PowerSynchro Transmission Parts Manual - JLG Industries · PDF filePowerSynchro Transmission Parts Manual Models TH336, TH337, TH406, TH407, TH414, TH514, TH417 S/N TDE00100 & After

PowerSynchro TransmissionParts Manual

ModelsTH336, TH337, TH406, TH407, TH414, TH514,

TH417

S/N TDE00100 & AfterS/N TDF00100 & AfterS/N TBX00100 & AfterS/N TBY00100 & AfterS/N TBZ00100 & AfterS/N TBW00100 & AfterS/N TBT00100 & After

31200493

Original

June 25, 2008

Product and Dealer Information

Delivery Date:

Product Information

Model:

Product Identification Number:

Transmission Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

GENERAL INFORMATION

1. MACHINE IDENTIFICATION

Caterpillar machines are identified by ProductIdentification Numbers (PIN). Some componentsincluded in a machine may be identified by SerialNumbers (S/N). Typical components that will beserialized include engines, transmissions, bulldozers,and rippers. The machine and engine are furtheridentified by arrangement numbers and in some casesmodification numbers. These numbers are shown onthe product identification plate(s) and on the masterplate in the operator’s compartment.

Caterpillar dealers need all of these numbers todetermine accurate parts identification.

Effective First Quarter 2001 the Caterpillar ProductIdentification Number (PIN) will change from 8 to 17characters. In an effort to provide uniform equipmentidentification, Caterpillar and other constructionequipment manufacturers are moving to complywith the latest version of the product identificationnumbering standard. Non-road machine PINs aredefined by ISO 10261. The new PIN format will applyto all Caterpillar machines and generator sets. The PINplates and frame marking will display the 17 characterPIN. The new format will look like the following:

Where:

1. Caterpillar’s World Manufacturing Code (characters1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or ProductSequence Number (characters 10-17). These werepreviously referred to as the Serial Number.

Machines and generator sets produced before FirstQuarter 2001 will maintain their 8 character PIN format.

Components such as engines, transmissions, axles,etc. and work tools will continue to use an 8 characterSerial Number (S/N).

2. ORDERING PARTS

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world. Theirparts inventories are up to date and include allparts normally required to protect your investment inCaterpillar machines. Dealers may offer repair kits orremanufactured parts to allow selection of the mosteffective repair alternative for a particular situation.When ordering parts, your order should specify thequantity, part number, part name, and the serialnumber/product identification number of the machinefor which the parts are needed.

3. PARTS MANUAL ORGANIZATION

Product information in this manual is presentedas "information elements" that represent all ofthe components for the specific model. EngineArrangement and Seat Group are examples ofinformation elements.

4. TABLE OF CONTENTS

A table of contents (TOC) is found at the beginningof the manual. The TOC lists each section of themanual with a complete list of all information elementsorganized as they appear in the manual.

GENERAL INFORMATION

5. CAPTIONS

Captions located at the top of each page of aninformation element identify the part number and partname along with additional descriptive information.PIN and S/N information found in each caption shouldbe used to select correct information for a specificmachine. Field replacement options, identification ofoptional attachment components, and where used("part of") information is also provided.

The first line of a caption is shown in larger type fontto indicate the beginning of an information element.Captions for additional pages that may be requiredto illustrate an information element will be shown instandard type font and will include the term (contd.).

6. NON-SERVICED PARTS

In some instances it is necessary to displaynon-serviced parts that are a link to a lower levelserviceable consist lists. These non-serviced partnumbers are shown in italic type indicating that theyare not available.

7. PARTS LIST REFERENCE NUMBERS

Numbers shown in the Ref No column correspondto numbers used in the associated graphic(s). Analphabetic suffix may be added to a reference numberto identify lower level consist items. Numbers shownin the Graphic Ref column refer to the graphic numberidentifier displayed in the lower left corner of eachillustration. The Graphic Ref number may be used incombination with the item Ref No to determine thecorrect part number. There may be intentional omissionof a Ref No in a consist list as information is updatedto reflect the latest serviceable part numbers.

8. INDENTED PART NAMES

When a part name is indented in a parts list, it is partof (included in) the group or assembly under which it isindented.

9. ILLUSTRATION REFERENCE LETTERS

When necessary, illustrations contain reference letters(A, B, C etc.) that are intended to track lines andharnesses from one point to another. They are alsoused to show where to reconnect illustrations that havebeen separated.

10. ABBREVIATIONS AND SYMBOLS

O.D. – Outside DiameterI.D. – Inside DiameterA – Not Part Of This GroupB – Use As RequiredC – Change From Previous TypeD – Order By The MeterE – Order By The CentimeterF – Not ShownG – Order By The InchI – See Hose Fabrication GuideM – Metric PartR – Remfg Part May Be AvailableY – Separate IllustrationZ – Not Serviced Separately

NOTE:

Continuing improvement and advancement of productdesign may cause changes to your machine whichmay not be included in this publication. Whenever aquestion arises regarding your Caterpillar product orthis publication, please consult your Caterpillar dealerfor the latest available information.

4 Speed Transmission323-8993-00 ............................. 2

323-8994-00 ............................. 225 Speed Transmission

Table of Contents

POWERSYNCHRO TRANSMISSION4 SPEED

323-8993

2

POWERSYNCHRO TRANSMISSION - 4 SPEED323 - 8993 TRANSMISSION AR

ENGINEERING MODEL: PT070 SERIAL NUMBER PREFIX: LKTREFNO

GRAPHICNO

PART NAME SEEPAGENOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)

311-4066 1 TRANSMISSION ARY 217-7217 1 DRIVE GP - FLEX 5

230-7551 1 CONVERTER AS293-5003 1 TC GP - BASIC

Y 312-3580 1 XMSN GP - DIRECT DRIVE 6Y - SEPARATE ILLUSTRATION

<END>

4

POWERSYNCHRO TRANSMISSION - 4 SPEED217 - 7217 DRIVE GP - FLEXPART OF 311-4066 TRANSMISSION AR

REFNO

GRAPHICNO


1 1 6V-8455 6 BOLT2 1 117-9713 1 PLATE3 1 111-7906 1 PLATE

GRAPHIC # 1 <END>

5

POWERSYNCHRO TRANSMISSION - 4 SPEED312 - 3580 XMSN GP - DIRECT DRIVE

PART OF 311-4066 TRANSMISSION ARREFNO

GRAPHICNO


1 1 206-4395 1 CASE AS - FRONT9W-0717 4 PLUG147-0268 2 PLUG178-8231 1 XMSN CASE205-9244 1 PLUG

2 1 221-6780 1 CASE AS - REAR9W-0717 5 PLUG

3 2 8T-7942 2 DOWEL4 3,4 7T-3253 4 DOWEL5 3 206-4397 1 HOUSING6 1 316-1932 1 PLATE - COVER7 1 4F-4585 1 PLUG - CORE8 1 191-8304 1 SENSOR GP - SPEED9 1 178-8127 1 FLANGE

10 1 178-8229 1 PLATE11 1 216-2277 1 PLATE - COVER12 3,4 216-2278 2 HOUSING AS

147-0268 4 PLUG13 3,4 200-6210 4 VALVE GP - SOL

200-2371 1 SEAL KIT212-0061 1 FLANGE

14 1 121-7396 1 VALVE GP - CONVERTER RELIEF6V-4589 1 SEAL - O-RING8L-2746 1 SEAL - O-RING

15 4 296-6617 1 HOUSING AS - VALVEY 16 1,4 252-9715 3 VALVE GP - MDL 19

17 1 264-4297 1 SENSOR - TEMP18 1 206-4377 1 PLATE - COVER19 1 206-4382 1 HOUSING20 1 6V-5215 3 BOLT21 1,2 6V-5217 12 BOLT22 1,3 8C-5748 5 BOLT23 4 6V-5220 4 BOLT24 3,4 6V-5221 4 BOLT25 3 6V-5842 6 BOLT26 4 8T-0276 5 BOLT27 3,4 8T-0100 6 BOLT28 1 6V-5815 1 BOLT29 1 237-5185 4 PLUG 9/16"

3J-1907 1 SEAL - O-RING9S-8004 1 PLUG - HEX SOCKET

30 1,3,4 9S-4191 16 PLUG - STOR31 1 189-5746 1 SENSOR GP - SPD - A32 1 117-1385 2 SEAL - O-RING33 1,2,3 6V-5215 5 BOLT34 1 132-5789 3 CLIP - LADDER35 1 085-8091 22 BOLT36 2 178-8159 1 REACTOR AS 37 2 178-8169 2 WASHER - THRUST38 2 178-8166 1 GEAR AS

195-7657 1 SEAL - O-RING

(1 of 7)

6


(contd)REFNO

GRAPHICNO


39 2 178-8162 1 COVER GP178-8164 1 SEAL - OIL221-6782 1 COVER AS - SUB

Y 40 2 178-8201 1 SHAFT AS - INPUT 13Y 41 2 178-8203 1 DRIVE AS - FAN 14Y 42 3 206-4379 1 SHAFT AS - PUMP DRIVE 15Y 43 4 178-8205 1 SHAFT AS - FORWARD / REVERSE 16

44 4 178-8138 1 GEAR - IDLER45 3 178-8217 1 COUNTERSHAFT AS

7T-2646 1 SPACER8T-1580 1 CUP - RLR BRG8T-1581 1 CONE - RLR BRG123-8907 1 CONE - SPL TAPERED123-8908 1 CUP - SPL TAPERED178-8139 1 CONTERSHAFT178-8218 1 SPACER6T-9163 1 SHIM6T-9164 1 SHIM6T-9165 1 SHIM6T-9166 1 SHIM

46 2 206-4396 1 TUBE AS47 2 206-4381 1 TUBE AS48 2 206-4375 1 TUBE AS49 2 206-4399 1 FORK - SHIFT50 2 206-4400 1 FORK - SHIFT51 2 238-7561 2 SCREW - CAP52 2 214-8970 SENSOR AS

151-9274 1 RECEPTACLE KIT204-0728 1 SEAL - O-RING9X-3401 4 PIN - C0NNECTOR

53 2 8T-0328 4 WASHER54 2 238-7562 16 SCREW - CAP55 1 5P-4484 1 PLUG - MAGC O-RING56 2 216-2280 1 GUARD AS57 3 178-8237 1 PUMP GP - CHARGE58 3 178-8236 1 PUMP GP - SCAVENGE59 3 216-2283 1 INLET - SCAV PUMP60 3 216-2282 1 BAFFLE

Y 61 3 216-2275 1 SHAFT AS - OUTPUT 1862 3 9P-9150 2 WASHER63 2 6V-8675 2 BOLT64 2,3 238-7563 9 SCREW - CAP65 3 7T-3195 2 WASHER66 3 122-6787 2 YOKE AS

123-1377 1 GUARD67 3 6V-3668 2 BOLT68 1 237-5188 1 PLUG - EXPANSION69 3 5P-8347 2 BOLT70 3 206-4403 1 RAIL - SHIFT71 3 206-4402 1 RAIL - SHIFT72 3,4 216-2264 2 PISTON73 3,4 221-6768 2 PISTON - INTO GEAR

(2 of 7)

7


(contd)REFNO

GRAPHICNO


74 3,4 221-6767 2 PISTON - NEUTRAL75 3,4 216-2265 2 PISTON76 4 014-5645 6 BALL77 4 216-2271 1 PLUG78 4 6Y-1341 2 SPRING79 3,4 178-8209 4 PISTON SEAL80 3,4 178-8210 2 PISTON SEAL81 3,4 221-6769 2 PISTON SEAL82 2 138-1645 2 PIN - SPRING83 1 4P-7582 1 CLIP - LADDER84 1 6V-8177 1 BOLT85 2 120-9762 20 SEAL - O-RING86 2 238-6531 2 SEAL - O-RING87 4 005-0469 2 CUP - RLR BEARING88 4 7T-3034 1 SPACER89 3 302-8432 2 SEAL - LIP TYPE90 2 206-4392 1 PLATE - COVER91 2 206-4393 1 PLUG92 2 178-8171 1 QUAD RING

Y 93 1 278-0214 1 VALVE GP - RLF 2098 1 191-8303 1 SENSOR GP - SPD A99 1 178-8137 1 WASHER100 1 6V-4248 1 BOLT101 1 5F-7054 1 SEAL - O-RING103 3 4P-7581 2 CLIP - LADDER

SERVICEREPAIR

104 4 6T-9144 1 SHIM105 4 6T-9146 1 SHIM106 4 6T-9147 1 SHIM107 4 6T-9145 1 SHIM109 2 214-8970 SENSOR AS

Y - SEPARATE ILLUSTRATION

(3 of 7)

8

POWERSYNCHRO TRANSMISSION - 4 SPEED312 - 3580 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 1 (4 of 7)

9



10



11


GRAPHIC # 4 (7 of 7)<END>

12

POWERSYNCHRO TRANSMISSION - 4 SPEED178 - 8201 SHAFT AS - INPUT

PART OF 312-3580 XMSN GP - DIRECT DRIVEREFNO

GRAPHICNO


1 1 6Y-1192 1 RING - SEAL2 1 178-8117 1 SHAFT - INPUT3 1 178-8118 1 GEAR - 47 TEETH4 1 178-8214 1 CIRCLIP5 1 190-1570 1 BRG - SPL NEED THR6 1 190-1572 1 RACE - THRUST7 1 209-3766 1 BEARING - SPL AS

GRAPHIC # 1 <END>

13

POWERSYNCHRO TRANSMISSION - 4 SPEED178 - 8203 DRIVE AS - FAN


GRAPHICNO


1 1 095-0941 1 RING - RETAINING2 1 104-3288 1 SHIM3 1 121-2059 1 SHIM4 1 121-2060 1 SHIM5 1 121-2061 1 SHIM6 1 122-1878 1 RING - SEAL7 1 122-1879 1 SPACER - BRG8 1 221-6795 1 GEAR - 38 TEETH9 1 178-8125 1 GEAR - 38 TEETH

10 1 178-8129 1 WASHER - THRUST11 1 178-8208 1 SEAL - OIL12 1 190-1576 1 BRG AS - SPL TPR13 1 206-4383 1 THRUST WASHER14 1 209-3764 1 BEARING - SPL AS15 1 221-6781 1 SHAFT AS16 1 7T-3035 1 PIN17 1 123-8905 1 CONE - SPL TAPERED18 1 123-8906 1 CUP SPL TAPERED

GRAPHIC # 1 <END>

14

POWERSYNCHRO TRANSMISSION - 4 SPEED206 - 4379 SHAFT AS - PUMP DRIVE


GRAPHICNO


1 1 6V-9097 1 BOLT - LOCKING2 1 7T-3195 1 WASHER3 1 061-7539 1 SEAL - O-RING4 1 095-0942 1 RING - RETAINING5 1 178-8120 1 GEAR - 44 TEETH6 1 178-8122 1 WASHER - THRUST7 1 178-8238 1 SHAFT8 1 190-1574 2 BRG - SPL CGD R AS9 1 206-4378 1 WASHER - THRUST

10 1 209-3768 1 BEARING - SPL AS11 1 221-6796 1 GEAR - 44 TEETH12 1 238-7568 2 RING - RETAINING13 1 7T-3035 1 PIN14 1 5P-3132 1 BEARING - ROLLER

GRAPHIC # 1 <END>

15

POWERSYNCHRO TRANSMISSION - 4 SPEED178 - 8205 SHAFT AS - FORWARD / REVERSE


GRAPHICNO


1 1 104-3288 1 SHIM2 1 121-0694 1 WASHER - THRUST3 1 121-2059 1 SHIM4 1 121-2060 1 SHIM5 1 121-2061 1 SHIM6 1 121-2500 2 WASHER - THRUST7 1 122-1879 1 SPACER - BRG8 1 122-1880 12 DISC - FRICTION9 1 122-1881 12 PLATE - CLUTCH

10 1 122-1882 2 PLATE - END11 1 122-1886 3 RING - SEAL12 1 122-3649 2 RING - RET INT13 1 123-8913 4 BEARING - CAGED14 1 172-5317 2 BEARING - SPL15 1 178-8189 1 SHAFT AS16 1 178-8131 1 GEAR - 47 TEETH17 1 178-8132 2 PISTON - SEAL18 1 178-8134 2 SPRING19 1 178-8135 1 GEAR - 31 TEETH20 1 178-8136 1 GEAR - 34 TEETH21 1 178-8151 1 SPACER 22 1 178-8193 1 SPACER23 1 178-8200 2 SPRING - RETAINER24 1 178-8215 2 SLEEVE25 1 6V-8757 2 RING - RETAINING26 1 8T-1580 1 CUP - RLR BRG27 1 8T-1581 1 CONE - RLR BRG28 1 123-8905 1 CONE - SPL TAPERED29 1 123-8906 1 CUP - SPL TAPERED

(1 of 2)

16

POWERSYNCHRO TRANSMISSION - 4 SPEED178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)


17

POWERSYNCHRO TRANSMISSION - 4 SPEED216 - 2275 SHAFT AS - OUTPUT


GRAPHICNO


7T-2646 1 SPACER7T-6655 2 BEARING - RLR AS8T-1580 1 CUP - RLR BRG8T-1581 1 CONE - RLR BRG123-8907 1 CONE - SPL TAPERED123-8908 1 CUP - SPL TAPERED178-8144 1 DISC178-8145 1 SPACER178-8146 1 GEAR - 24 TEETH178-8147 1 SYNCHRONIZER178-8148 1 GEAR - 31 TEETH178-8149 1 GEAR - 40 TEETH178-8150 1 SYNCHRONIZER178-8152 1 GEAR - 48 TEETH178-8153 1 WASHER - THRUST178-8220 1 SPACER190-1575 4 BRG - SPL CGD R AS196-0187 1 RING - RETAINING206-4398 1 SHAFT - OUTPUT209-3765 2 BEARING - SPL AS238-7569 1 RING - RETAINING238-8539 1 RING - RETAINING6T-9163 1 SHIM6T-9164 1 SHIM6T-9165 1 SHIM6T-9166 1 SHIM

NO GRAPHIC

<END>

18

POWERSYNCHRO TRANSMISSION - 4 SPEED252 - 9715 VALVE GP - MODULATING


GRAPHICNO


1 1 164-2108 1 WASHER 2 1 218-2373 1 NUT3 1 226-9629 1 COIL AS4 1 253-0247 1 CARTRIDGE AS

108-2148 1 SEAL KIT

GRAPHIC # 1 <END>

19

POWERSYNCHRO TRANSMISSION - 4 SPEED278 - 0214 VALVE GP - RELIEF


GRAPHICNO


1 1 7X-4744 1 SEAL 2 1 6V-9178 1 SEAL3 1 106-9586 1 SEAL

GRAPHIC # 1 <END>

20

POWERSYNCHRO TRANSMISSION5 SPEED

323-8994

22

POWERSYNCHRO TRANSMISSION - 5 SPEED323 - 8994 TRANSMISSION AR

ENGINEERING MODEL: PT070 SERIAL NUMBER PREFIX: LKTREFNO

GRAPHICNO


311-4067 1 TRANSMISSION ARY 217-7217 1 DRIVE GP - FLEX 25

230-7551 1 CONVERTER AS293-5003 1 TC GP - BASIC

Y 312-3581 1 XMSN GP - DIRECT DRIVE 26Y - SEPARATE ILLUSTRATION

<END>

24

POWERSYNCHRO TRANSMISSION - 5 SPEED217 - 7217 DRIVE GP - FLEXPART OF 311-4067 TRANSMISSION AR

REFNO

GRAPHICNO


1 1 6V-8455 6 BOLT2 1 117-9713 1 PLATE3 1 111-7906 1 PLATE

GRAPHIC # 1 <END>

25


PART OF 311-4067 TRANSMISSION ARREFNO

GRAPHICNO


1 1 206-4395 1 CASE AS - FRONT9W-0717 4 PLUG147-0268 2 PLUG178-8231 1 XMSN CASE205-9244 1 PLUG

2 5 8T-7942 2 DOWEL3 5 7T-3253 4 DOWEL4 1 206-4394 1 CASE AS - REAR

9W-0717 5 PLUG5 5 206-4397 1 HOUSING6 4 178-8127 1 FLANGE 7 4 206-4391 1 ACTUATOR AS

123-2920 1 PLUG178-8235 1 ACTUATOR

8 4 200-6210 1 VALVE GP - SOL200-2371 1 SEAL KIT212-0061 1 FLANGE

9 4,5 216-2278 2 HOUSING AS147-0268 4 PLUG





Y 14 3 278-0214 1 VALVE GP - RLF 4115 3 121-7396 1 VALVE GP - CONVERTER RELIEF

6V-4589 1 SEAL - O-RING8L-2746 1 SEAL - O-RING

16 5 296-6617 1 HOUSING AS - VALVE17 4 206-4377 1 PLATE - COVER18 4 206-4382 1 HOUSING

Y 19 3 252-9715 3 VALVE GP - MDL 4020 4 239-7344 3 SCREW - CAP21 4,5 8C-5748 5 BOLT22 4,5 6V-5220 4 BOLT23 4,5 6V-5221 4 BOLT24 5 6V-5842 6 BOLT25 4 6V-5815 1 BOLT26 3 237-5185 4 PLUG - 9/16"27 3,4,5 9S-4191 18 PLUG - STOR28 1,4 6V-5217 9 BOLT29 4 9S-4182 1 PLUG - O-RING30 4 189-5746 1 SENSOR GP - SPD - A31 5 191-8304 1 SENSOR GP - SPEED32 4 191-8303 1 SENSOR GP - SPD A33 4 117-1385 2 SEAL - O-RING34 3,4,5 6V-5215 7 BOLT

(1 of 8)

26


(contd)REFNO

GRAPHICNO


35 3 132-5789 3 CLIP - LADDER36 4 085-8091 22 BOLT37 1 178-8159 1 REACTOR AS 38 1 178-8169 2 WASHER - THRUST39 1 178-8166 1 GEAR AS

195-7657 1 SEAL - O-RING40 1 178-8162 1 COVER GP

178-8164 1 SEAL - OIL221-6782 1 COVER AS - SUB

Y 41 1 178-8201 1 SHAFT AS - INPUT 34Y 42 1 178-8203 1 DRIVE AS - FAN 35Y 43 1 206-4379 1 SHAFT AS - PUMP DRIVE 36Y 44 1 178-8205 1 SHAFT AS - FORWARD / REVERSE 37

45 2 178-8138 1 GEAR - IDLER46 1 178-8206 1 COUNTERSHAFT AS

7T-2646 1 SPACER8T-1580 1 CUP - RLR BRG8T-1581 1 CONE - RLR BRG123-8907 1 CONE - SPL TAPERED123-8908 1 CUP - SPL TAPERED123-8913 2 BEARING - CAGED178-8139 1 CONTERSHAFT178-8140 1 GEAR - 46 TEETH178-8141 1 SYNCHRONIZER178-8218 1 SPACER6T-9163 1 SHIM6T-9164 1 SHIM6T-9165 1 SHIM6T-9166 1 SHIM

47 5 206-4396 1 TUBE AS48 5 206-4381 1 TUBE AS49 5 206-4375 1 TUBE AS50 1 206-4399 1 FORK - SHIFT51 1 206-4400 1 FORK - SHIFT52 3,4 214-8970 3 SENSOR AS

151-9274 1 RECEPTACLE KIT204-0728 1 SEAL - O-RING9X-3401 4 PIN - C0NNECTOR

53 2 206-4401 1 FORK - SHIFT54 3,4 8T-0328 6 WASHER55 3,4,5 238-7562 18 SCREW - CAP56 4 5P-4484 1 PLUG - MAGC O-RING57 4 216-2280 1 GUARD AS58 5 178-8237 1 PUMP GP - CHARGE59 5 178-8236 1 PUMP GP - SCAVENGE60 5 216-2283 1 INLET - SCAV PUMP61 5 216-2282 1 BAFFLE

Y 62 1 216-2276 1 SHAFT AS - OUTPUT 3963 5 9P-9150 2 WASHER64 4 6V-8675 2 BOLT65 1,3 238-7563 9 SCREW - CAP66 4 238-7564 1 SCREW - CAP

(2 of 8)

27


(contd)REFNO

GRAPHICNO


67 5 8T-0100 6 BOLT68 1 7T-3195 2 WASHER69 1 122-6787 2 YOKE AS

123-1377 1 GUARD70 1 6V-3668 2 BOLT71 1 5F-7054 1 SEAL - O-RING72 1 178-8137 1 WASHER73 1 6V-4248 1 BOLT74 3 237-5188 1 PLUG - EXPANSION75 5 5P-8347 2 BOLT76 2 206-4403 1 RAIL - SHIFT77 2 206-4402 1 RAIL - SHIFT78 2 206-4404 1 RAIL - SHIFT79 2 178-8128 1 ROD80 2 216-2264 3 PISTON81 2 221-6768 2 PISTON - INTO GEAR82 2 221-6767 2 PISTON - NEUTRAL83 2 216-2265 2 PISTON84 2 178-8171 1 QUAD RING85 2 014-5645 7 BALL86 2 216-2271 1 PLUG87 2 6Y-1341 3 SPRING88 2 178-8209 4 PISTON SEAL89 2 178-8210 3 PISTON SEAL90 2 221-6769 2 PISTON SEAL91 1,2 138-1645 3 PIN - SPRING92 2,5 120-9762 22 SEAL - O-RING93 5 238-6531 2 SEAL - O-RING94 2 005-0469 2 CUP - RLR BEARING95 2 7T-3034 1 SPACER96 1 302-8432 2 SEAL - LIP TYPE97 3 4F-4585 1 PLUG - CORE98 5 4P-7581 3 CLIP - LADDER99 4 316-1932 1 PLATE - COVER100 4 6V-8177 1 BOLT101 5 8T-0276 5 BOLT

SERVICEREPAIR

104 2 6T-9144 1 SHIM105 2 6T-9145 1 SHIM106 2 6T-9146 1 SHIM107 2 6T-9147 1 SHIM

Y - SEPARATE ILLUSTRATION

(3 of 8)

28



29



30



31



32



33

POWERSYNCHRO TRANSMISSION - 5 SPEED178 - 8201 SHAFT AS - INPUT


GRAPHICNO


1 1 6Y-1192 1 RING - SEAL2 1 178-8117 1 SHAFT - INPUT3 1 178-8118 1 GEAR - 47 TEETH4 1 178-8214 1 CIRCLIP5 1 190-1570 1 BRG - SPL NEED THR6 1 190-1572 1 RACE - THRUST7 1 209-3766 1 BEARING - SPL AS

GRAPHIC # 1 <END>

34

POWERSYNCHRO TRANSMISSION - 5 SPEED178 - 8203 DRIVE AS - FAN


GRAPHICNO


1 1 095-0941 1 RING - RETAINING2 1 104-3288 1 SHIM3 1 121-2059 1 SHIM4 1 121-2060 1 SHIM5 1 121-2061 1 SHIM6 1 122-1878 1 RING - SEAL7 1 122-1879 1 SPACER - BRG8 1 221-6795 1 GEAR - 38 TEETH9 1 178-8125 1 GEAR - 38 TEETH

10 1 178-8129 1 WASHER - THRUST11 1 178-8208 1 SEAL - OIL12 1 190-1576 1 BRG AS - SPL TPR13 1 206-4383 1 THRUST WASHER14 1 209-3764 1 BEARING - SPL AS15 1 221-6781 1 SHAFT AS16 1 7T-3035 1 PIN17 1 123-8905 1 CONE - SPL TAPERED18 1 123-8906 1 CUP SPL TAPERED

GRAPHIC # 1 <END>

35

POWERSYNCHRO TRANSMISSION - 5 SPEED206 - 4379 SHAFT AS - PUMP DRIVE


GRAPHICNO


1 1 6V-9097 1 BOLT - LOCKING2 1 7T-3195 1 WASHER3 1 061-7539 1 SEAL - O-RING4 1 095-0942 1 RING - RETAINING5 1 178-8120 1 GEAR - 44 TEETH6 1 178-8122 1 WASHER - THRUST7 1 178-8238 1 SHAFT8 1 190-1574 2 BRG - SPL CGD R AS9 1 206-4378 1 WASHER - THRUST

10 1 209-3768 1 BEARING - SPL AS11 1 221-6796 1 GEAR - 44 TEETH12 1 238-7568 2 RING - RETAINING13 1 7T-3035 1 PIN14 1 5P-3132 1 BEARING - ROLLER

GRAPHIC # 1 <END>

36

POWERSYNCHRO TRANSMISSION - 5 SPEED178 - 8205 SHAFT AS - FORWARD / REVERSE


GRAPHICNO


1 1 104-3288 1 SHIM2 1 121-0694 1 WASHER - THRUST3 1 121-2059 1 SHIM4 1 121-2060 1 SHIM5 1 121-2061 1 SHIM6 1 121-2500 2 WASHER - THRUST7 1 122-1879 1 SPACER - BRG8 1 122-1880 12 DISC - FRICTION9 1 122-1881 12 PLATE - CLUTCH

10 1 122-1882 2 PLATE - END11 1 122-1886 3 RING - SEAL12 1 122-3649 2 RING - RET INT13 1 123-8913 4 BEARING - CAGED14 1 172-5317 2 BEARING - SPL15 1 178-8189 1 SHAFT AS16 1 178-8131 1 GEAR - 47 TEETH17 1 178-8132 2 PISTON - SEAL18 1 178-8134 2 SPRING19 1 178-8135 1 GEAR - 31 TEETH20 1 178-8136 1 GEAR - 34 TEETH21 1 178-8151 1 SPACER 22 1 178-8193 1 SPACER23 1 178-8200 2 SPRING - RETAINER24 1 178-8215 2 SLEEVE25 1 6V-8757 2 RING - RETAINING26 1 8T-1580 1 CUP - RLR BRG27 1 8T-1581 1 CONE - RLR BRG28 1 123-8905 1 CONE - SPL TAPERED29 1 123-8906 1 CUP - SPL TAPERED

(1 of 2)

37

POWERSYNCHRO TRANSMISSION - 5 SPEED178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)


38

POWERSYNCHRO TRANSMISSION - 5 SPEED216 - 2275 SHAFT AS - OUTPUT


GRAPHICNO


7T-2646 1 SPACER7T-6655 2 BEARING - RLR AS8T-1580 1 CUP - RLR BRG8T-1581 1 CONE - RLR BRG123-8907 1 CONE - SPL TAPERED123-8908 1 CUP - SPL TAPERED178-8143 1 GEAR - 20 TEETH178-8144 1 DISC178-8145 1 SPACER178-8146 1 GEAR - 24 TEETH178-8147 1 SYNCHRONIZER178-8148 1 GEAR - 31 TEETH178-8149 1 GEAR - 40 TEETH178-8150 1 SYNCHRONIZER178-8152 1 GEAR - 48 TEETH178-8153 1 WASHER - THRUST190-1575 4 BRG - SPL CGD R AS196-0187 1 RING - RETAINING206-4398 1 SHAFT - OUTPUT209-3765 2 BEARING - SPL AS238-7569 1 RING - RETAINING238-8539 1 RING - RETAINING6T-9163 1 SHIM6T-9164 1 SHIM6T-9165 1 SHIM6T-9166 1 SHIM

NO GRAPHIC

<END>

39

POWERSYNCHRO TRANSMISSION - 5 SPEED252 - 9715 VALVE GP - MODULATING


GRAPHICNO


1 1 164-2108 1 WASHER 2 1 218-2373 1 NUT3 1 226-9629 1 COIL AS4 1 253-0247 1 CARTRIDGE AS

108-2148 1 SEAL KIT

GRAPHIC # 1 <END>

40

POWERSYNCHRO TRANSMISSION - 5 SPEED278 - 0214 VALVE GP - RELIEF


GRAPHICNO


1 1 7X-4744 1 SEAL 2 1 6V-9178 1 SEAL3 1 106-9586 1 SEAL

GRAPHIC # 1 <END>

41

Documents

PowerSynchro Transmission Parts Manual - JLG Industries · PDF filePowerSynchro Transmission Parts Manual Models TH336, TH337, TH406, TH407, TH414, TH514, TH417 S/N TDE00100 & After