Twin Splitter Transmission: Service Manual
Twin Splitter Transmission: Service Manual
Twin Splitter Transmission: Service Manual
Service Manual
T20113
Issue 01 / 2001
Service Manual
5/01
Section 1
1/1
1/2
1/3
1/4
1/5
1/7
1/9
1/10
Section 2
2/1
2/2
2/3
2/4
2/5
2/6
2/7
2/8
2/9
2/10
2/11
2/12
2/14
2/16
2/17
Section 3
3/1
3/2
3/3
3/4
3/5
3/6
General
Letter and Model Designation
Technical Data
Lubrication
Recommended Lubricants
Torque Tightening Recommendations
Disassembly Precautions and Inspection of Expendable Parts
Reassembly Precautions
Special Tools
Air System
General Description - 12 Speed
Single H Pattern Gear Change
Splitter System - Signal Connections
Filter Pressure Regulator
Selector Valve Switch
Selector Valve - Removal and Refitment
Pulse Unit
Splitter Shift - Cylinder Operation
Splitter Cylinder Cover Assembly - Logic Valves
Splitter Cylinder Cover Assembly - Twin Spool Valves
Splitter Gear Air Line Connections
Splitter Air Circuit Diagrams - Logic Valves
Splitter Air Circuit Diagrams - Twin Spool Valves
Splitter Cylinder - Disassembly and Reassembly
Splitter Cylinder Cover - Trouble Shooting Hints
Shifting Controls
Remote Control - Exploded View
Disassembly of Remote Control (LRC)
Reassembly of Remote Control (LRC)
Shift Bar Housing - Exploded View
Shift Bar Housing Disassembly
Shift Bar Housing Reassembly
>>>>
5/01
Section 4
4/1
4/5
4/7
4/7
4/8
4/9
4/13
4/17
4/17
4/19
4/20
4/24
4/26
4/36
4/42
Section 5
5/1
5/2
Section 6
6/1
6/2
6/4
Section 7
7/1
7/2
Main Transmission
Auxiliary Section Removal and Disassembly
Output Shaft and Rear Sliding Gear Removal and Disassembly
Auxiliary Countershaft Bearing Renewal
Auxiliary Section Splitter Gears and Sensor Disassembly
Splitter Gears Reassembly
Output Shaft and Rear Sliding Gear Reassembly and Installation
Main Section Disassembly
Input Shaft Disassembly
Input Shaft Reassembly
Reverse Idler Gear Disassembly and Reassembly
Mainshaft Disassembly
Mainshaft End Float
Mainshaft Reassembly
Main Transmission Reassembly
Auxiliary Section Reassembly
Upshift Brake
Upshift Brake - Exploded View
Upshift Brake Disassembly
Upshift Brake Reassembly
PTO Installation
Fitting Extended Countershaft
Assembly of Extended Countershaft
<<<<
5/01
Section 1
General
5/01
General
Letter and Model Designation
Example: TS 12612A
TSO 12612A
T
- Twin Countershaft
- Splitter Transmission
- Overdrive
12
- Design level
12
1/1
5/01
General
Technical Data
Permissible Torque
TS(O) 11612A
1560 Nm
TS(O) 12612A
1730 Nm
TS(O) 13612A
1815 Nm
TS(O) 15612A
2080 Nm
Weight1)
325 kg
Length2)
745 mm
12,5 lit
0,51
Clutch Housing
1/2
5/01
General
Lubrication
Proper Oil Level
1. Oil Level
2. Yes
3. No
Draining Oil
Drain transmission while oil is warm. To drain oil
remove the drain plug at the bottom of case.
Refilling
Clean the drain plug before re;installing. Clean area
round filler plug. Fill transmission to the level of the
filler opening.
The exact amount of oil will depend on the
transmission inclination. In every instance, fill to the
level of the filler opening. Do not overfill; this will
cause oil to be forced out of the case past the
mainshaft and input shaft seals.
Adding Oil
It is recommended that different types and brands
of oil are not intermixed because of possible
incompatibility.
Operating Temperature
It is important that the transmission operating
temperature does not exceed 120C for an
extended period of time. Operating temperatures
above 120C will cause breakdown of oil and
shorten transmission life.
The following conditions in any combination can
cause operating temperatures of over 120C:
1. Operating consistently at road speeds under
32 km/h (20 m.p.h.)
Towing
When towing the vehicle, the propeller shaft
between the axle and transmission must be
disconnected.
1/3
5/01
General
Recommended Lubricants
Only use recommended lubricants to ensure smooth running.
Every 16,000 km
Every 80,000 km
Off Highway
First 30 hours
Every 40 hours
Type
Quality
Temperature
SAE 50
over -12C
MIL-L-2104C or MIL-L-46152
SAE 40
over -12C
or API-SC or API-CC
SAE 30
under -12C
SAE 90
over -12C
API-GL-1
SAE 80 W
under -12C
SAE 90
MIL-L-2105 or API-GL-4
SAE 80 W
SAE 85 W 140
over -12C
MIL-L-2105B or MIL-L-2105C
or API-GL-5
SAE 80 W 140
SAE 90
over -26C
from -12C to 38C
SAE 80 W 90
SAE 80 W
SAE 75 W
* These oils are NOT recommended when lubricant operating temperatures are above 110C.
Note: Synthetic oils are NOT recommended.
1/4
5/01
General
8. Shift Bar Housing. 16 Capscrews M10 Thread 53 to 66 Nm. Thread coated with Loctite.
9. Air Filter Bracker. 2 Capscrews M10 Thread - 53
to 66 Nm Spring Lockwashers.
10. Filter Pressure Regulator and Pulse Unit. 2
Capscrews M6 Thread - 11 to 16 Nm. With Spring
Lockwashers and Plain Nuts.
11. Output Shaft. Nut 2" - 16 Thread- 610 to 680
Nm. With Nyon Locking Insert or Staking Collar.
Ensure nut is securely staked into the shaft groove.
4. Clutch Housing. 6 Studs - M16 Thread minimum 81 Nm, driven until bottomed. Installed
with Loctite 270.
5. Input Shaft Front Bearing Cover. 6 Capscrews
M10 Thread - 53 to 66 Nm. Thread coated with
Loctite 270.
6. 5 Yoke Lockscrews. 7/16" - 20 Thread - 47 to
61 Nm secure with Lockwire.
1/5
5/01
General
6. Lower P.T.O. Cover. 8 Capscrews M12 Thread 96 to 109 Nm. Thread coated with Loctite,
Lockwashers.
1/6
5/01
General
Disassembly Precautions
A. Bearings
1. Wash all bearings in clean solvent. Check balls,
rollers and races for pits and spalled areas. Renew
damaged bearings.
2. Lubricate undamaged bearings and check for
axial and radial clearances. Renew bearings with
excessive clearances.
B. Gears
1/7
5/01
General
D. Splines
K. Bearing Covers
E. Thrust Washers
M. Sensor/Jaw Clutches
N. Sliding Clutches
1. Check all yokes and yoke slots in sliding
clutches for extreme wear or discolouration from
heat.
O. O-Rings
1. Renew all O-rings.
1/8
5/01
General
Reassembly Precautions
bearing, preventing damage to balls and races and
maintaining correct bearing alignment with shaft
and bore. A Tubular type driver, if used, will apply
force only to the inner race.
1/9
5/01
General
Special Tools
Some illustrations show the use of specialised tools. These tools are recommended for disassembly and
reassembly of the transmission. They make repair easier, faster and prevent damage.
The following tools are available from SPX UK (Ltd) Tel : +44 (0)1327 704461
1/10
5/01
General
1/11
5/01
Section 2
Air System
5/01
Air System
General Description
Twin Splitter 12 speed
A = Main section
B = Auxiliary section
The Twin Splitter Transmission has a 4 speed main section with an auxiliary section containing 3 splitter
ratios
Main section
Auxiliary section
I Low
II Intermediate
III High
4 forward speeds
1 reverse speed
Gear shift by means
of shift lever
2/1
5/01
Air System
Single 'H' pattern gate, four position plus reverse, three splitter gears available in each position.
Splitter
I Low
II Intermediate
III High
Three position flick-switch, Low (I), Intermediate (II) and High (III), for pre-selection of splitter gears
engaged through throttle operation or clutch control.
2/2
5/01
Air System
Transmission Connections
Overdrive
Filter/Regulator
Exhaust
Shift Cover 'R'
Shift Cover 'F'
Blank Off
Direct
Filter/Regulator
Exhaust
Shift Cover 'R'
Blank Off
Shift Cover 'F'
1. 3 Way Pilot Valve to be operated only when the clutch is fully depressed
2. Pulse Unit Supply (5.5 bar)
3. 'R' Port and 'F' Port (shift cover)
4. Air Supply (7-8 bar)
5. Regulated Air (5.5 bar)
2/3
5/01
Air System
6. Plug
2. Filter element
3. Seal ring
8. Outlet port *
4. 'O' ring
5. End cap
* Alternative positions
2/4
5/01
Air System
Selector Switch
Splitter Ratios
I. Low
II. Intermediate
III. High
Function
Constant air supply to '1' from filter/regulator.
Shift Position I
Overdrive
Direct
position.
2/5
5/01
Air System
Re-fitment
1. Renew seal ensuring that it is fitted correctly.
2. Smear sealing surface of base using lubricant
supplied in Service Kit.
Caution: Do not use any other type of lubricant.
3. Reassemble valve and tighten socket headed
screw to the correct torque.
4. Screw selector valve onto shift lever and secure
with lock nut.
1. Cowl
2. Socket head screw
3. Base
4. Seal
6. Refit cowl.
5. Housing
Torque:
6. Pressure pad
7. Anti-rattle spring
8. Plunger
= 10-12 Nm.
Air connection
= 2.7-3.4 Nm.
9. Compression spring
10. Lever
11. Cap
2/6
5/01
Air System
1. 3 Way Pilot Valve to be operated only when the clutch s fully depressed
2. Pulse unit supply 1/8 27 N.P.T.F.
3. Air Supply 3/8 - 18 N.P.T.F.
4. Regulated Air 5.5 bar 1/8 N.P.T.F.
2/7
5/01
Air System
Splitter shift
Cylinder Operation
Constant air is supplied to the shift cylinder cover
port 'S' from the filter/regulator. Pilot signals (to F
and R) from the splitter switch in the cab cause the
valves on the cylinder cover to supply air to the
pistons. Refer to Table 1 and Figures 1 and 2. The
interlock pin prevents both piston shafts being
selected at the same time.
Fig. 1 Overdrive Transmission
2. Intermediate
2. High
3. Interlock Pin
3. Interlock Pin
4. Low
4. Low
5. High
5. Intermediate
Table 1
Overdrive
B
C
Direct
B
Splitter/Cylinder
I Low
II Intermediate
III High
2/8
5/01
Air System
2/9
5/01
Air System
2/10
5/01
Air System
I.
IV. Filter/Regulator
V. Regulated Air (5,5 bar)
III. Filter/Regulator
Direct
I.
IV. Filter/Regulator
V. Regulated Air (5,5 bar)
III. Filter/Regulator
2/11
5/01
Air System
2/12
5/01
Air System
Fig. 2 TS - Intermediate
1. Filter
2. Regulator
3. Switch
4. High
5. Interlock Pin
6. Low
7. Intermediate
8. Right hand
9. Left hand
Fig. 3 TS - High
1. Filter
2. Regulator
3. Switch
4. High
5. Interlock Pin
6. Low
7. Intermediate
8. Right hand
9. Left hand
2/13
5/01
Air System
2/14
5/01
Air System
Direct Drive Transmission
Fig. 1 TS - Low
1. Low
2. Vent
3. Exhaust
4. Switch
5. Filter
6. Regulator
Fig. 2 TS - Intermediate
1. Intermediate
2. Vent
3. Exhaust
4. Switch
5. Filter
6. Regulator
Fig. 3 TS - High
1. High
2. Vent
3. Exhaust
4. Switch
5. Filter
6. Regulator
2/15
5/01
Air System
Splitter Cylinders
Disassembly and Reassembly
Reassembly
1. Assemble the new O rings into the cylinder bores
using a light application of silicone lubricant,
assemble new sealing rings to the pistons using a
light application of silicone lubricant. Excessive
lubricant causes contamination in the splitter valves
and adversely affects the performance.
1.
2.
3.
4.
Splitter Cylinder
Piston
Seal ring
Gasket
5.
6.
7.
8.
Cover assembly
Seal ring
Piston (neutral stop)
Seal ring
2/16
9. Piston
10. Interlock pin
11. O ring
12. O ring
5/01
Air System
TSO
NOT
L/H YES
R/H YES
Low
Int
High
Green
Red
No
Green/Red
No
No
No
Green/Red
No
Low
Int
High
Green
No
Red
Green/Red
No
No
TS
No
No
Green/Red
1. Red 2. Green
Fig. 2 Logic valve units indicator plungers.
2/17
5/01
Section 3
Shifting Controls
5/01
Shifting Controls
Shift Bar Housing - Single 'H' Shift
Remote Control (LRC) - Single 'H' Shift - Exploded View
3/1
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Gasket
Housing Cover, front
Capscrew
Sliding Bearing
Seal Ring
Bellows
Pinch Bolt
Lever
Locknut
Ball Joint
Reaction Rod Ball Joint
Locknut
Reaction Rod
Link
5/01
Shifting Controls
A. Disassembly of Remote Control (LRC)
3/2
5/01
Shifting Controls
B. Reassembly of Remote Control (LRC)
3/3
5/01
Shifting Controls
Shift Bar Housing Assembly - Exploded View
1.
2.
3.
4.
5.
6.
Plug/Neutral Switch
Plug/Reverse switch
Detent balls (3)
Detent springs (3)
Capscrew (2)
Lifting eye
7. Actuating pin
8. Plug - (oil pump or cooler
feed)
9. Plug - (breather)
10. Shift bar housing
11. Gasket
12. Capscrew (14)
13. Gasket
14. Gasket
15. Stud
16. Gasket
17. Plug
18. Spring
3/4
19. Plunger
20. Reverse gear shift yoke
21. Lockscrew
22. 1st/2nd gear selector block
23. Lockscrew
24. 3rd/4th gear selector block
25. Lockscrew
26. 3rd/4th gear selector block
27. Interlock ball
28. Interlock pin
29. 1st/2nd gear shift bar
30. Reverse gear shift bar
31. 1st/2nd gear shift yoke
32. Lockscrew
33. Lockscrew
34. 3rd/4th gear shift yoke
35. Actuating plunger - neutral switch
Not fitted on SAMT transmissions
5/01
Shifting Controls
A. Removal and Disassembly
3/5
5/01
Shifting Controls
B. Reassembly and Installation
3/6
5/01
Shifting Controls
3/7
5/01
Shifting Controls
3/8
5/01
Shifting Controls
11. Install the three detent balls into the shift bar
housing bores.
3/9
5/01
Section 4
Main Transmission
5/01
Main Transmission
A. Removal/Disassembly of Auxiliary Section
Caution: Drain Gear Oil
Note: The overdrive auxiliary section is shown in the following steps. The procedure is the same for the
direct version except that the actual gear sizes in respect to the number of teeth on each gear will differ
from these illustrated. In order to avoid confusion between the functions of any particular gear in the
auxiliary section of either model, i.e. high/low/intermediate/overdrive, the splitter gears installed on the
main shaft will be referred to by their relative positions, not their functions.
4/1
5/01
Main Transmission
4/2
5/01
Main Transmission
4/3
5/01
Main Transmission
4/4
5/01
Main Transmission
B. Removal and Disassembly of the Output shaft and Auxiliary Section Rear
Sliding Gear
1. Bush
2. Output shaft
5. Inner spacer
6. Outer spacer
13. O-ring
4/5
5/01
Main Transmission
4/6
5/01
Main Transmission
C. Auxiliary Countershaft Bearing
Renewal
4/7
5/01
Main Transmission
E. Splitter Gears Reassembly
Splitter Sliding Gears and Jaw Clutches - Exploded View.
1. Spring retainer
2. Spring (short)
3. Jaw clutch
4. Energiser ring
5. Sensor
6. Yoke
7. Centre sliding gear
8. Sensor
9. Retaining snap ring
10. Jaw clutch
11. Spring (long)
4/8
5/01
Main Transmission
F. Rear Sliding Gear and Output Shaft
Reassembly and Installation
4/9
5/01
Main Transmission
4/10
5/01
Main Transmission
4/11
5/01
Main Transmission
4/12
5/01
Main Transmission
G. Main Section Disassembly
4/13
5/01
Main Transmission
4/14
5/01
Main Transmission
4/15
5/01
Main Transmission
4/16
5/01
Main Transmission
H. Input Shaft Disassembly
1.
2.
3.
4.
5.
6.
7.
4/17
5/01
Main Transmission
4/18
5/01
Main Transmission
J. Reverse Idler Gear Disassembly
and Reassembly
1. Circlip
2. Washer
3. Sleeve
4.
5.
6.
7.
8.
Bearing
Reverse idler gear
Idler gear shaft
Support washer
Capscrew
4/19
5/01
Main Transmission
K. Mainshaft Disassembly
Serial Numbers: upto and including N 535711 (ERF), upto and including N 537124 (all other models).
A. Main Section
B. Auxiliary Section
1. Sliding clutch
2. Circlip
3. Graded washer - 3rd gear
4. Spacer
5. Snap ring
6. 3rd speed gear
7. 2nd speed gear
8. Snap ring
9. Spacer
10. Thrust race pack
a Standard washer
b Needle roller thrust race
c Graded washer
4/20
5/01
Main Transmission
K. Mainshaft Disassembly
Serial Numbers: upto and including N 535711 (ERF), upto and including N 537124 (all other models).
4. Lift off the 2nd speed gear and remove the 2nd
gear stepped spacer. If necessary remove the
internal snap rings from 1st, 2nd, 3rd and reverse
gears.
4/21
5/01
Main Transmission
K. Mainshaft Disassembly
Serial Numbers: N 535712 and above (ERF); N 537125 and above (all other models).
A. Main Section
B. Auxiliary Section
1. Sliding clutch
2. Snap ring
3. Graded washer - 3rd gear
4. Spacer
5. Snap ring
6. 3rd speed gear
7. 2nd speed gear
8. 2nd/3rd gear spacer
9. 2nd gear spacer
10. Thrust race pack
a Standard washer
b Needle roller thrust race
c Graded washer
4/22
5/01
Main Transmission
K. Mainshaft Disassembly
Serial Numbers: N 535712 and above (ERF); N 537125 and above (all other models).
4/23
5/01
Main Transmission
L. Determine and Adjust Mainshaft
End Float
4/24
5/01
Main Transmission
1,52
1,84
2,16
2,48
2,80
3,12
to
to
to
to
to
to
1,60mm
1,92mm
2,44mm
2,56mm
2,88mm
3,20mm
4/25
5/01
Main Transmission
M. Mainshaft Reassembly (Main
Section)
Serial Numbers upto and including N 535711
(ERF), upto and including N 537124 (all other
models).
Mainshaft Gears - Axial Clearances
The axial clearances for mainshaft gears are:
Reverse/Forward speed gears - 0,13-0,30mm
Graded washers are used to obtain the clearances
within the correct limits; six different thicknesses
are available as follows:
Thickness
Colour Code
6,30 - 6,35mm
White
6,43 - 6,48mm
Green
6,55 - 6,60mm
Orange
6,68 - 6,73mm
Purple
6,80 - 6,86mm
Yellow
6,93 - 6,99mm
Black
4/26
5/01
Main Transmission
4/27
5/01
Main Transmission
4/28
5/01
Main Transmission
M. Mainshaft Reassembly (Main
Section)
Serial Numbers: N 535712 and above (ERF); N
537125 and above (all other models).
Colour Code
6,30 - 6,35mm
White
6,43 - 6,48mm
Green
6,55 - 6,60mm
Orange
6,68 - 6,73mm
Purple
6,80 - 6,86mm
Yellow
6,93 - 6,99mm
Black
4/29
5/01
Main Transmission
4/30
5/01
Main Transmission
10. Install the 1st speed gear snap ring into its
groove in the mainshaft.
4/31
5/01
Main Transmission
14. Fit the plain washer against the 1st speed gear.
13. Install the 1st speed gear on the shaft and over
the spacer, clutching teeth downwards towards the
sliding clutch.
4/32
5/01
Main Transmission
18. Install the reverse gear front snap ring into the
groove in the mainshaft.
4/33
5/01
Main Transmission
22. Fit the flat washer against the reverse gear and
the spacer ring against the flat washer.
4/34
5/01
Main Transmission
4/35
5/01
Main Transmission
N. Main Transmission Reassembly
4/36
5/01
Main Transmission
6. Rotate the shaft to align the slot with the oil hole
in the housing. Apply sealer to the capscrew
threads and install the support washer. Do not
overtighten.
4/37
5/01
Main Transmission
4/38
5/01
Main Transmission
4/39
5/01
Main Transmission
20. Push the input shaft fully home and install the
input shaft cover. Note the correct position of the
drilled capscrews, when fitted. Tighten to the
correct torque. Insert two wedges between reverse
gear and the housing to prevent the mainshaft
sliding rearwards.
Check to ensure that the countershaft is still
correctly timed to the input shaft.
4/40
5/01
Main Transmission
4/41
5/01
Main Transmission
Main Transmission
O. Reassembly of Auxiliary Section
25. Drive the shaft into the housing until the circlip
groove is accessible and install the circlip. Align
the slot in the shaft with the oil hole in the housing,
apply sealer to the capscrew threads and install
the support washer.
4/42
5/01
Main Transmission
4/43
5/01
Main Transmission
4/44
5/01
Main Transmission
12. Remove the bar supporting the lower (righthand) auxiliary countershaft, align the timing marks
and install the countershaft into its front bearing.
Check to ensure the gears are correctly timed.
4/45
5/01
Main Transmission
4/46
5/01
Main Transmission
4/47
5/01
Main Transmission
25. Ensure that all the sliding clutches and the shift
bar housing yokes are in neutral and install the
shift bar housing, using a new gasket.
4/48
5/01
Main Transmission
4/49
5/01
Section 5
5/01
5/1
5/01
1.
2.
3.
4.
5/2
5. Input gear
6. Input shaft
7. Spigot bush
5/01
5/3
5/01
5/4
5/01
5/5
5/01
Section 6
Upshift Brake
5/01
5/01
Upshift Brake
Serial Numbers upto and including N 533586.
1. Capscrew
2. Tab washer
3. Keep plate
4. Spacer
5. Bearing
6. Spacer
7. Gear
8. Friction disc outer (3 off)
9. Friction disc inner (4 off)
10. Hub shaft
16.
17.
18.
19.
O-ring
O-ring
Gasket
Housing
6/1
5/01
Upshift Brake
Upshift Brake Removal and
Disassembly
6/2
5/01
Upshift Brake
6/3
5/01
Upshift Brake
Reassembly and Installation
6/4
5/01
Upshift Brake
6/5
5/01
Upshift Brake
6/6
5/01
Upshift Brake
Serial Numbers N 533587 and above.
1.
2.
3.
4.
5.
6.
Housing
Splined shaft
Gear
Bearing
Spacer
Bolt
13.
14.
15.
16.
17.
18.
O-ring
O-ring
Shaft
O-ring
Bolt
Washer
19.
20.
21.
22.
23.
O-ring
Drain plug
Washer
Gasket
Elbow
6/7
5/01
Upshift Brake
Removal and Disassembly
6/8
5/01
Upshift Brake
6/9
5/01
Upshift Brake
Reassembly and Installation
6/10
5/01
Upshift Brake
6/11
5/01
5/01
Section 7
PTO Installation
5/01
5/01
PTO Installation
Fitting Extended Countershaft
7/1
5/01
PTO Installation
Assembly of Extended Countershaft
2. Fit the adaptor coupling onto the rear of the lefthand countershaft.
7/2
5/01
PTO Installation
7/3
5/01