41-02 CARRARO TX Workshop.
41-02 CARRARO TX Workshop.
41-02 CARRARO TX Workshop.
02
CHASSIS
TRANSMISSION 1
CARRARO
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
2 CHASSIS
TRANSMISSION
DISASSEMBLY
DISASSEMBLY (cont’d)
4 CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
DISASSEMBLY (cont’d)
6 CHASSIS
TRANSMISSION
ASSEMBLY
ASSEMBLY (cont’d)
Assemble the connector (7) for the oil filter (6) then tighten it
to the prescribed torque.
8 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
10 CHASSIS
TRANSMISSION
DISASSEMBLY
DISASSEMBLY (cont’d)
12 CHASSIS
TRANSMISSION
ASSEMBLY
ASSEMBLY (cont’d)
14 CHASSIS
TRANSMISSION
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
HMK 102 ENERGY WORKSHOP MANUAL 41
02
CHASSIS
TRANSMISSION 15
DISASSEMBLY
16 CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
DISASSEMBLY (cont’d)
ASSEMBLY
18 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
HMK 102 ENERGY WORKSHOP MANUAL 41
02
19
Assemble the new gasket (3).
CHASSIS
TRANSMISSION
20
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
CHASSIS
TRANSMISSION
DISASSEMBLY
HMK 102 ENERGY WORKSHOP MANUAL 41
02
CHASSIS
TRANSMISSION
ASSEMBLY
CHASSIS
TRANSMISSION
TRANSMISSION HOUSING
HMK 102 ENERGY WORKSHOP MANUAL 41
02
23
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
CHASSIS
TRANSMISSION
DISASSEMBLY
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
HMK 102 ENERGY WORKSHOP MANUAL 41
02
Remove seal ring (5).
Note: This is a destructive operation for the O-ring. 25
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
26
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
27
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
28
CHASSIS
TRANSMISSION
ASSEMBLY
detergent.
HMK 102 ENERGY WORKSHOP MANUAL 41
02
29
Assemble all the transmission internal parts.
Apply a thin film of prescribed sealant on the edge of rear half-housing.
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
30
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
32
Assemble bearing (11) on transmission shaft PTO (8).
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
33
CHASSIS
TRANSMISSION
SHAFTS A - D
41 HMK 102 ENERGY WORKSHOP MANUAL
02
34 Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
CHASSIS
TRANSMISSION
DISASSEMBLY
35
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
36
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS 39
TRANSMISSION
DISASSEMBLY (cont’d)
40 CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS 41
TRANSMISSION
DISASSEMBLY (cont’d)
Check the sealing ring grooves (large and small) for wear and damage if necessary.
Use new parts as required.
Check the ball bearings and the needle bearings for flat areas, pitting, and other
damage.
Use new parts as required.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
42 CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS 43
TRANSMISSION
DISASSEMBLY (cont’d)
Inspect the bore of the shaft in the input shaft housing for damage that will cause
leakage when the clutch is assembled.
Check the slots in the side of the input shaft housing for damage from the tangs on
the steel discs.
Use new parts as required during assembly.
44 CHASSIS
TRANSMISSION
ASSEMBLY
CHASSIS 45
TRANSMISSION
ASSEMBLY (cont’d)
46 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
ASSEMBLY (cont’d)
48 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
ASSEMBLY (cont’d)
50 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS 51
TRANSMISSION
ASSEMBLY (cont’d)
52 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
ASSEMBLY (cont’d)
For the introduction of the other three (2nd, 3rd, 4th ) Teflon rings, repeat the operations
from sequence before applied.
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
54 Apply compressed air of approximately 6 bar to the forward clutch passage. Listen to
hear the forward piston moving to lock the forward clutch pack.
Try to move the forward gear. The forward gear must not turn on the input shaft. Try
to move the reverse gear. The reverse gear must turn freely on the input shaft. If the
clutches do not work correctly, disassemble the clutches to find the problem.
Apply compressed air of approximately 6 bar to the reverse clutch passage. Listen to
hear the reverse piston moving to lock the reverse clutch pack. Try to move the
reverse gear. The reverse gear must not turn on the input shaft. Try to move the
forward gear. The forward gear must turn freely on the input shaft. If the clutches do
not work correctly, disassemble the clutches to find the problem.
CHASSIS
TRANSMISSION
AXIS B
HMK 102 ENERGY WORKSHOP MANUAL 41
02
55
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
CHASSIS
TRANSMISSION
DISASSEMBLY
41 HMK 102 ENERGY WORKSHOP MANUAL
02
56
Lift the three shafts B-C-E, at the same time by using tool.
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
HMK 102 ENERGY WORKSHOP MANUAL 41
02
57
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
58
Remove roller retainers (7) and washer (13).
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
HMK 102 ENERGY WORKSHOP MANUAL 41
02
59
Remove thrust plate (10) by means of two screwdrivers.
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
60
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Check the sealing ring grooves (large and small) for wear and damage if necessary.
Use new parts as required.
Check the ball bearings and the needle bearings for flat areas, pitting, and other
damage.
Use new parts as required.
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
If using a new clutch kit soak the clutch plates in clean transmission oil for at least an
hour before assembly.
In any case lubricate the contact surfaces of clutch drive plates with clean
transmission oil before assembly.
HMK 102 ENERGY WORKSHOP MANUAL 41
02
Inspect the bore of the shaft in the input shaft housing for damage from the tangs on
the steel discs. 63
Use new parts as required during assembly.
CHASSIS
TRANSMISSION
ASSEMBLY
64
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
65
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
66
Loosen the handles of the threaded rods to release the tension from the spring.
Remove the top piece of the special tool.
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
67
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
68
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
69
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
See illustration.
Try to rotate the 2nd speed gear. The 2nd speed gear must turn freely on the input
shaft.
Apply compressed air of approximately 6 bar to the 2nd speed gear clutch oil
passage. Hear the 2nd speed gear piston moving to lock the 2nd speed gear clutch
pack.
Try to move the 2nd speed gear. The 2nd speed gear must not turn on the input shaft.
If the clutch does not work correctly, disassemble the clutch to find the problem.
70
CHASSIS
TRANSMISSION
AXIS C
HMK 102 ENERGY WORKSHOP MANUAL 41
02
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway. 71
CHASSIS
TRANSMISSION
DISASSEMBLY
72
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
73
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
74
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
75
Remove gear (37) with an extractor.
Remove bushing (47) and (56), roller bearing (46) and (55) and spacer (50).
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
76
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
78
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
79
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
80
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Push down the thrust plate (5) to set free the lock ring (4). 81
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Lower the
spring (11) lock washer (10) by using tool.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
82
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Extract clutch piston (13) from its seat by blowing in compressed air through the 83
delivery hole.
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Check the sealing ring grooves (large and small) for wear and damage.
If necessary use new parts as required.
Check the ball bearings and the needle bearings for flat areas, pitting, and other
damage.
Use new parts as required.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
84
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Verify that the all clutch plates do not appear burned or that the friction material is not
damaged and the splines are well traced.
Verify also that all the clutch drive plates (A) are
perfectly plane and inspect for pitting or scoring.
In any case lubricate the contact surfaces of clutch drive plates with clean 85
transmission oil before assembly.
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
Inspect the bore of the shaft in the input shaft housing for damage that will cause
leakage when the clutch is assembled.
Check the slots in the side of the input shaft housing for damage from the tangs on
the steel discs.
Use new parts as required during assembly.
1d GEAR CLUTCH
Number of clutch plate 6
Number of clutch steel plate 6
Nominal clutch plate thickness 2,20 ± 0,05 mm
Nominal clutch kit thickness * 27,50 ~ 27,70 mm
Maximum clutch plate wear (each side) 0,15 mm
Maximum clutch kit wear 0,90 mm
86
CHASSIS
TRANSMISSION
ASSEMBLY
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
88
Loosen the handles of the threaded rods to release the tension from the spring.
Remove the top piece of the special tool.
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
89
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
90
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
91
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
92
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
ASSEMBLY (cont’d)
94
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble the new seal rings (49) and (51) to the bush (50) with the special tools.
Note: For correct assembly of seal rings follow operations before mentioned.
CHASSIS 95
TRANSMISSION
ASSEMBLY (cont’d)
96
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS 97
TRANSMISSION
ASSEMBLY (cont’d)
98
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS 99
TRANSMISSION
ASSEMBLY (cont’d)
100 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
ASSEMBLY (cont’d)
102 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Apply compressed air of approximately 6 bar to the 1st speed gear clutch passage.
Hear the 1st speed gear piston moving to lock the 1st speed gear clutch pack.
Try to move the 1st speed gear. The 1st speed gear must not turn on the input shaft.
If the clutch does not work correctly, disassemble the clutch to find the problem.
Apply compressed air of approximately 6 bar to the 3rd speed gear clutch passage.
Hear the 3rd speed gear piston moving to lock the 3rd speed gear clutch pack.
Try to move the 3rd speed gear. The 3rd speed gear must not turn on the input shaft.
If the clutch does not work correctly, disassemble the clutch to find the problem.
Apply compressed air of approximately 6 bar to the 4th speed gear clutch passage.
Hear the 4th speed gear piston moving to lock the 4th speed gear clutch pack.
Try to move the 4th speed gear. The 4th speed gear must not turn on the input shaft. If
the clutch does not work correctly, disassemble the clutch to find the problem.
AXIS E
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
41 HMK 102 ENERGY WORKSHOP MANUAL
02
104 CHASSIS
TRANSMISSION
DISASSEMBLY
CHASSIS
TRANSMISSION
HMK 102 ENERGY WORKSHOP MANUAL 41
02
DISASSEMBLY (cont’d)
105
Remove roller bearing (19).
CHASSIS
TRANSMISSION
41 HMK 102 ENERGY WORKSHOP MANUAL
02
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
HMK 102 ENERGY WORKSHOP MANUAL 41
02
107
CHASSIS
TRANSMISSION
DISASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
108 Verify that the all clutch plates do not appear burned or that the friction material is not
damaged and the splines are well traced.
Verify also that all the clutch drive plates (A) are
perfectly plane and inspect for pitting or scoring.
In any case lubricate the contact surfaces of clutch drive plates with clean
transmission oil before assembly.
Inspect the bore of the shaft in the input shaft housing for damage that will cause
leakage when the clutch is assembled.
Check the slots in the side of the input shaft housing for damage from the tangs on
the steel discs.
Use new parts as required during assembly.
CHASSIS
TRANSMISSION
ASSEMBLY
HMK 102 ENERGY WORKSHOP MANUAL 41
02
109
Insert inner (7) and outer (9) O-rings on clutch piston (8).
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
110
Overturn the shaft (12) and fully insert the clutch piston (8).
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
111
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
112 Turn shaft (12). Make sure that the disc/ counter-disc pack and the piston are
correctly seated.
S = X – S1 = X – 1,80 mm
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
114
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
115
CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
41 HMK 102 ENERGY WORKSHOP MANUAL
02
116
Apply compressed oil pressure of approximately 10 bar to the 4WD clutch passage.
Listen to hear the piston moving to unlock the clutch pack. The spring washers
compresses. Try to move the 4WD gear. The 4WD gear must turn freely on the shaft.
If clutch does not work correctly, disassemble the clutch to find the problem.
CHASSIS
TRANSMISSION
TROUBLESHOOTING
HMK 102 ENERGY WORKSHOP MANUAL 41
02
This list of possible failures and remedies provides no more than an indication of 117
what the problem might be and how to fix it.
It should be remembered that the problems are not caused by just one part, but by
part’s interaction with other elements. Accordingly, additional action over and above
the steps described is frequently required.
This list may not cover all possible problems and remedies.
Specialist personnel must identify the problem and its cause and then proceed with
the necessary repairs.
Warning: All checks and tests must be performed with the oil at working temperature
80 ± 2 0C.
Pressure test
Several transmission breakdowns can be identified by running pressure checks.
Irregular measurements might indicate that there is a problem, which specialist
personnel must identify.
Stall test
In order to create ideal conditions for troubleshooting, the converter stall procedure
must be performed first. The purpose of this test is to determine whether the torque
converter and hydraulic clutch units are operating correctly.
This operation will also bring the oil up to its working temperature of 80 ± 2 0C,
allowing any problems in the engine, converter or transmission to be identified.
Proceed as follows:
Check the oil level.
Apply the parking brake to block the wheels.
Start the engine and keep it ticking over at idle speed (88-00-1000 rpm).
Put the gear lever into 4th.
Put the reverser in the FORWARD position.
Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the
oil up to working temperature.
Important: The converter stall test must not exceed a maximum duration of 30
seconds each time. After this 30 sec period, put the reverser in NEUTRAL for
15 seconds than repeat the procedure. Warning: Failure to keep to these test
periods may result in the oil overheating and attendant damage to the
clutches, filter, converter and seals.
Gradually reduce the engine revs to minimum.
Put the reverser in NEUTRAL.
CHASSIS
TRANSMISSION
41 HMK 102 ENERGY WORKSHOP MANUAL
02
Mechanical problems
Check that all of the transmission’s internal and external mechanical parts are
correctly fitted.
Check the efficiency of the parking brake.
Check that the cooling system is in good operating condition.
Check the efficiency of the engine. Make sure that the engine’s idling speed is
set correctly and that it complies with the maximum speed specifications under
no load conditions.
Hydraulic problems
Check the transmission oil level.
Use the specified oils.
Check that the hydraulic system is correctly filled.
Check the efficiency of the hydraulic system. Check for oil leaks.
Check the efficiency of the transmission’s hydraulic components (converter, oil
pump, filter, connections, hoses)
Electrical problems
Check the efficiency and correct installation of the vehicle battery.
Check the efficiency and correct installation of all electrical components,
outside the transmission (wiring, cables, alternator, battery, et.).
Check the efficiency and correct installation of all transmission electrical
components (wiring, sensors, solenoid valves, EGM/ECU, etc.).
CHASSIS
TRANSMISSION
TROUBLESHOOTING OF TRANSMISSION
HMK 102 ENERGY WORKSHOP MANUAL 41
02
The next table lists problems, possible causes and recommended corrective action. 119
CHASSIS
TRANSMISSION
CHASSIS
TRANSMISSION
CHASSIS
TRANSMISSION
SPECIAL TOOLS
HMK 102 ENERGY WORKSHOP MANUAL 41
02
123
Description CARRARO Part No: Figure
Handle CA119033
Driver CA715004
Driver CA7150046
Driver CA715149
Calibrator CA715356
Clutch
CA715358
assemble/disass.
CHASSIS
TRANSMISSION
124
Description CARRARO Part No: Figure
Axe B,C,E
CA715750
rising tool
Driver CA715409
Check CA715494
Protection +
CA715495
shims
Pusher CA715497
Protection CA715499
CHASSIS
TRANSMISSION
Driver CA715501
Driver CA715623
Calibrator CA715745
Pusher CA715746
Calibrator CA715747
CHASSIS
TRANSMISSION
Pusher CA715748
Calibrator CA716009
Protection CA716010
Pusher CA716019
Calibrator CA716020
Extractor CA716021