Gehl CT7-23 TURBO Telescopic Handler SERVICE MANUAL(913234) – PDF DOWNLOAD

Gehl CT7-23 TURBO Telescopic Handler SERVICE MANUAL(913234) – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Gehl CT7-23 TURBO Telescopic Handler SERVICE MANUAL(913234) – PDF DOWNLOAD

General Information
Engine Description

• This Workshop Manual has been written to provide assistance in the service and overhaul of Perkins 1100 Series 4 cylinder engines. It should be used in conjunction with normal workshop practise and information contained in current service bulletins.
• Mention of certain accepted practices therefore, has been purposely omitted in order to avoid repetition. For overhaul procedures the assumption is made that the engine is removed from the application.
• The engine conforms with USA (EPA/CARB) Tier 2 and EEC stage 2 emissions legislation for agriculture, construction and industrial applications. Most of the general information which is included in the relevant Operator’s Manual has not been repeated in this workshop manual and the two publications should be used together. Where the information applies only to certain engine types, this is indicated in the text.
• The details of some operations will be different according to the type of fuel injection pump that is fitted. The specific pump type used can be found by reference to the manufacturer’s identification plate on the pump body but, generally, the type of pump fitted is as shown below:

 Delphi – DP210 Series
 Bosch – VP 30
 Bosch – EPVE.

• When reference is made to the “left” or “right” side of the engine, this is as seen from the flywheel end of the engine.
• Special tools have been made available and a list of these is given in Chapter 16, Special tools. Reference to the relevant special tools is also made at the beginning of each operation. POWERPART recommended consumable products are listed under
• “POWERPART recommended consumable products” on page 9. Reference to the relevant consumable products is also made at the beginning of each operation. Data and dimensions are included in Chapter 2, Specifications. Read and remember the “Safety precautions” on page 5. They are given for your protection and must be used at all times.

TABLE OF CONTENTS:

Gehl CT7-23 TURBO Telescopic Handler SERVICE MANUAL(913234) – PDF DOWNLOAD

Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
1 General information
Introduction 1
Engine views 2
Engine identification 3
Safety precautions 5
Engine lift equipment 7
Viton seals 8
POWERPART recommended consumable products 9
2 Specifications
Basic engine data 11
Data and dimensions 12
Thread sealant 29
Standard torque values 30
Specific torque values 31
Compression test data 34
General description 35
Atomiser cover
Operation 3-1 To remove and to fit 36
Rocker cover
Operation 3-2 To remove 37
Operation 3-3 To fit 38
Rocker assembly
Operation 3-4 To remove and to fit 39
Operation 3-5 To dismantle and to assemble 40
Operation 3-6 To inspect and to correct 40
Valve tip clearances
Operation 3-7 To check and to adjust 41
Valve springs
Operation 3-8 To change the valve springs (with cylinder head fitted) 42
Cylinder head assembly
Operation 3-9 To remove 44
Operation 3-10 To fit 46
Valves and valve springs
Operation 3-11 To remove 49
Operation 3-12 To fit 50
Operation 3-13 To inspect and to correct 51
Valve guides
Operation 3-14 To inspect 52
Operation 3-15 To remove 53
Operation 3-16 To fit 54
Cylinder head
Operation 3-17 To inspect and to correct 56
Operation 3-18 To correct a valve seat with a valve seat cutter 57
Operation 3-19 To fit valve seat inserts 59
General description 61
Big end bearing
Operation 4-1 To remove 63
Operation 4-2 To fit 64
Operation 4-3 To inspect 64
Piston and connecting rod
Operation 4-4 To remove 65
Operation 4-5 To fit 66
Operation 4-6 To check the piston height above the cylinder block 68
Piston rings
Operation 4-7 To remove 69
Operation 4-8 To fit 69
Piston and connecting rod assembly
Operation 4-9 To dismantle 70
Operation 4-10 To assemble 71
Operation 4-11 To check the length of a connecting rod 72
Piston and piston rings
Operation 4-12 To inspect 73
Connecting rod
Operation 4-13 To inspect 74
Partially finished small end bush
Operation 4-14 To remove and to fit 75
Piston cooling jets
Operation 4-15 To remove and to fit 76
Operation 4-16 To check the jet alignment 76
5 Crankshaft assembly
General description 77
Crankshaft pulley
Operation 5-1 To remove and to fit 78
Operation 5-2 To remove and to fit the rear end oil seal assembly 79
Operation 5-3 To remove and to fit a wear sleeve 83
Thrust washers
Operation 5-4 To check crankshaft end-float 84
Operation 5-5 To remove 85
Operation 5-6 To fit 86
Main bearings
Operation 5-7 To remove (with the crankshaft in position) 87
Operation 5-8 To fit (with the crankshaft in position) 88
Operation 5-9 To inspect 88
Crankshaft
Operation 5-10 To remove 89
Operation 5-11 To fit 90
Operation 5-12 To inspect 93
Operation 5-13 To remove 94
Operation 5-14 To fit 95
Balancer unit
Operation 5-15 To remove and to fit 96
Operation 5-16 To dismantle (oil pump) 98
Operation 5-17 To assemble (oil pump) 99
Operation 5-18 To inspect 100
6 Timing case and drive assembly
General description 101
Timing case cover
Operation 6-1 To remove 102
Operation 6-2 To fit 103
Mechanical fuel pump gear
Operation 6-3 To remove 104
Operation 6-4 To fit 106
Electronic fuel pump gear
Operation 6-5 To remove 108
Operation 6-6 To fit 109
Operation 6-7 To remove 110
Operation 6-8 To fit 111
Operation 6-9 To remove and fit idler gear bushes 113
Heavy duty idler gear assembly
Operation 6-10 To dismantle 114
Operation 6-11 To assemble 115
Camshaft gear
Operation 6-12 To remove and to fit 116
Front oil seal
Operation 6-13 To remove 117
Operation 6-14 To fit 118
Operation 6-15 To fit a wear sleeve 120
Timing case
Operation 6-16 To remove 121
Operation 6-17 To fit 122
Crankshaft gear
Operation 6-18 To remove and to fit 124
Camshaft and tappets
Operation 6-19 To remove 125
Operation 6-20 To fit 126
7 Cylinder block assembly
General description 129
Cylinder block
Operation 7-1 To dismantle 130
Operation 7-2 To assemble 131
Operation 7-3 To inspect 132
Cylinder bore
Operation 7-4 To inspect 133
8 Engine timing
General description 135
Operation 8-1 To set number 1 piston to TDC on the compression stroke 136
Operation 8-2 To check the timing of the Bosch VP30 fuel injection pump 137
Operation 8-3 To check the timing of the Bosch EPVE fuel injection pump 138
Operation 8-4 To adjust the timing of the Bosch EPVE fuel injection pump 139
Operation 8-5 To check the timing of the Delphi DP210 fuel injection pump 141
Operation 8-6 To check the valve timing 142
9 Aspiration system
General description 143
Aspiration system
Operation 9-1 To remove and to fit an exhaust elbow 145
Turbocharger side mounted
Operation 9-2 To remove 146
Operation 9-3 To fit 147
Operation 9-4 To check the operation of the waste-gate 149
Turbocharger faults 150
Open engine breather
Operation 9-5 To remove and to fit the breather pipe 152
Naturally aspirated engine breather
Operation 9-6 To remove and fit the breather pipe 154
Closed engine breather
Operation 9-7 To clean and to renew 156
10 Lubrication system
General description 157
Lubrication system flow diagram 158
Filter canister
Operation 10-1 To renew (canister type oil filter) 159
Operation 10-2 To renew (element type oil filter) 160
Operation 10-3 To remove and to fit 161
Operation 10-4 To remove 162
Operation 10-5 To fit 163
Dipstick tube
Operation 10-6 To remove and to fit 166
Oil strainer and suction pipe
Operation 10-7 To remove and to fit 167
Operation 10-8 To inspect and to correct 167
Lubricating oil pump assembly
Operation 10-9 To remove 168
Operation 10-10 To fit 168
Operation 10-11 To inspect 169
Relief valve
Operation 10-12 To remove and to fit the relief valve of the balancer 170
Operation 10-13 To remove and to fit the relief valve of the lubricating oil pump 171
Operation 10-14 To inspect the relief valve of the lubricating oil pump/balancer 171
11 Fuel system
General description 173
Cold start advance unit (KSB) 175
Typical fuel system 177
Fuel filter assembly
Operation 11-1 To renew 178
Atomisers
Operation 11-2 To identify a faulty atomiser 179
Operation 11-3 To remove 180
Operation 11-4 To fit 181
Fuel lift pump and filter assembly
Operation 11-5 To remove and to fit 182
Operation 11-6 To test 183
Operation 11-7 To test pressure regulator 183
Air in the fuel system
Operation 11-8 To eliminate air from the fuel system 184Bosch VP30 fuel injection pump
Operation 11-9 To remove 186
Operation 11-10 To fit 188
Bosch EVPE fuel injection pump
Operation 11-11 To remove 192
Operation 11-12 To fit 194
Delphi DP210 fuel injection pump
Operation 11-13 To remove 197
Operation 11-14 To fit 199
12 Cooling system
General description 201
Coolant flow diagram 202
Thermostat
Operation 12-1 To remove 203
Operation 12-2 To fit 204
Operation 12-3 To test 205
Coolant pump 206
Operation 12-4 To remove 206
Operation 12-5 To fit 207
Operation 12-6 To dismantle 208
Operation 12-7 To assemble 210
Fan
Operation 12-8 To remove and to fit 212
Fan drive
Operation 12-9 To remove and to fit 212
Lubricating oil cooler
Operation 12-10 To remove 213
Operation 12-11 To fit 213
Operation 12-12 To dismantle and to assemble 214
Operation 12-13 To remove and to fit a coolant by-pass pipe 215
13 Flywheel and housing
General description 217
Flywheel
Operation 13-1 To remove and to fit 217
Ring gear
Operation 13-2 To remove and to fit 218
Flywheel housing
Operation 13-3 To remove and to fit 219
14 Electrical equipment
Alternators
Operation 14-1 To check the drive belts 222
Operation 14-2 To adjust drive belt tension 223
Operation 14-3 To remove and to fit the drive belts 223
Operation 14-4 To remove and to fit the alternator 224
Operation 14-5 To maintain 224
Operation 14-6 Fault diagnosis for the alternator 225
Starter motors
Operation 14-7 To remove and to fit 228
Operation 14-8 To maintain the brush gear and the commutator 229
Operation 14-9 To test on the engine 229
Starting aid
Operation 14-10 To remove and to fit a glow plug 230
Operation 14-11 To check the glow plugs’ power supply continuity 231
Operation 14-12 To check the operation of the glow plug 232
Electronic components
Operation 14-13 To remove and to fit the Engine Control Module (ECM) 235
Operation 14-14 To remove and to fit the Voltage Load Protection Module (VLPM) 237
Operation 14-15 To program a new ECM 238
Operation 14-16 To remove and to fit the speed and timing sensor 239
Operation 14-17 To remove and to fit a pressure sensor 240
Operation 14-18 To remove and to fit a temperature sensor 242
Wiring harness
Operation 14-19 To repair a sensor connector 246
Operation 14-20 To repair a Diagnostic, a ECM, or a MIC connector 248
Operation 14-21 To connect a new wire or connector to the wiring harness 250
15 Auxiliary equipment
Power steering pump
Operation 15-1 To remove and to fit 252
Adaptor for a hydraulic pump or a steering pump
Operation 15-2 To remove and to fit 253
Operation 15-3 To dismantle 254
Operation 15-4 To assemble 255
Exhauster
Operation 15-5 To remove and to fit 256
16 Special tools
List of special tools 258