7-48
Published 01-29-2014, Control # 496-00
POWER TRAIN TMS800E SERVICE MANUAL
Removal of the Transmission
1. Refer to Engine Removal, page 7-2 and remove the
engine and transmission as an assembly from the crane.
2. Remove the bolts and washers securing the
transmission housing to the engine housing.
3. Carefully pull back on the transmission, keeping it level
until the input shaft is clear of the clutch assembly.
4. Continue to pull back and remove the transmission.
Special Procedure for Changing Clutch (Input) Shaft
General
In some cases in field repair it may be necessary to replace
only the input shaft due to clutch wear on the splines.
In these instances the input shaft can be removed without
disassembling the transmission other than removing the
shifting bar housing. Removal of the clutch housing is
optional.
NOTE: The below instructions are for changing the input
shaft only. To change the drive gear, complete
disassembly of the front section must be made.
Disassembly
1. Remove the gear shift lever housing and shift bar
housing from the transmission.
2. Engage the mainshaft sliding clutches in two gears and
remove the drive gear bearing nut.
3. Move the drive gear assembly as far forward as possible
and remove the drive gear bearing.
4. Remove the washer from the input shaft.
5. From the front, remove the snap ring from the inside
diameter of the drive gear.
6. Pull the input shaft forward and from the splines of the
drive gear.
Assembly
1. Install the new input shaft into the splines of the drive
gear just far enough to expose the snap ring groove in
the inside diameter of the drive gear.
2. Install the snap ring in the inside diameter of the drive
gear.
3. Install the washer on the shaft.
Range shift inoperative or
malfunctioning.
Air lines crossed between control valve
on shift lever and air valve on
transmission (steady leakage from
exhaust port on range shift control valve
with button in the up position).
Disconnect crossed air lines and
connect properly.
Lines crossed between air valve on
transmission and the shift cylinder.
Disconnect crossed air lines and
connect properly.
Low range (down position) on button
results in high range gear engagement,
and vice versa.
Disassemble control valve and
replace o-ring seals.
Range shift control valve leaking due to
poor O-ring seals. Leakage from exhaust
port of regulator due to ruptured
diaphragm or clogged regulator piston.
Disassemble, clean, and repair
regulator.
Bearing failure.
Use of wrong lubricant or grade of
lubricant.
Drain transmission; flush and refill
with proper grade and type of
lubricant.
Bearings adjusted to tight or too loose. Obtain correct adjustment.
Lack of cleanliness in overhaul of
transmission resulting in damaged
gearing due to foreign matter in oil.
Properly clean transmission.
SYMPTON PROBABLE CAUSE SOLUTION
CAUTION
Risk of damage!
Ensure any lifting device used is capable of supporting the
transmission in a level position during removal.
Reference Only
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