69
Dumping (disipation) of hydraulic pressure 1.70
Hydraulic level 1.71
SECTION 2
ENGINE
Description 2.1
Engine Data 2.1
Removal and Installation 2.2
General 2.2
Removal 2.2
Installation 2.4
Testing 2.4
SECTION 3
TRANSMISSION
Description 3.1
Hydrostatic system (up to Machines S/No.50600162 only) 3.1
Hydrostatic system (from Machines S/No.50600163 only) 3.2
Operation 3.5
Hydrostatic pump 3.5
Pressure relief valve 3.7
Proportional pressure reducing valve 3.7
Multi function valves 3.7
Pressure relief valve 3.7
Over pressure valve 3.8
Bypass valve function 3.9
Setting the bypass function 3.9
Hydrostatic motor 3.10
Removal and installation 3.12
Hydrostatic pump 3.12
Removal 3.12
Installation 3.13
Hydrostatic motor 3.14
Removal 3.14
Installation 3.15
Drive shaft 3.16
Removal 3.16
Installation 3.16
Testing 3.18
Trouble shooting guide 3.22
SECTION 4
BOOM
Description and operation 4.1
Description 4.1
Operation 4.2
Maintenance 4.3
Boom 4.3
Removal 4.3
Installation 4.4
Hydraulic cylinder 4.6
Crowd cylinder 4.6
Compensator cylinder 4.6
Lift cylinder 4.6
Extension cylinder 4.6
Boom tray cassette 4.7
Removal 4.7
Installation 4.9
CONTENTS
SECTION 4
BOOM
Maintenance (continued)
Boom tray hoses 4.9
Dismantling 4.9
Assembly 4.9
Inner boom 4.10
Removal 4.10
Installation 4.11
Boom wear pads 4.12
General 4.12
Replacement of outer boom wear pads (front) 4.12
Replacement of outer boom wear pads (rear) 4.14
Quattro control handle 4.15
Removal 4.15
Installation 4.15
SECTION 5
CHASSIS
Description 5.1
Operators cab 5.2
Removal 5.2
Installation 5.3
Fuel tank 5.5
Removal 5.5
Installation 5.5
Heater and Air Conditioning 5.7
Description 5.7
Blower motor 5.7
Removal 5.7
Installation 5.8
Heater coil 5.9
Removal 5.9
Installation 5.9
Air conditioning evaporator coil 5.10
Removal 5.10
Installation 5.11
Receiver - Drier assembly 5.12
Removal 5.12
Installation 5.13
Air conditioning condensor coil 5.13
Removal 5.13
Installation 5.13
Axial fan 5.15
Removal 5.15
Installation 5.15
Compressor 5.17
Removal 5.17
Installation 5.17
CONTENTS
SECTION 6
TECHNICAL DATA
Dimensions 6.1
Weight 6.1
Machine speed 6.2
Carriage 6.2
Cycle time 6.2
Engine 6.3
Cooling 6.3
Transmission 6.3
Tyres 6.3
Hydraulics 6.4
Electrics 6.4
Capacities 6.4
Brakes 6.4
INTRODUCTION
General
The contents of this Repair Manual, although correct at the time of publication, may be subject to alteration by
the manufacturer without notice.
This manual assumes that maintenance personnel have a sound knowledge of workshop practices and
safety procedures associated with the repairs of this type of machine. This manual is designed to assist with
the more specialised information required for removal and strip-down of major components.
It is recommended that the relevant part of this Repair Manual is studied carefully before proceeding with any
maintenance.
Machine identification
To make sure that the correct parts are obtained, always quote the machine Serial Number when ordering
parts.
To prevent injury to personnel and damage to equipment and machinery, care must be taken to operate in a
safe manner. Read the Safety Warnings that follow and always work in a safe manner and obey the relevant
Warnings.
Throughout this manual and on the machine there are safety notes. Each note starts with a single word. The
meaning of these single words is as follows:
Identifies a hazard exists. If proper precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously injured.
Identifies a reminder of safety practices. Failure to observe these safety practices could result
in injury to the operator (or others) or damage to the machine.
In general these notes are used to indicate that the procedures being described in the manual must be
followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine
from unsafe maintenance practices.
SAFETY WARNINGS
Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely
dangerous when operating or maintaining a machine.
Where possible, only work on or close to engines or machinery when they are stopped. If this
is not practical, remember to keep tools, test equipment and all parts of your body well away
from moving parts.
Avoid contact with exhaust pipes and exhaust manifolds when the engine is running; these
can be very hot.
Many liquids used on this machine are harmful if taken internally or splashed into the eyes. In
the event of accidentally swallowing oil, diesel fuel, anti-freeze, battery acid etc., DO NOT
induce vomiting, but OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Never run an engine in an enclosed space unless an exhaust extraction system is used.
Always disconnect battery cables before working on the electrical system to prevent injury
caused by electric shock.
When it is necessary to work on the electrical system with power on, for fault diagnosis,
always have a safety man in attendance
Any dust found on the machine or produced during work on the machine should be removed
by extraction, not by blowing. Dust waste should be dampened, placed in a sealed container
and marked for safe disposal.
Always dump pressure from the hydraulic system before carrying out any maintenance or
adjustment (refer to Hydraulic Repair Manual).
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to
check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid
penetrates your skin OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Never allow unqualified personnel to attempt to remove or replace any part of the machine.
Always use the correct lifting equipment to remove large or heavy components.
Never attempt to lift or hold up the machine using the lash-down points.
SECTION 1
AXLES
DESCRIPTION
The front axle has a transmission/reduction box
fitted, with both front and rear axles having epicyclic
reduction gears contained in the wheel hubs. The
front axle is fitted with a limited slip differential whilst
the rear axle has a standard type differential. The
front axle housing incorporates the brakes.
FRONT AXLE
Removal
Installation
REAR AXLE
Removal
Installation
NOTES:
DISMANTLING
TRANSMISSION BOX
(Front Axle only)
1. Remove the drain plug (1) and drain oil into a suitable
container.
The half box is heavy and must be
supported with suitable equipment
during removal.
NOTE: This will damage the oil seal, use a new oil
seal on assembly.
TRUNNIONS
(Rear Axle only)
1. Circlip
2. Input flange
3. O-ring
4. Washer
5. Front trunnion
6. Rear trunnion
7. Bolt
8. Bush
9. Centering bush
10. Grease nipple
11. Bush
12. O-ring
AXLES & STEERING 1.9
STEERING CYLINDER
(Front and rear axle)
5. Cylinder overhaul
1. Track rod
2. Nut
3. Bolt
4. Hydraulic adapter
5. Steering cylinder
1.10 AXLES & STEERING
1. Drain plug
2. Planetary carrier
3. Retaining screws
4. Wheel hub
5. Lock ring
6. Triangular washer
7. Pin
8. Planetary gear
9. Needle roller bearings
10. O-ring
AXLES & STEERING 1.11
WHEEL HUB
(Front and Rear Axle)
11. Circlip
12. Washer
13. Washer
14 U/J shaft
15. Bolt
16. Threaded hole
17. Hub lock ring gear
18. Epicyclic gear
19. Hub
20. Sealing ring
21. Outer cone bearing
22. Bearing cups
23. Inner cone bearing
24. Swivel housing
1.12 AXLES & STEERING
10. Examine hub lock ring gear (17) and epicyclic ring
gear (18) for wear. If necessary, remove centering
bushes (26) of hub lock ring gear with a hammer and
special tool Part No CA715027.
The swivel housing is heavy and
must be supported with suitable
equipment before the king-pins are
removed.
25 Lock ring
26 Bush
27 Bolt
28 King pin
29 Axle beam
30 Belleville washer
31 Sealing ring
32 Bush
33 Shim
AXLES & STEERING 1.13
1. Drive shaft
2. Axle beam
3. Sealing ring
4. Bush
5. Belleville washer
6. Shim
7. Bush
8. Bush
9. Bush
10. King pin
1.14 AXLES & STEERING
BRAKE GROUP
(Front Axle only)
11. Differential
12. Brake pack
13. Screw
14. O-ring
15. Brake disc
16. Fixed disc
17. Sleeve
AXLES & STEERING 1.15
1. Screw
2. Carrier
3. Seal
4. Screw
5. Retainer
6. Ring nuts
7. Screw
8. Half-collar
9. Differential unit
10. Bearing cup
1.18 AXLES & STEERING
NOTE: The rear axle only has one thrust ring and no
discs either side of the sun gears.
ASSEMBLY
PINION GROUP
(Front Axle)
1. Differential housing
2. Outer bearing track
3. Inner bearing track
4. Special tool Part No. CA715040
5. Ring nut
6. Brake housing
7. False differential Part No. CA715041
AXLES & STEERING 1.21
(A + C) – B = X
Example: A = 164.9 mm
Therefore: X = [(164.9 + 45) – 100] = 109.9 mm
S=X-V
8. Pinion
1.22 AXLES & STEERING
14. Fit a new ring nut washer (16) and ring nut
retainer (17).
15. Fit a new ring nut (17). Hold ring nut retainer with
special tool Part No. CA715022, tighten ring nut with
special tool Part No. CA119099.
The pinion drive seal ring must not
be fitted when the pre-loading is
checked.
18. Dynamometer
PINION GROUP
(Rear Axle)
14. Insert a new ring nut washer (17) and locking 11. Shim
ring nut retainer (5). 12. Pinion
13. Bearing
15. Hold ring nut retainer with special tool Part No. 14. Shim
CA715022, tighten ring nut with special tool Part No. 15. Collapsible spacer
CA119099. 16. Bearing
17. Washer
The pinion drive seal ring must not be 18. Dynamometer
fitted when the pre-loading is checked. 19. Tool Part No. CA715116
DIFFERENTIAL GROUP
(Front and Rear Axle)
NOTE: The rear axle has only one thrust ring and no
discs either side of the sun gears.
12. Fit ring nuts (14) to both sides of the housing and
evenly tighten using tool Part No. CA119030 until
backlash is eliminated.
AXLES & STEERING 1.29
0.18 – 0.25 mm
22. Fit ring nut retainer (16) to secure ring nut (14) to
housing and secure with bolt (17), turn ring nut
slightly to align bolt hole, if necessary. Torque load
bolt to 13 Nm (9.6 lbf ft.).
3. Fit and tighten two ring nuts (6) with special tool
Part No. CA119030, to pre-load the differential
bearings slightly. Tap the bearings with a rubber 1. Differential assembly
hammer to ensure correct seating. 2. Bearing cup
3. Carrier
4. Half collar
5. Bolt
6. Ring nut
AXLES & STEERING 1.33
0.18 – 0.25 mm
14. Fit ring nut retainers (10) to secure ring nuts (6)
to housing and secure with bolts (11), if necessary
turn ring nuts slightly to align with retainers. Torque
load bolts (11) to 13 Nm (9.6 lbf ft.).
10. Retainer
11. Bolt
12. Seal
13. Axle beam
14. Bolt
1.36 AXLES & STEERING
GENERIC INFORMATION
To test the marks on the bevel gear teeth, paint the
ring gear with red lead paint.
OK = Correct contact
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Correction movements
1 - move the pinion for type X contact adjustments.
2 – move the pinion for type Z contact adjustments.
1.38 AXLES & STEERING
WHEEL HUB
(Front and Rear Axles)
12. Fit wheel hub (10) to swivel housing (2) and fit
outer taper roller bearing (15) to hub.
4. Fit planetary gears (3) to pins (4), then fit 1. Planetary carrier
triangular washer (5) and secure with circlips (6). 2. Needle roller bearings
3. Planetary gear
4. Pin
5. Fit new O-ring (7) to planetary carrier (1).
5. Triangular Washer
6. Circlip
6. Fit planetary carrier to wheel hub and secure with 7. O-ring
retaining screws (8). Torque load retaining screws to 8. Screw
25 Nm (18 lbf ft.). 9. Drain plug
STEERING CYLINDER
(Front and Rear Axle)
TOE-IN ADJUSTMENT
FRONT A 60 mm 60 mm
FRONT B 60 mm 60 mm
FRONT C 57 mm 57 mm
FRONT D 55 mm 57 mm
REAR A 74 mm 60 mm
REAR B 74 mm 65 mm
REAR C 65 mm 65 mm
REAR D 65 mm 60 mm
1A tyres - 10.5-20 Cross Ply
1B tyres - 10.5-20 Cross Ply
AXLES & STEERING 1.47
3. Fit bearing (6) and lower flanged shaft (7). Fit gear
wheel (8) and seat gear wheel and bearing using
special tool Part No. CA715145 and a hammer.
1. Axle
2. Half box
4. Fit bearing (9) with Special tool Part No. 3. Bolt
CA715145. Fit circlip (10) to lock assembly.
TRUNNIONS ASSEMBLY
(Rear Axle)
4. Fit seal ring (9) to housing with special tool Part 1. Trunnion
No. CA715043 and a hammer. 2. Trunnion
3. Bush
5. Fit shim (10), O-ring (11) and pinion shaft flange 4. Bush
(12) and secure with circlip (13). 5. Bolt
6. Volt
7. O-ring
6. Lubricate trunnions after assembly to axle
8. Bush
housing.
9. Seal ring
10. Shim
11. O-ring
12. Flange
13. Circlip
1.50 AXLES & STEERING
TROUBLESHOOTING
Operating problems
The following information is given as a guide to Operating problems and possible causes.
Possible Causes
Problems
1 2 3 4 5 6 7 8 9 10 11
Friction noise * * * * * * *
Key to Operating problems table Machines with wide steering angles may proceed
with kicks, have steering difficulty or cause tyre
1. Incorrect installation/defective axle wearing on sharp turns. Reduce the steering angle
Correct installation or repair or replace the differential to minimum and decelerate the machine when the
in case it does not survive any one of the test steering begins to kick.
phases.
7. Incorrect wheel adjustment
2. Overloading/incorrect weight distribution Check group integrity and wheel side bearings.
Remove excessive weight and redistribute load, Adjust accordingly.
following instructions related to the machine.
8. Spoiled or worn out axle parts
3. Different rotation radius of the tyres Check the condition of the ring gear, pinion gear,
If one tyre has a smaller radius, it will cause partial bearings etc. Replace components as necessary.
wheel slipping when force is applied. The other tyre
with larger radius will have to support all the work. 9. Contamination in the axle box or incorrect
Replace the tyre or adjust pressure to have same assembly of parts
radius on both tyres. Look for foreign particles. Check the assembly of the
axle components.
4. Broken halfshaft
It is not advisable to operate the machine with a 10. Incorrect adjustment of bevel gear set: Parts
broken halfshaft. It is acceptable to move the of the transmission worn out
machine (engine off loaded) a few metres only. Replace or adjust as required (transmission gears, U
joints etc.).
5. Bent halfshaft
Replace halfshaft. 11. Incorrect use of the product
Refer to the machine manufactures instructions.
6. Blocked differential
Abnormal functioning of the differential or breakage/
blockage of command device. Verify assembly and
all components.
1.52 AXLES & STEERING
Axle problems
The following table gives a description of common axle problems, the cause and repair action to correct the
problem.
Problem C au se Action
Ring gear tooth broken at the outer side 1. Excessive gear load compared to the Replace bevel gear set. Follow carefully the
one forseen. recommended operations for the adjustment
2. Incorrect gear adjustment (excessive of bevel gear and backlash.
backlash).
3. Pinion nut loose.
Ring gear tooth broken side 1. Load bump. Replace bevel gear set. Follow carefully the
2. Incorrect gear adjustment (insufficient recommended operations for the adjustment
backlash). of bevel gear and backlash.
3. Pinion nut loose. Use correct lubricants, fill to the correct level
and replace at correct intervals.
Overheated ring and pinion teeth. See if 1. Prolonged functioning at high Replace bevel gear set. Use correct
gear teeth have faded. temperatures. lubricants, fill to the correct level and replace
2. Incorrect lubrication. at correct intervals.
3. Low oil level.
4. Contaminated oil.
Pinion teeth pitting 1. Excessive use. Replace bevel gear set. Use correct
2. Insufficient lubrication. lubricants, fill to the correct level and replace
at correct intervals.
Axle beam body bent 1. Machine overloaded. Replace axle beam body.
2. Machine accident.
3. Load bump.
Worn out or pitted bearings 1. Insufficient lubrication. Replace bearings. Use correct lubricants, fill
2. Contaminated oil. to the correct level and replace at correct
3. Excessive use. intervals.
4. Normal wear.
5. Pinion nut loose.
Oil leakage from gaskets and seals 1. Prolonged functioning at high oil Replace the gasket or seal and mating
temperatures. surface, if damaged.
2. Oil gasket assembled incorectly. Use correct lubricants, fill to the correct level
3. Seal lip damaged. and replace at correct intervals.
4. Contaminated oil.
Excessive wearing out of input flange spline 1. Exhaustive use. Replace the flange. Check that the pinion
2. Pinion nut loose. spline is not excessively worn. Replace
3. Pinion axle backlash. bevel gear set if necessary.
Fatigue failure of pinion teeth. See if 1. Exhaustive use. Replace bevel gear set.
fracture line is well defined (wave lines, 2. Continuous overload.
beach lines)
Pinion and ring gear breakage 1. Crash load of differential components. Check and replace other differential
components.
Side gear spline worn out. Replace all 1. Excessive use. Replace differential gear group. Replace
scratched washers (excessive backlash) halfshaft if necessary.
Thrust washer surface worn out or 1. Insufficient lubrication. Use correct lubricants, fill to the correct level
scratched 2. Incorrect lubrication. and replace at correct intervals.
3. Contaminated oil. Replace all scratched washers and those
with 0.1 mm thickness less than the new
washers.
Inner diameter of tapered roller bearing 1. Excessive use. Replace bearing. Check pinion axial
worn out 2. Excessive pinion axial backlash. backlash.
3. Insufficient lubrication. Use correct lubricants, fill to the correct level
4. Contaminated oil. and replace at correct intervals.
Halfshaft broken at wheel side 1. Wheel support loose. Replace. Check that wheel support is not
2. Beam body bent. worn out or incorrectly adjusted.
AXLES & STEERING 1.53
The following table gives a description of axle noises problems, the cause and repair action to correct the
problem.
Problem C au se Action
Noise while driving 1. Excessive backlash between pinion and ring gear. 1. Adjust.
2. Worn out pinion and gear ring. 2. Replace.
3. Worn out pinion bearings. 3. Replace.
4. Pinion bearings loose . 4. Adjust.
5. Excessive axial pinion backlash. 5. Adjust.
6. Worn out differential bearings. 6. Replace.
7. Differential bearings loose. 7. Adjust.
8. Ring gear not conecentric. 8. Replace.
9. Low lubricant level. 9. Replenish.
10.Bent halfshaft. 10. Replace.
Noise while driving in 1. Noises coming from axle are usually heard when 1. Replace or adjust (see above).
neutral machine moves in neutral gear but are not loud.
2. Incorrect backlash between pinion and ring (sound 2. Replace.
heard while decelerating, disappears while
accelerating).
3. Pinion or input flange worn out. 3. Replace.
Constant noise 1. Ring gear teeth or pinion damaged. 1. Replace bevel gear set.
2. Worn out bearings. 2. Replace.
3. Pinion spline worn out. 3. Replace.
4. Bent halfshaft. 4. Replace.
Special Tools
It is recommended that the correct special tools are
used when dismantling and assembling the axle.
The interchangeable handle should always be used
when removing and fitting bearings and bushes,
together with a suitable safety handle.
Interchangeable handle
CA119033
False pinion
CA715023
Bush driver
CA715027
Dummy pinion
CA715040
1.58 AXLES & STEERING
Bush driver
CA715104
Bearing driver
CA715145
Bush driver
CA715157
Bearing driver
CA715403
STEERING
Description
Operation
LS LS – line
AXLES & STEERING 1.65
Servicing
Removal
Installation
Assembly
General
1. Front left
2. Trailer brake valve (if fitted)
Check
ENGINE
ENGINE 2.1
DESCRIPTION
Engine Data
Removal
22. Unclip the wiring loom from the engine and tie
clear of engine.
Installation
10. Stop the engine and check the fluid levels of the
cooling system, hydraulic system, transmission and
engine lubricating oil. Replenish as necessary.
Testing
TRANSMISSION
TRANSMISSION 3.1
DESCRIPTION
1 Hydraulic tank
6 One way valve (bypass) Located in the leakage oil circuit (3 bar)
58 Multi-function valve
61 Over pressure, pressure relief valve 530 bar ± 10 bar (shock function)
62 Multi-function valve
64 One way valve (relief valve) Separation of charge pressure and position pressure
OPERATION
The servo valve (6) controls the servo ram (7) to deflect
the swashplate (5) to control direction of travel and
speed. During this procedure the piston rods (2) rotate
around the drive shaft (3). Oil is forced out of the filled
cylinder space at pressure by the angled swashplate
(5) depressing the piston rods (2).
The servo valve (6) controls the servo ram (7) to act on
the swashplate (5) which is then moved to exchange
the high and low pressure sides
1. Cylindrical rotor
2. Piston rod
3. Drive shaft
4. Slide
5. Swashplate
6. Servo valve
7. Servo ram
8. Base
9. Return spring
10. Eccentric screws
TRANSMISSION 3.7
5. Purge valve
6. Charge pressure
1. Piston
2. Cylinder block
3. Output shaft
4. Servo piston
5. Valve segment
6. Constant pressure regulator
7. Solenoid valve
8. Shaft
9. Bearing
3.12 TRANSMISSION
Removal
6. Make sure the pump and hoses are free from dirt
to avoid contamination of the hydraulic system.
13. Remove cap screw (16) and circlip (17) from gear
hub (18). Slide gear hub from pump shaft.
TRANSMISSION 3.13
Installation
Fit new O-rings (6) between pump (8) and hoses (5).
Removal
8. Make sure the pump and hoses are free from dirt
to avoid contamination of the hydraulic system.
Drive shaft
Removal
NOTE: Mark the drive shaft flanges (front and rear) for
installation purposes.
Installation
1. Drive shaft
2. Bolt
3. Washer
3.18 TRANSMISSION
TESTING
Troubleshooting guide
Refer to the following troubleshooting guide for the
diagnosis of typical transmission problems.
Problem C au se Action
Neutral difficult or impossible to find 1. Input to pump control is operating Check control input and repair or replace as
incorrectly. necessary.
2. Pump displacement control linkages Adjust, repair or replace control module as
are not secure, control orifices blocked necessary.
etc.
System operating hot 1. Insufficient hydraulic fluid will not meet Fill reservoir to correct level.
cooling demands of system.
2. Heat exchanger not cooling system Check airflow and input air temperature for
sufficiently. heat exchanger. Clean, repair or replace
heat exchanger.
3. Low charge pressure overworking Measure charge pressure. Inspect and
system. adjust or replace charge relief valve. Repair
leaking charge pump.
4. Charge pump inlet vacuum Inspect inlet filter and replace as necessary.
overworking system. Dirty filter or Check for correct line diameter, length or
inadequate line size will restrict flow. other restrictions.
5. System relief valve settings are too Verify settings of pressure limiters and high
low. Relief valves are overworked. pressure relief valves and adjust or replace
multi-function valves as necessary.
6. Internal leakage in motor reducing low Monitor motor case flow without loop
side system pressure and overworking flushing in the circuit (use defeat spool) . If
system. flow is excessive, replace motor.
7. High system pressure overheating Measure system pressure. If pressure is
system. high reduce loads.
Transmission operates normally in one 1. Input to control module is operating Check control input and repair or replace as
direction only. incorrectly. necessary.
2. Pump control linkages are not secure, Repair or replace control module as
control orifices are blocked etc. necessary.
3. Incorrect operation of interchange Interchange the multi-function valves to show
system pressure limiters, high pressure if the problem is related to the functions
relief valves and system check valves in contained in the multi-functionf valves. If the
multi-function valves. problem changes direction, repair or
replace the valve on the side that does not
operate.
4. Charge pressure decaying in one Measure charge pressure in forward and
direction caused by the loop flushing reverse. If pressure decays in one direction,
valve sticking in one direction. inspect and repair the motor loop flushing
valve.
System will not operate in either direction. 1. Insufficient hydraulic fluid to supply Fill reservoir to correct level.
system loop.
2. Input to control is operating incorrectly. Check control input and repair or replace as
necessary.
3. Pump displacement control linkages Repair or replace control module as
not secure, control orifices blocked. necessary.
4. Bypass valves are open, system loop Close bypass valves. Replace multi-function
depressurised. valves if defective.
5. Low charge with pump in neutral, Measure charge pressure with pump in
pressure insufficient to charge system neutral. If pressure is low, go to step 6;
loop. otherwise continue with step 5.
6. Low charge pressure with pump in Measure charge pressure with pump in
stroke indicates a motor charge relief stroke. If pressure is low. adjust or replace
valve or system pressure relief valve may motor charge relief valve, otherwise go to
be improperly set. step 9.
7. Pump charge relief valve is leaking or Adjust or replace the pump charge relief
set too low depressurising the system. valve as necessary.
8. Clogged filter reducing supply to Inspect filter and replace if necessary.
system loop.
9. Charge pump malfunction providing Repair or replace the charge pump. If OK
insufficient charge flow. go to last step.
10. Pump displacement control linkages Repair or replace control module as
are not secure, control orifices blocked, necessary.
etc.
11.Low system pressure not providing Measure system pressure. Continue with
power necessary to move load. next step.
12. Defective multi-function valves Repair or replace multi-function valves.
causing system pressure to be low.
TRANSMISSION 3.23
Problem C au se Action
Low motor output torque 1. Pressure limiter causing low pressure Measure system pressure at motor. If
at the motor reducing torque. pressure limiter setting is low, increase
setting.
2. Variable motor stuck at minimum Check control supply pressure or repair
displacement, yielding low output torque. displacement control. Check motor control
orifices.
3. Internal leakage reducing system Check for leakage in O-rings, gaskets and
pressure. other fittings. Repair unit as required, or
replace leaking unit.
Improper motor output speed 1. Insufficient hydraulic fluid reducing Fill reservoir to correct level.
motor speed.
2. Incorrect pump outflow affecting output Measure pump output and check for correct
speed. Incorrect output flow indicates the pump speed. Check that the pump is in full
swashplate is out of position. stroke.
3. Variable motor displacement control See if variable motor displacement control
not functioning correctly. Variable motor is responding. If not, replace control.
swashplate may be in wrong position.
4. Internal leakage reducing system Check for leakage in O-rings, gaskets and
pressure. other fittings. Repair or replace unit as
required.
Excessive noise and/or vibration 1. Insufficient hydraulic fluid leading to Fill reservoir to correct level.
cavitation.
2. Air in sytem leading to cavitation. Look for foam in reservoir. Check for leaks
on inlet side of system loop. Afterwards let
reservoir settle until bubbles are gone. Run
system at low speed to move system fluid
reservoir. Repeat operation until clear of air.
3. High pump inlet vacuum creating Inspect and relace filter as necessary.
excessive noise. Check suction line for correct size or
restrictions.
4. Loose shaft coupling causing Replace loose shaft coupling in charge
excessive noise. pump or replace pump or motor.
5. Misaligned shaft causing frictional Align shafts.
noise.
System response is sluggish 1. Insufficient hydraulic fluid reducing Fill reservoir to correct level.
system output pressure.
2. Multi-function valves pressure setting Adjust or replace multi-function valves.
incorrect, affecting system reaction time.
3. High pump inlet vacuum reducing Measure charge inlet vacuum. If high
system pressure. replace inlet filter.
4. Low engine speed reducing system Adjust engine speed.
performance.
5. Incorrect charge or control pressures Measure charge and control pressures and
affecting system performance. correct if necessary.
6. Internal leakage reducing system Check for leakage in O-rings, gaskets and
pressure. other fitings.
SECTION 4
BOOM
BOOM 4.1
OPERATION
MAINTENANCE
BOOM
Removal
10. Take the weight of the boom with the lifting 1. Hoses
equipment. 2. Boom connector bracket
3. Auxiliary hydraulic hoses
NOTE: Identify all hydraulic hoses to make sure they 4. Plate
are reconnected correctly and blank all open
hydraulic hoses and connections.
13. Remove the bolt (6), and washer (7) securing the
upper attachment pin (8).
14. Drive out the upper attachment pin (8) and lower
the cylinder onto a suitable support placed between
the chassis and side members.
4.4 BOOM
17. Drive out the upper attachment pin (12) and lower
the cylinder onto the lift cylinder or a suitable
support.
19. Drive out the boom pivot pins (16 & 17), using a
slide hammer and suitable punch, maintaining
alignment of the boom and chassis trunnions.
5. Lift cylinder
Make sure that the boom does 6. Bolt
not swing as it is lifted from the 7. Washer
machine. 8. Attachment pin
9. Compensator cylinder
20. Operate the overhead lifting equipment and 10. Bolt
remove boom from machine. 11. Washer
12. Attachment pin
Installation
13. Bolt
14. Washer
15. Keep plate
16. Pivot pin
17. Pivot pin
18. Boom
19. Chassis
20. Shim
4.6 BOOM
HYDRAULIC CYLINDER
Crowd cylinder
Compensator cylinder
Lift cylinder
Extension cylinder
1. Cover 7. Hose
2. Grille 8. Expansion tube
3. Catch 9. Hose
4. Surround 10. Screw
5. Oil cooler 11. Plate
6. Radiator
4.8 BOOM
Installation
Dismantling
Assembly
INNER BOOM
Removal
11. Lift the inner boom out of the outer boom using
either a forklift or overhead lifting equipment.
1. Pipe 5. Pipe
2. Bracket 6. Circlip
3. Bolt and washer 7. Attachment pin
4. Extension cylinder
BOOM 4.11
Installation
11. Remove bolt (1), washer (2), and retainer (3) and
withdraw the wear pad and shims (4 & 5) at positions
A and D from the left and right side of the outer boom
(6).
12. Clean and inspect the wear pads for wear and
damage. Fit wear pad D to the side of the boom with
a 2.5 mm (0.10 in.) shim the pad.
BOOM 4.13
Removal
10. Disconnect cable locator (11) from base (12). 1. Quattro control handle
2. Screw
11. Loosen locknut (13) and unscrew the handle (1) 3. Cover
from the base (12), retaining the washer (14) in the 4. Screw
process. 5. Washer
6. Nut
Installation 7. Gaiter
8. Retainer
Before reconnecting cables ensure
the control handle is locked in the
neutral position.
9. Loom
10. Connector
11. Locator
12. Base
13. Locknut
14. Washer
15. Lever
SECTION 5
CHASSIS
CHASSIS 5.1
CHASSIS
Description
Operators Cab
Removal
17. Remove the two fuel hoses from the back of the
tank and fit suitable blanks to the hoses and
connectors.
19. Remove the front and rear bolts attaching the cab
to the pod.
20. Lift the cab from the machine using suitable lifting
equipment and position on a stand.
Installation
Fuel Tank
Removal
6. Remove bolts (7) washers (6) and nuts (5) from the
rear bulkhead. Remove bolts (10) and washers (9)
from the front bulkhead.
Installation
Blower Motor
Removal
Installation
1. Self-tapping screw
2. Housing lid
3. Self-tapping screw
4. Blower motor
5. Electrical connectors
CHASSIS 5.9
Heater Coil
Removal
4. Clamp the two hoses (1) and (3) to the heater coil
(4).
Installation
1. Hose
2. Hose clip
3. Hose
4. Heater coil
5. Housing
Installation
1. Expansion valve
2. Adapter
3. Adapter
4. Evaporator coil
5. Housing
5.12 CHASSIS
Receiver-Drier Assembly
Removal
Installation
7. Support the unit then remove the four bolts (3) and
washers (4) securing the condenser coil housing (5)
to the machine support (2) and remove the unit.
Pulling the cable through from the cab.
Installation
Installation
Compressor
Removal
Installation
1. Bolt 7. V-belt
2. Hose 8. Nut
3. Electrical lead 9. Compressor
4. Hose 10. Nut
5. Bolt 11. Mounting bracket
6. Washer
SECTION 6
TECHNICAL DATA
TECHNICAL DATA 6.1
C 40 C 50
Dimensions
C 40 C 50
Forward Low 8 8
Forward High 30 30
Carriage
Cycle time
C 40 C 50
Engine
Cooling
Thermostat - opens °C 70 - 80 70 - 80
Transmission
Tyres
C 40 C 50
Hydraulics
Electrics
Capacities
Brakes
Following the policy of Caterpillar to improve their products as technical developments continue, Caterpillar
reserve the right to make alterations which may not necessarily correspond to text and illustrations contained
in this publication, and without incurring obligation to alter any machines previously delivered.
Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of
Caterpillar.
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349859.0
08/2003