Remove/install shift cover

AR26.30-G-6500B

Remove/install shift cover

23.03.2016

Transmission

718.840 in model 405.05/09/10/11/12/20/22

Transmission

718.841 in model 437.42/43/46

Shown on model 405.102

1

Range cylinder gearshift lever

2

Range cylinder turnbuckle

3

Gear cylinder

4

Bolt

5

Bracket for central connector

6

Pneumatics connection (range group, high)

7

Pneumatics connection (range group, low)

8

Bolts (Gate cylinder solenoid valve)

9

Range cylinder

10

Electrical connectors

11

Pneumatic connection

12

Gear cylinder solenoid valves

13

Gate cylinder solenoid valve

14

Electrical connector

15

Shift cover

16

Bolts

 Danger !

Risk of death. There is a risk of death to persons located within the tilting range or underneath the raised dump body during operation. Risk of injury There is a risk of body parts being crushed or pinched when the dump body is lowered.

All persons must remain outside the tilting range of the dump body during its operation. Always secure the dump body with dump body supports before starting any work underneath it.

AS55.20-Z-0001-01A



Remove

1.1

Remove power hydraulics

Transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 with power hydraulics code H63 or code H64 or code H65, transmission 718.840 in model 405.104/105/110/125/202/222 with power hydraulics with code HL4 or code HL5

Transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 with power hydraulics with code H63 or code H64 or code H65

AR55.30-G-0002B

 Transmission 718.840 in model 405.104/105/110/125/202/222 with power hydraulics with code HL4 or code HL5
A reference document is not available for these models for removal of the power hydraulics.

1.2

Raise and secure dump platform

Transmission 718.840 in model 405.050/090 with tipper platform, transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 except power hydraulics code H63 or code H64 or code H65 with tipper platform, transmission 718.840 in model 405.104/105/110/125/202/222 except power hydraulics code HL4 or code HL5 with tipper platform

 See operator's manual.

1.3

Tilt cab into repair position

Transmission 718.841 in model 437.42/43
with code F07 (Crew cab)

AR60.80-G-0005B

1.4

Remove body

Transmission 718.841 in model 437.46

2

Release bracket for central connector (5) on transfer case (arrow) and place to one side

Transmission 718.840 in model 405.05/09/10/11/12/20/22

3

Remove bolts (4) from gear cylinder (3)

4.1

Remove banjo bolt at air connection (11) of gear cylinder (3)

Compressed air connection of pneumatics connection (11) with banjo bolt.

4.2

Remove compressed air connector of pneumatics connection (11)

Compressed air connection of pneumatics connection (11) with compressed-air connector.

AR42.10-G-0900BC

5

Disconnect electrical connections (10) from gear cylinder solenoid valves (12)

6

Remove gear cylinder (3)

 Turn gear cylinder (3) slightly while doing so.

7

Disconnect electrical connection (14) and remove gate cylinder solenoid valve (13)

8

Remove range cylinder turnbuckle (2) from range cylinder gearshift lever (1)

9.1

Unscrew banjo bolts from pneumatics connections (6, 7) of range cylinder (9)

Compressed air connection of pneumatics connections (6, 7) with banjo bolt.

9.2

Remove compressed air connectors from pneumatics connections (6, 7)

Compressed air connection of pneumatics connections (6, 7) with compressed-air connector.

AR42.10-G-0900BC

10

Remove shift cover (15)



Clean

11

Clean shift cover (15) and sealing surfaces on shift cover (15)



Check

12

Check shift cover (15) for wear and damage

If there are problems



Disassemble shift cover (15), replace worn and damaged parts then reassemble.

AR26.30-G-6510B



Install

13

Coat sealing surface on shift cover (15) with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

14

Install shift cover (15)

 Bolt, shift cover to transmission housing

*BA26.30-N-1002-01F

15

Coat banjo bolts of pneumatics connections (6, 7) with some thread-locking adhesive

Compressed air connection of pneumatics connections (6, 7) with banjo bolt.

Thread locking adhesive, Loctite 241

*BR00.45-Z-1001-02A

16.1

Screw in banjo bolts of pneumatics connections (6, 7)

Compressed air connection of pneumatics connections (6, 7) with banjo bolt.

 Banjo bolt to cover for shift cylinder range group

*BA26.20-N-1001-01A

16.2

Mount compressed air connectors of pneumatics connections (6, 7)

Compressed air connection of pneumatics connections (6, 7) with compressed-air connector.

SCHÄFER "SDF" (NG 6) or VOSS "232" (NG 8, 12) compressed air connector

AR42.10-G-0900BC

17

Install range cylinder turnbuckle (2) onto range cylinder gearshift lever (1)

18

Install gate cylinder solenoid valve (13) and connect electrical connection (14)

19

Pull selector finger forward in direction of 1st gear and install gear cylinder (3)

 Screw in gear cylinder (3) downwards.

20

Connect electrical connections (10) to gear cylinder solenoid valves (12)

21

Coat banjo bolt for pneumatics connection (11) with some thread-locking adhesive

Compressed air connection of pneumatics connection (11) with banjo bolt.

Thread locking adhesive, Loctite 241

*BR00.45-Z-1001-02A

22.1

Screw in banjo bolt of pneumatics connection (11)

Compressed air connection of pneumatics connection (11) with banjo bolt.

 Banjo bolt to gear cylinder

*BA26.60-N-1001-01K

22.2

Mount compressed air connector of pneumatics connection (11)

Compressed air connection of pneumatics connection (11) with compressed-air connector.

With SCHÄFER "SDF" (NG 6) or VOSS "232" (NG 8, 12) compressed air connector

AR42.10-G-0900BC

23

Screw in bolts (4) on gear cylinder (3)

 Bolt, gear cylinder to cover

*BA26.30-N-1001-01F

24

Position bracket for central connector (5) on transfer case (arrow) and screw-in bolts

25

Adjust range cylinder

Transmission 718.840 in model 405.05/100/101/102/103/120/121/122/123/200/201/220/221
Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

AR26.20-G-1003B

Transmission 718.840 in model 405.090/104/105/110/125/202/222
Transmission 718.841 in model 437.427/437

AR26.20-G-1003U

26.1

Install power hydraulics

Transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 with power hydraulics with code H63 or code H64 or code H65, transmission 718.840 in model 405.104/105/110/125/202/222 with power hydraulics with code HL4 or code HL5

Transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 with power hydraulics with code H63 or code H64 or code H65

AR55.30-G-0002B

 Transmission 718.840 in model 405.104/105/110/125/202/222 with power hydraulics with code HL4 or code HL5
A reference document is not available for these models for installation of the power hydraulics.

26.2

Lower tipper platform

Transmission 718.840 in model 405.050/090 with tipper platform, transmission 718.840 in model 405.100/101/102/103/120/121/122/123/200/201/220/221 except power hydraulics code H63 or code H64 or code H65 with tipper platform, transmission 718.840 in model 405.104/105/110/125/202/222 except power hydraulics code HL4 or code HL5 with tipper platform

 See operator's manual.

26.3

Lower cab

Transmission 718.841 in model 437.42/43
with code F07 (Crew cab)

AR60.80-G-0005B

26.4

Mount body

Transmission 718.841 in model 437.46

 Range group shift cylinder

Number

Designation

Transmission 718.840/841

BA26.20-N-1001-01A

Banjo bolt to cover for shift cylinder range group

Nm

30

 Cover

Number

Designation

Transmission 718.840/841

BA26.30-N-1001-01F

Bolt, gear cylinder to cover

Nm

80

 Cover

Number

Designation

Transmission 718.840/841

BA26.30-N-1002-01F

Bolt, shift cover to transmission housing

Nm

20

 Shift

Number

Designation

Transmission 718.840/841

BA26.60-N-1001-01K

Banjo bolt to gear cylinder

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-02A

Thread locking adhesive, Loctite 241

A 002 989 94 71

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10