Clutch

MOTOR GRADERS 120H (2AN1(2AN1-UP, UP,3GR13GR1-UP, UP,4MK1-U 4MK1-UP, P,5FM15FM1-UP, UP,6NM16NM1-UP, UP,6YN16YN1-UP, UP,9FN19FN1UP,9YR1-UP), 135H (3YK1-UP,7MN1-UP,8WN1-UP,BDJ1-UP), 12H (2GS1(2GS1-UP, UP,2R12R1-UP, UP,2WR12WR1-UP, UP,4!R14!R1-UP, UP,4"M14"M1-UP, UP,5#M15#M1-UP, UP,8MN1-U 8MN1-UP), P), 140H (2#K1 (2#K1-UP, -UP,3AS1-U 3AS1-UP, P,3FR13FR1-UP, UP,5HM1-U 5HM1-UP, P,8JM1-U 8JM1-UP, P,8KM1-U 8KM1-UP, P,9$N19$N1-UP, UP,9#N19#N1UP), 143H (1A1-UP), 160H (2HS1(2HS1-UP, UP,2FM1-U 2FM1-UP, P,3GM13GM1-UP, UP,3HR13HR1-UP, UP,6WM16WM1-UP, UP,9!J19!J1-UP, UP,9JM19JM1-UP), UP), 163H (5AK1-UPM%$%R GRAD!RS

Problem: There have been reports of unexplained No! "lut"h "lut"h failures failures The No! "lut"h "lut"h is is the lo# ran$e "lut"h "lut"h and and is en$a$ed in all lo#er $ears %&'()' and &R(*R+ The No! "lut"h "lut"h is is uni,ue be"ause it is the onl- "lut"h "lut"h that that uses a balan"e piston The balan"e piston is used to .eep the "lut"h "lut"h from from self(en$a$in$ due to "entrifu$al for"e #hen the transmission is bein$ used in the hi$her $ears %!th and /th+ 'ifteen sprin$s and lube oil pressure in the balan"e piston "avit- are used to exert a for"e on the "lut"h "lut"h piston piston to .eep it from movin$ #hen the "entrifu$al for"e is hi$h The lube oil is feed into the balan"e piston "avit- throu$h a suppl- passa$e orifi"e %A+ in the output shaft Refer to the illustration

Solution: There are several thin$s that "ould "ause the No! "lut"h "lut"h to to fail 0isted belo# are some on the obvious items that #ould not onl- appl- to No! "lut"h "lut"h11 but to all "lut"h "lut"hes es &0o# "lut"h "lut"h pressure1 pressure1 "aused b- "ontrol valve problem or "lut"h "lut"h piston piston seal failure 2Slo# "lut"h "lut"h pressure pressure de"a- #hen the "lut"h "lut"h is is disen$a$ed1 "aused b- a blo".ed de"a- orifi"e in the "ontrol valve * 3lut"h 3lut"h piston piston "o".in$ in its bore The thin$s uni,ue to the No! "lut"h deal #ith the balan"e piston and are sometimes overloo.ed #hen investi$atin$ the failure The- are the balan"e piston seal and the lube oil feed orifi"e The balan"e piston seal "an "ause lea.a$e of the lube oil from the "avit- The feed orifi"e "an be"ome plu$$ed or partiall- blo".ed bdebris in the oil s-stem 4n both "ases1 the loss of lube oil pressure "an allo# the No! "lut"h "lut"h to to partiall- en$a$e "ausin$ "lut"h "lut"h slippa$e slippa$e 5hen investi$atin$ a No! "lut"h "lut"h failure1 failure1 spe"ial attention should be made to the above t#o items The balan"e piston seal should be inspe"ted for "uts or andama$e that #ould allo# oil lea.a$e The output shaft lube oil passa$e must be inspe"ted for debris 6se an inspe"tion li$ht in order to inspe"t for debris in the passa$e

N%$!& DO NOT use air pressure do#n the passa$e This "an 7am the debris ti$hter into the orifi"e and "ould $o undete"ted

COPYRIGHT 2001 CATERPILLAR ALL RIGHTS RESERVED

U'*& &9 98 2'M &2 &28 8 ES ES 2GS &28 &A0 &)*8 &A0 &298 2AN &98 2'M & ES 2GS & &98 98 ES 28S & &98 98 ES 28S &2 &28 8 ES 20R &2 &28 8 NA 25R &28 NA 25R &) &)98 98 NA 2;< &) &)98 98 NA 2;< &) &)98 98 ES *AS &) &)98 98 ES *AS &98 NA *GM & &98 98 NA *GM &* &*=8 =8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &2 &298 98 NA )M< &2 &298 98 NA )M< &2 &28 8 NA NA )?M &28 NA )?M & &*8 *8 NA =A< &*8 NA =A< &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &298 ES NM &2 &298 98 ES NM &2 &29 98 TM &298 TM & &98 98 ES 5M &298 NA >N &2 &298 98 NA >N &*=8 !MM &*=8 !MM &)98 /@M &) &)9 98 /@M &)98 &)*8 &) *8

ES /
/MN &2 &28 8 NA /MN &* &*=8 =8 /5N &* &*=8 =8 /5N &98 NA E@ & &98 98 NA E@

Illustration 1

g00

Illustration 2

View A-A

%&+ Sprin$ Test len$th  &9 mm %* in"h+ Test for"e  2)= B &= N %== B * lb+ 'ree len$th after test  &)9 mm %== in"h+ Outside diameter  *&= mm %&2) in"h+

%2+ 3able assembl%*+ Shim Outside diameter  )=9 mm %&!/ in"h+ Thi".ness  9=& mm %9929 in"h+

g00

%A+ Distan"e from "ab floorplate to the bottom ed$e of the pedal  = B  mm %*! B 92 in"h+ %C+ Distan"e from "enterline to "enterline of the rod ends  ))! B * mm %&! B 9& in"h+

Illustration 3

Cable Assembly

%)+ 'inal installation tor,ue  */ B ! Nm %2/ B = lb ft+ %=+ 'inal installation tor,ue  / B * Nm %!& B 2! lb in+

U'*&

&A0 &)*8 &A0 &298 2AN &98 2'M &98 2'M &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES 28S &28 ES 20R &28 ES 20R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA 2;< &)98 ES *AS &)98 ES *AS &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &298 NA )M< &298 NA )M< &28 NA )?M &28 NA )?M &*8 NA =A< &*8 NA =A< &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &28 =;M &298 ES NM &298 ES NM &298 TM &298 TM &98 ES 5M &98 ES 5M &298 NA >N &*=8 !MM &*=8 !MM &)98/@M &)98 /@M &)98 ES /
g00

Ad7ustment of the "lut"h pedal ma- be ne"essar- after repla"ement of an- of the follo#in$ items: me"hanism for the "lut"h pedal1 "lut"h "ontrol "able and transmission "ontrol valve for the "lut"h pedal 6se the follo#in$ information for the ad7ustment of the "lut"h pedal

Illustration 1

(1) Clutch control cable (2) Nut (3) Nut (4) Housing (5) Nut

g01

() !o" en"

&

0oosen 9S-1354 Nut %2+ and 9S-1354 Nut %*+ on 144-5323 3able As %&+  The "able end is lo"ated in 8D-9973 8ousin$ %)+ 

2

Ad7ust nut %2+ in order to sho# a minimum of t#o threads on "lut"h "ontrol "able %&+  Ti$hten nut %*+ 

* ) =

0oosen 6+-8187 Nut %=+ that is lo"ated on the end of "lut"h "ontrol "able %&+  S"re# 5P-7704 Rod End %+ to the end of "able %&+  Ad7ust 5P-7704 Rod End %+ until the rod end is approximatel- )/ mm %9& in"h+ from the end of the "able %&+  Ti$hten 6+-8187 Nut %=+ 

Illustration 2

g01

(#) $olt (%) &oc'nut () Clutch e"al

Illustration 3

*ransmission Control Val+e



Ad7ust "lut"h pedal %+  Pedal %+ "an be ad7usted in either of the follo#in$ t#o #a-s

g01

i

Pro"edure %A+  •

•

Clo". the front #heels Position the ma"hine on stands Ensure that all the drivin$ #heels #ill rotate freel- 0oosen lo".nut %/+ and ti$hten bolt %!+ to the bottom of the ad7ustment

•

Start the en$ine

•

Depress pedal %+  Shift the transmission into 'irst Speed 'or#ard

•

•

•

Slo#l- release pedal %+ until the tires start to rotate 8old pedal %+ in position 6ns"re# the pedal stop bolt %!+ so there is a =* mm %9*!= in"h+ $ap bet#een pedal %+ and bolt %!+  Depress pedal %+ and shift the transmission into Neutral En$a$e the par.in$ bra.e

•

Release pedal %+ 

•

8old bolt %!+ in position and ti$hten lo".nut %/+ 

•

Shut off the en$ine and remove the stands

i

Pro"edure %C+  •

•

•

•

•

•

•

•

•

Clo". the front #heels 0oosen lo".nut %/+ and ti$hten bolt %!+ to the bottom of the ad7ustment 3onne"t a pressure $au$e on the pressure test port %C+ of the valve assembl- for the transmission Start the en$ine En$a$e the servi"e bra.es in order to prevent the ma"hine from movin$ Depress pedal %+  Shift the transmission into &st 'or#ard Slo#lrelease pedal %+  Slo#l- depress the pedal %+ until the pressure drops to Fero and maintain the pedal position 6ns"re# the pedal stop bolt %!+ so there is a =* mm %9*!= in"h+ $ap bet#een pedal %+ and the bolt %!+  'ull- depress pedal %+  Shift the transmission into Neutral and en$a$e the par.in$ bra.e

•


•


•

Shut off the en$ine

U'*&

When testing and adjusting the transmission and power train, move the machine to an area clear of obstructions, with safe exhaust ventilation for the exhausts. Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, do the procedure that follows before testing and adjusting the transmission and power train.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. e prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. !ispose of all fluids according to local regulations and mandates.

Cefore -ou be$in the test1 refer to S-stems Operation1 Testin$ and Ad7ustin$1 Ma"hine Preparation for Troubleshootin$

Table 1

Required Tools Part Number

Description

1U-5482

Pressure Adapter roup

1

8T-0855

Pressure auge !0 to 4"000 #Pa !0 to 580 psi$$

1

&

Operate the ma"hine until the transmission oil is at operatin$ temperature of =& 3 %&2) '+

2

Stop the ma"hine on a hard level surfa"e En$a$e the par.in$ bra.e Turn off the en$ine Pla"e blo".s in front of the #heels and pla"e blo".s behind the #heels

Quanti

Illustration 1

g01

(1) Co+er ,or the transmission control +al+e

*

Remove "over %&+ from the transmission  Remove the differential drive shaft

Illustration 2

g01

*ransmission control +al+e (2) *est ort

)

Remove the "over on test port %2+  3onne"t 8$-0855 Pressure Gau$e %9 to )1999 .Pa %9 to =/9 psi++ to test port %2+ 

Illustration 3

i"e +iew o, clutch e"al (3) Clutch e"al

g01

(4) .e"al sto bolt (5) &oc'nut

Illustration 4

i"e +iew o, clutch control cable assembly/ (3) Clutch e"al () Clutch control cable (#) Val+e sool

=

Press "lut"h pedal %*+ a$ainst pedal stop bolt %)+  Move the transmission "ontrol lever to '4RST GEAR 'OR5ARD position and operate at half throttle



Depress "lut"h pedal %*+  The transmission should be turnin$ The pressure at test port %2+ should read a minimum of 2&2= .Pa %*&9 psi+  Press do#n "lut"h pedal %*+  Ad7ust pedal stop bolt %)+ in order to tou"h "lut"h pedal %*+ #hen pressure at test port %2+ rea"hes 999 .Pa %999 psi+ Ti$hten lo".nut %=+ 

g01

!

4f the pressure is "orre"t in Step 1 the modulation is #or.in$ "orre"tl- 4f the pressure is not "orre"t in Step 1 follo# Step /

/

Dis"onne"t "lut"h "ontrol "able %+ from valve spool %!+  i

Operate the ma"hine in '4RST GEAR 'OR5ARD at half throttle

i

Manuall- pull out valve spool %!+  The pressure $au$e should read 999 .Pa %999 psi+

i

Push valve spool %!+ into the valve bod- The spool should move freel- The spool should also be firm be"ause of the sprin$ The transmission drive shaft should start to turn in the ran$e of 999 .Pa %999 psi+ to /*) .Pa %&29 psi+

i 

The spool ma- need to be "leaned if the spool does not move freel- 4f the spool moves freel- and modulation o""urs in Step /1 "lut"h "ontrol "able %+ ma- need to be repla"ed

&9 'or more information on the "lut"h pedal1 refer to theS-stems Operation1 Testin$ and Ad7ustin$1 3lut"h Pedal ( Ad7ust

U'*&

&A0 &)*8 &A0 &)*8 &A0 &298 2AN &298 2AN &298 2AN &98 2' M &98 2'M &982'M &28 ES 2GS &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES 28S &98 ES 28S &28 ES20R &28 ES 20R &28 ES 20R &28 NA 25R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA2;< &)98 NA 2;< &)98 ES *AS &)98 ES *AS &)98 ES *AS &)98 NA *'R &)98 NA *'R &)98 NA *'R &98 NA *GM &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &28 )ER &298 NA )M< &298 NA )M< &298 NA )M< &28 NA )?M &28 NA)?M &28 NA )?M &*8 NA =A< &*8 NA =A< &*8 NA =A< &298 ='M &298 ='M &298 ='M &)*8

M. G./*.& 120H (SN& 2AN1-UP 4MK1-UP 3GR1-UP 5FM1-UP 6NM1-UP 6$M1-UP 9FN1-UP 9YR1-UP) 135H (SN& 3YK1-UP 7MM1-UP 8WN1-UP) 12H (SN& 2GS1-UP 4!R1-UP 5#M1-UP 2R1-UP 2WR1-UP 4"M1-UP 8MN1-UP) 140H (SN& 2#K1-UP 5HM1-UP 8JM1-UP 8KM1-UP 9$N1-UP 9#N1-UP 3FR1-UP 3AS1-UP) 143H (SN& 1A1-UP) 160H (SN& 2HS1-UP 3GM1-UP 9!J1-UP 2FM1-UP 6WM1-UP 9JM1-UP) 163H (SN& 5AK1-UP) Servi"e Ma$aFine SEPD9/9=1 &9 O"tober 299=1 Ad7ustment Pro"edure for the 4n"hin$ Pedal Disre$ard this arti"le Refer to the information belo#

Ad7ustment of the in"hin$ pedal ma- be ne"essar- after repla"ement of an- of the follo#in$ items: me"hanism for the in"hin$ pedal1 in"hin$ "able and transmission "ontrol valve for the in"hin$ pedal 6se the follo#in$ information for the ad7ustment of the in"hin$ pedal

Illustration 1

(1) 0nching cable (2) Nut (3) Nut

g00

(4) Housing (5) Nut () !o" en"

&

0oosen 9S-1354 Nut %2+ and 9S-1354 Nut %*+ on 144-5323 3able %&+ The "able end is lo"ated in 8D-9973 8ousin$ %)+

2

Ad7ust nut %2+ in order to sho# a minimum of t#o threads on in"hin$ "able %&+ Ti$hten nut %*+ 

* ) =

0oosen 6+-8187 Nut %=+ that is lo"ated on the end of in"hin$ "able %&+  S"re# 5P-7704 Rod End %+ to the end of "able %&+ Ad7ust 5P-7704 Rod End %+ until the rod end is approximatel- )/ mm %9& in"h+ from the end of the "able %&+  Ti$hten 6+-8187 Nut %=+ 

Illustration 2

g01

(#) $olt (%) &oc'nut () 0nching e"al

Illustration 3

g01

*ransmission Control Val+e



Ad7ust in"hin Ad7ust in"hin$ $ pedal pedal %+ %+ Pedal Pedal %+ %+ "an be be ad7uste ad7usted d in eithe eitherr of the the follo#i follo#in$ n$ t#o t#o #a-s i

Pro"edure %A+  •

•

Clo". the front #heels Position the ma"hine on stands Ensure that all the drivin$ #heels #ill rotate freel- 0oosen lo".nut %/+ and ti$hten bolt %!+ to the bottom of the ad7ustment

•

Start the en$ine

•

Depress pedal %+ Shift the transmission into 'irst Speed 'or#ard

•

•

•

Slo#l- release pedal %+ until the tires start to rotate 8old pedal %+ in position 6ns"re# the pedal stop bolt %!+ so there is a =* mm %9*!= in"h+ $ap bet#een pedal %+ and bolt %!+  Depress pedal %+ and shift the transmission into Neutral En$a$e the par.in$ bra.e

•


•


•

Shut off the en$ine and remove the stands

i

Pro"edure %C+  •

•

•

•

•

•

•

•

•

•

Clo". the front #heels 0oosen lo".nut %/+ and ti$hten bolt %!+ to the bottom of the ad7ustment 3onne"t a pressure $au$e on the pressure test port %C+ of the valve assembl- for the transmission transmission Start the en$ine En$a$e the servi"e bra.es in order to prevent the ma"hine from movin$ Depress pedal %+ Shift the transmission into &st 'or#ard Slo#lrelease pedal %+  Slo#l- depress the pedal %+ until the pressure drops to Fero and maintain the pedal position 6ns"re# the pedal stop bolt %!+ so there is a =* mm %9*!= in"h+ $ap bet#een pedal %+ and the bolt %!+  'ull- depress pedal %+ Shift the transmission into Neutral and en$a$e the par.in$ bra.e Release pedal %+ 

•


•

Shut off the en$ine

U'*&

&A0 &298 2AN &98 2'M &2 &28 8 ES ES 2GS & &98 98 ES 28S &28 NA 25R &) &)98 98 NA 2;< &) &)98 98 ES *AS & &98 98 NA *GM &*=8 NA *>< &28 )ER &2 &298 98 NA )M< &2 &28 8 NA )?M &*8 NA =A< &298='M &)98 =8M &298 TM &2 &298 98 NA >N &8 NA ;@ &*=8 !MM &) &)8 8 NA !5@ &)98 /@M &2 &28 8 NA /MN &*=8 /5N &98 NA E@ &98 @M &) &)98 98 NA TN &2 &298 98 ES >R &)98 NA ;N &*=8CD@ &)98 ?;8 &28 ?;@ &98 ?;< &)*8 &) *8

Illustration 1

The transmission modulator "ontrol %pedal+ is on the floor of the operator "ompartment and to the left of the steerin$ "onsole The transmission modulator pedal disen$a$es the po#er to the #heels Depress the transmission modulator pedal #hen -ou start the ma"hine and #hen -ou stop the ma"hine Also1 depress the transmission modulator pedal #hen -ou "han$e the dire"tion of the ma"hine

g00

Release the transmission modulator pedal in order to re(en$a$e the po#er to the #heels N*& 6se the transmission modulator pedal to in"h the ma"hine

U'*&

&A0 &98 2'M &2 &28 8 ES ES 2GS & &98 98 ES 28S &2 &28 8 ES 20R &28 NA 25R &) &)98 98 NA 2;< &) &)98 98 ES *AS & &98 98 NA *GM &*=8 NA *>< &28 )ER &2 &298 98 NA )M< &2 &28 8 NA )?M &*8 NA =A< &298='M &)98 =8M &28 =;M &2 &298 98 ES NM &298 TM &98 ES 5M &*=8 !MM &)98 /@M &) &)98 98 ES /R &) &)98 98 NA ;N &)*8 &) *8

Illustration 1

chematic o, the Circuit o, the hi,t &e+er

N*& Refer to the Ele"tri"al S-stem S"hemati" in the Servi"e Manual of the ma"hine for the "orre"t s"hemati"

g00

Problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the ma"hine to respond in"orre"tl- to the a"tions of the lever Some problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the transmission to remain in the present speed and dire"tion #hen a problem is dete"ted Other problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the transmission to shift to neutral &

+* * '' i

6se the 3aterpillar Ele"troni" Te"hni"ian %ET+ to vie# the status Group & Gear 0ever Parameters

i

A"tuate the transmission shift lever throu$h all speeds in for#ard and reverse Herif- the positions on the displa- of the ET

i

Operate the ma"hine in all speeds and all dire"tions All speeds and all dire"tions ma- not be available

!**/ R*':: The failure is NOT present R*':': %K - The failure is NOT present Suspe"t an intermittent failure

•

STOP •

2

N%$ %K - The failure is still present Note the positions that #ere in"orre"t on the ET s"reen Pro"eed to Step 2

;*< * .=*'' i

3he". the harness "onne"tors and the harness from the transmission dire"tion and speed "ontrol lever to the po#er train ele"troni" "ontrol module %E3M+

i

Thorou$hl- inspe"t the "onne"tors for the transmission dire"tion and speed "ontrol lever and the "onne"tors for the po#er train E3M

i

Hisuall- inspe"t the harness #irin$ from the transmission dire"tion and speed "ontrol lever to the po#er train E3M

i

6se the ET to vie# the status Group & Gear 0ever Parameters

i

A"tuate the transmission dire"tion and speed "ontrol lever throu$h all speeds in for#ard and reverse Herif- the positions on the displa- for the ET

i

Operate the ma"hine in all speeds and all dire"tions All speeds and all dire"tions ma- not be available

!**/ R*':: The harness and harness "onne"tors are "orre"t The fault is NOT present R*':':

•

•

*

%K - The harness and the harness "onne"tors are "orre"t The fault is NOT present Pro"eed to Step * N%$ %K - The harness andIor the harness "onne"tors are NOT "orre"t and the fault is still present Repair the ma"hine harness andIor the harness "onne"tors 4f ne"essar-1 repla"e the ma"hine harness andIor the harness "onne"tors Ensure that all the seals are properl- in pla"e Also1 "he". that the "onne"tors mate "ompletel- Herif- that the repair eliminates the problem 3lear all dia$nosti" "odes STOP

;*< * >:* i

Dis"onne"t the transmission dire"tion and speed "ontrol lever from the ma"hine harness

i i

Turn the .e- start s#it"h to the ON position Measure the volta$e bet#een pin 2 and pin &= of the 2)(pin "onne"tor for the transmission dire"tion and speed "ontrol lever

!**/ R*':: S-stem volta$e is present R*':': %K - S-stem volta$e is present Pro"eed to Step )

•

•

)

N%$ %K - S-stem volta$e is NOT present There is a problem #ith the po#er suppl- to the transmission dire"tion and speed "ontrol lever 3he". the fuse for the transmission dire"tion and speed "ontrol lever and the asso"iated harness STOP

;*< * ==? i

Ensure that the .e- start s#it"h is in the O'' position

i

The transmission dire"tion and speed "ontrol lever and the po#er train E3M are dis"onne"ted from the ma"hine harness

i

3he". for "ontinuit- from pin 2 to all a"tive pins on the 2)(pin "onne"tor of the transmission dire"tion and speed "ontrol lever

!**/ R*':: 3ontinuit- is NOT present R*':': •

•

=

%K - 3ontinuit- is NOT present Pro"eed to Step = N%$ %K - 3ontinuit- is present The problem is in the harness Repair the harness or repla"e the harness

;*< * ==? i

3he". for "ontinuit- from pin &= to all a"tive pins on the 2)(pin "onne"tor of the transmission dire"tion and speed "ontrol lever

!**/ R*':: 3ontinuit- is NOT present

R*':': %K - 3ontinuit- is NOT present Pro"eed to Step 

•

•



N%$ %K - 3ontinuit- is present The problem is in the harness Repair the harness or repla"e the harness STOP

;*< * .='@''= /.*= =/ '**/ =.: :*>*. i i i i

Re"onne"t the "onne"tors for the po#er train E3M 3reate a 7umper #ire that "an short from pin 2 to t#o of the other pins on the "onne"tor for the transmission dire"tion and speed "ontrol lever The .e- start s#it"h should be in the ON position 6se the ET to displa- Group & Gear 0ever Parameters 3ondu"t the follo#in$ items and vie# the parameters on the ET Refer to Table & for the "orre"t "onne"tions of the 7umper #ire to the harness for the transmission dire"tion and speed "ontrol lever

Table 1

Check of the ear Parameters! "umper #ire Connections! $%&

round Contact

Directional Contact

'peed Contact

Indicated e

2

11

3

%1%

2

11

4

%2%

2

11

5

%3%

2

11

6

%4%

2

11

7

%5%

2

11

8

%6%

2

11

9

%7%

2

11

10

%8%

2

12

3

%1&%

2

12

4

%2&%

2

12

5

%3&%

!1$

2

12

6

%4&%

2

12

7

%5&%

2

12

8

%6&%

2

12

9

%7&%

2

12

10

%8&%

2

14

10

%'%

All (onta(ts are on t)e )arness *or t)e s)i*t le+er,

iii

!**/ R*':: All the $ear parameters read the proper $ear

iv

R*':': •

•

%K - All $ear parameters read the proper $ear Repla"e the transmission dire"tion and speed "ontrol lever and verif- "orre"t operation STOP N%$ %K - All $ear parameters DO NOT read the proper $ear 4t is unli.el- that the po#er train E3M is fault- Exit this pro"edure and perform this 34D 'M4 a$ain 4f the "ause of the fault is not found1 repla"e the po#er train E3M Refer to Testin$ and Ad7ustin$1 Ele"troni" 3ontrol Module %Po#er Train+ ( Repla"e for more information on repla"in$ the po#er train E3M STOP

U'*&

2'M &28 )ER &298 ='M &)98 =8M &298 TM &*=8 !MM &)98 /@ M &*=8 /5N &98@M &)98 ?;8 &28 ?;@ &98 ?;< &98

Illustration 1

The transmission dire"tion and speed "ontrol %lever+ is to the ri$ht of the operatorJs seat N*& >ou must move the lever from the PAR<4NG CRA
1 ( 'irst Speed 2 ( Se"ond Speed 3 ( Third Speed 4 ( 'ourth Speed 5 ( 'ifth Speed 6 ( Sixth Speed 7 ( Seventh Speed 8 ( Ei$hth Speed

g00

Neutral $*& - o+e t)e le+er to t)e 'UT&A position .)en ou ()ange dire(tion or .)en ou are preparing to par# t)e /a()ine, A stopped /a()ine on a s/oot) )oriontal sur*a(e s)ould not /o+e .)en t)e le+er is in t)e 'UT&A position, Re+erse $,& - o+e t)e le+er to t)e rig)t and pull ba(# t)e le+er to t)e desired speed, T)e /a()ine .ill /o+e in re+erse,

1 ( 'irst Speed 2 ( Se"ond Speed 3 ( Third Speed 4 ( 'ourth Speed 5 ( 'ifth Speed 6 ( Sixth Speed

U'*&

2'M &98 2'M &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES 28S &28 ES 20R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA 2;< &)98 ES *AS &)98 ES *AS &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &298 NA )M< &298 NA )M< &28 NA )?M &28 NA )?M &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &298 ES NM &298 ES NM &298 TM &298 TM &98 ES 5M &298 NA >N &298 NA >N &*=8 !MM &*=8 !MM &)98 /@M &)98 /@M &)98 ES /R &98

Illustration 1

%&+ Tor,ue for *= bolts  *9 B ) Nm %22 B * lb ft+ %2+ Tor,ue for pressure s#it"h assembl-  *= B * Nm %2= B 2 lb ft+ %*+ Tor,ue for temperature s#it"h assembl-  & B * Nm %&) B 2 lb ft+ %)+ Tor,ue for adapter  &) B ) Nm %&9 B * lb ft+ %=+ Tor,ue for ei$ht nipple assemblies  &) B ) Nm %&9 B * lb ft+ %+ Sprin$ Test len$th  &2!9 mm %9=99 in"h+ Test for"e  &! B 9& N %9*/ B 992 lb+ 'ree len$th after test  &9 mm %9!= in"h+ Outside diameter   m %9*/ in"h+

%A+ Position for adapter %)+  /9 B = de$rees

U'*& &9 98 2'M &2 &28 8 ES ES 2GS &28 &A0 &)*8 &A0 &298 2AN &98 2'M & ES 2GS & &98 98 ES 28S & &98 98 ES 28S &2 &28 8 ES 20R &2 &28 8 ES E S 20R &28 NA 25R &2 &28 8 NA 25R &) &)98 98 NA 2;< &) &)98 98 NA 2;< &) &)98 98 ES *AS &)98 ES *AS & &98 98 NA *GM & &98 98 NA *GM &* &*=8 =8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &2 &298 98 NA )M< &2 &298 98 NA )M< &2 &28 8 NA NA )?M &28 NA )?M & &*8 *8 NA =A< &*8 NA =A< &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &28 =;M &298 &2 98 ES NM &2 &298 98 ES NM &298 TM &298 TM & &98 98 ES 5M &98 ES 5M &2 &298 98 NA >N &*=8 !MM &*=8 !MM &)98/@M &)98 /@M &)98 ES /
g00

Illustration 1

(1) *ransmission control +al+e (2) *ransmission wiring harness

Transmission "ontrol valve %&+ provides the proper flo#s and the proper pressures in order to en$a$e the desired transmission "lut"h "lut"hes es The transmission "ontrol valve is lo"ated on the left side of the transmission "ase The transmission "ontrol valve is "onstru"ted of t#o "ast aluminum valve bodies1 three "ast aluminum manifolds1 three steel plates1 several aluminum spools1 and mis"ellaneous steel parts

g01

Illustration 2

(3) anual mo"ulation +al+e (4) ain relie, +al+e

g01

(5) .riority re"ucing +al+e () o"ulating re"ucing +al+es (#) olenoi" +al+es

The transmission "ontrol valve "onsists of the follo#in$ "omponents: one main relief valve %)+1 one priorit- redu"in$ valve %=+1 one manual modulation valve %*+1 #irin$ harness %2+1 ei$ht solenoid valves %!+ and ei$ht modulatin$ redu"in$ valves %+

M= R*:* +:>*

Illustration 3

(4) ain relie, +al+e (%) ool () .assage to transmission oil cooler

g01

(1) ri,ice (11) lug (12) A"ustment screw an" loc'nut (13) ring

The main relief valve is lo"ated in the top front ,uadrant of the inside valve bod- Main relief valve %)+ provides a restri"tion in the flo# that sets the outlet pressure of the transmission pump The oil that b-passes the main relief valve flo#s to transmission oil "ooler line %+  The main relief valve %)+ has a slu$ %&&+ that is "onne"ted to the outlet flo# borifi"e %&9+ that is "ontained in spool %/+ Slu$ %&&+ "reates a rea"tion "hamber Oil in the rea"tion "hamber a"ts a$ainst a sprin$ in order to set the pressure Sprin$ %&*+ has an external ad7ustment s"re# and a lo".nut %&2+ that varies the valve pressure settin$ per turn

P..? R*/= +:>*

Illustration 4

(4) ain relie, +al+e (5) .riority re"ucing +al+e (14) ool

g01

(15) .assage (1) ri,ice (1#) lug (1%) rings

The priorit- redu"in$ valve is lo"ated at the top rear ,uadrant of the inside valve bod- Priorit- redu"in$ valve %=+ redu"es the supplpressure throu$h passa$e %&=+ to the sele"tor valves and solenoids The priorit- redu"in$ valve also provides priorit- to the sele"tor valves and to the solenoids that are over the fill for the transmission "lut"h or over the modulation for the transmission "lut"h The priorit- redu"in$ valve %=+ re"eives oil in parallel to main relief valve %)+ Slu$ %&!+ provides a rea"tion "hamber that is "onne"ted to the pump suppl- flo# from the solenoid in passa$e %&=+ b- orifi"e %&+ The oil is "ontained in spool %&)+ and balan"es a$ainst the for"e of sprin$s %&/+ in order to set the pressure N*& There is a plu$ that is lo"ated in the bottom of the manifold that is for the transmission "ontrol valve Remove the plu$ and install a suitable pressure $au$e in order to measure the pump suppl- flo# from the solenoid and the priorit- of the redu"in$ pressure

M=: M/:= +:>* (== +:>*)

Illustration 5

(3) anual mo"ulation +al+e (1) Connection ,or .ush-.ull cable (2) to (21) .lunger (22) .iston (23) rings (24) ool (25) lug (2) A"ater (2#) .ort ,or temerature sensor

The manual modulation valve is lo"ated in the uppermost portion of the outermost valve bod-

g01

Manual modulation valve %*+ is "onne"ted to the pedal #ith a push(pull "able %&+ The manual modulation valve disen$a$es or the manual modulation valve redu"es the po#er that is transmitted to the drive #heels This is a""omplished b- redu"in$ the supplpressure to the dire"tional modulatin$ redu"in$ valves Modulation valve %*+ "onsists of plun$er %2&+1 stop %29+1 piston %22+1 spool %2)+1 sprin$s %2*+1 and slu$ %2=+ 4n order to have full pressure at the dire"tion "lut"hes1 the transmission modulator "ontrol %pedal+ must not be a"tivated

Illustration 6

&ocation o, the transmission mo"ulator control (e"al)

Depressin$ the pedal redu"es the supplpressure to the modulatin$ redu"in$ valve for the dire"tion "lut"h The pedal is lo"ated in the "ab 'ull- depressin$ the pedal redu"es supplpressure to 9 .Pa %9 psi+ Slo#l- releasin$ the pedal allo#s supplpressure to $raduall- in"rease follo#in$ pedal movement to approximatel- !== .Pa %&&9 psi+ On"e the pressure rea"hes !== .Pa %&&9 psi+1 the pressure automati"all- modulates to a minimum of 29/= .Pa %*99 psi+ after approximatel- 92 se"onds Temperature sensor %2!+ is mounted into an adapter %2+ in the manual modulation valve Temperature sensor %2!+ monitors the oil temperature of the drive train

g00

M/:= R*/= +:>*

Illustration 7

(#) olenoi"

g01

(2%) elector sool (2) ecay ori,ice (3) &oa" iston (31) o"ulation ori,ice (32) !e"ucing sool (33) lug (34) rings

There are ei$ht modulation redu"in$ valves 'our of the modulation redu"in$ valves are lo"ated in ea"h valve bod- These four provide individual pressure "ontrol for the "lut"h The modulation redu"in$ valve "onsists of sele"tor spool %2/+1 load piston %*9+1 redu"in$ spool %*2+1 slu$ %**+1 modulation orifi"e %*&+1 de"aorifi"e %2+ and sprin$s %*)+ Ea"h valve provides a uni,ue pressure for ea"h transmission "lut"h throu$h different "ombinations of the sprin$s and the orifi"es To pressuriFe a transmission "lut"h1 solenoid %!+ is ener$iFed #ith a 2) volt si$nal from the ele"troni" "ontrol module %E3M+ The E3M is a"tivated b- the transmission shift lever This "auses sele"tor spool %2/+ to move to#ard the "enter of the valve This "auses load piston %*9+ and redu"in$ spool %*2+ to move a#afrom the "enter of the valve This #ill allo# oil from the main relief valve to pass a"ross the redu"in$ valve in order to fill the "lut"h 5hen the "lut"h is full of oil1 the oil flo#s throu$h modulation orifi"e %*&+ that is "ontained in redu"in$ spool %*2+ This moves load piston %*9+ to#ard the sele"tor spool %2/+1 "ompressin$ the modulation sprin$ %*)+ and "ausin$ the transmission "lut"h pressure to $raduall- rise 4n order to disen$a$e the transmission "lut"h1 the solenoid is de(ener$iFed This allo#s sele"tor spool %2/+ to move a#a- from the "enter of the valve The sele"tor spool "onne"ts the load piston "avit- in order to drain throu$h de"a- orifi"e %2+ that is "ontained in the valve bod- This #ill $raduall- redu"e the "lut"h pressure

S:*=/ +:>*'

Illustration 8

(#a) olenoi" (#b) olenoi" (#c) olenoi"

g01

(#") olenoi" (#e) olenoi" (#,) olenoi" (#g) olenoi" (#h) olenoi" (35) ee" selector sool (3) ee" range selector sool (3#) irection selector sool

Solenoid valves %!+ "onne"t pressuriFed oil from the priorit- redu"in$ valve to the "orrespondin$ sele"tor spool The solenoid valves are 2) volt ONIO'' poppet t-pe valves These poppet t-pe valves are a"tivated Table 1

ear

'olenoids

Clutches

8-

!$" !$" !$

!1$" !8$" !5$

7-

!$" !$" !$

!1$" !8$" !4$

6-

!$" !$" !$

!2$" !8$" !4$

5-

!$" !$" !$

!1$" !8$" !6$

4-

!$" !$" !$

!1$" !5$" !7$

3-

!$" !$" !$

!2$" !5$" !7$

2-

!$" !$" !$

!2$" !4$" !7$

1-

!$" !$" !$

!1$" !6$" !7$

'

!$" !$

!8$" !5$

P

!$" !$

!8$" !5$

1-&

!A$" !$" !$

!3$" !6$" !7$

2-&

!A$" !$" !$

!3$" !4$" !7$

3-&

!A$" !$" !$

!3$" !5$" !7$

4-&

!A$" !$" !$

!3$" !8$" !6$

5-&

!A$" !$" !$

!3$" !8$" !4$

6-&

!A$" !$" !$

!3$" !8$" !5$

S**/ R=* S*:*. S:' Speed ran$e sele"tor spools %*+ tri$$er the be$innin$ of modulation Speed ran$e sele"tor spools %*+ also tri$$er the be$innin$ of the de"rease of the "lut"h pressure The speed ran$e sele"tor spool also prevents the appli"ation of t#o speed ran$e $ears at a time Ener$iFin$ solenoid %!h+ "auses speed ran$e sele"tor spool %*+ to move to#ard the "enter of the valve This blo".s the flo# of oil to disen$a$ed solenoid %!d+ Also1 this drains the suppl- port of disen$a$ed solenoid %!d+ 

D.*= S*:*. S:' The dire"tion sele"tor spools are lo"ated in the front "enter re$ion of the outer valve bod- The dire"tion sele"tor spools are part of "lut"h stations %A+1 %C+1 and %3+  Dire"tion sele"tor spools %*!+ tri$$er the be$innin$ of the modulation or the be$innin$ of the de"rease in "lut"h pressure The dire"tion sele"tor spools also prevent the appli"ation of t#o dire"tion "lut"hes at a time Ener$iFin$ solenoid %!b+ "auses dire"tion sele"tor spool %*!+ to move to#ard the "enter of the valve This blo".s the flo# of oil to disen$a$ed solenoid %!a+ and %!"+ Also1 this drains the suppl- port of disen$a$ed solenoid %!a+ and %!"+ 

S**/ S*:*. S:' The speed sele"tor spools that are lo"ated in the front "enter re$ion of the inner valve bod- are part of "lut"h stations %E+1 %'+1 and %G+  Speed sele"tor spools %*=+ tri$$er the be$innin$ of modulation or the be$innin$ of the de"rease in "lut"h pressure The speed "lut"h sele"tor spools also prevent the

appli"ation of t#o speed "lut"hes at a time Ener$iFin$ solenoid %!f+ "auses speed sele"tor spool %*=+ to move to#ard the "enter of the valve This blo".s the flo# of oil to disen$a$ed solenoids %!e+ and %!$+ Also1 this drains the suppl- port of disen$a$ed solenoids %!e+ and %!$+ 

M=:/ P.' . * $.='@''= ;=.: +:>*

Illustration 9

(3%) .assage ,or clutch 2 (3) &ubrication (4) 6le+ate" "rain (41) .assage ,rom the hy"raulic um (42) .assage to the oil cooler (43) rain (44) .assage ,or clutch % (45) Clutch # at station (H) (4) Clutch 5 at station (7) (4#) Clutch  at station (8) (4%) .assage ,or clutch 4 (4) .assage ,or clutch 3 (5) .assage ,or clutch 1 (51) .ilot ressure

U'*&

&A0 &298 2AN &98 2'M &28 ES 2GS &98 ES 28S &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298='M &)98 =8M &298 TM &298 NA >N &*=8 !MM &)98 /@M &28 NA /MN &*=8 /5N &98 NA E@ &98 @M &)98 NA TN &298 ES >R &)98 NA ;N &*=8 CD@ &)*8

g01

S* U P.*/.*'

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, do the procedure that follows before testing and adjusting the transmission and power train.

1 Move the ma"hine to a smooth horiFontal lo"ation Move a#a- from #or.in$ ma"hines and personnel 2 0o#er all implements to the $round 3 Put the transmission "ontrol lever in the Par.in$ Cra.e ON position Stop the en$ine 4 Put blo".s in front of and behind the #heels 5 Permit onl- one operator on the ma"hine
Al#a-s ma.e visual "he".s first 3he". the operation of the ma"hine and then "he". #ith instruments

=./=

%&+ Ele"troni" 3ontrol Module

Motor Graders #ith the "ountershaft transmission in"lude an onboard ele"troni" "ontroller referred to as an Ele"troni" 3ontrol Module %E3M+ The E3M should improve the abilit- of the me"hani" to determine #hen and #here a failure has o""urred T#o methods of testin$ and troubleshootin$ the transmission s-stem from the E3M are provided The first %and the re"ommended+ method of "he".in$ s-stem status and dia$nosti"s is #ith the use of the /T(/! Ele"troni" 3ontrol Anal-Fer Pro$rammer %E3AP+ or an ET Coth the E3AP and the ET "an also be used to pro$ram the transmission E3M 5ith the use of a dia$nosti" tool1 a variet- of useful information is readil- available 3urrent operatin$ information "an be obtained su"h as: transmission output speed1 $ear lever position1 batter- volta$e1 et" Also1 from the dia$nosti"s s"reen1 transmission dia$nosti" "odes are available to help identif- the sour"e of an- ele"tri"al failure Transmission dia$nosti"s "an also be obtained from the transmission E3M #ithout the use of E3AP or ET This method #ill provide the same dia$nosti" "odes available from E3AP and ET This method #ill not provide "urrent displa- status "apabilit- available from E3AP or ET

U'= ;*.::. !:*.= $*== (!$) $ D**.@=* S*.>* ;/*'

ET 3onne"tions

%&+ Datalin. servi"e "onne"tor ( at fuse panel %2+ !?(&=!9 3able %*+ !?(&!99 3ommuni"ation Adapter %#ith NE?G)=2* 3ommuni"ation Adapter Soft#are installed+ %)+ !?(&// 3able %=+ 4CM "ompatible personal "omputer #ith 3aterpillar Ele"troni" Te"hni"ian soft#are installed %see note belo#+

N%$!& 3aterpillar Ele"troni" Te"hni"ian is a soft#are pro$ram that runs on an 4CM "ompatible personal "omputer To use 3aterpillar Ele"troni" Te"hni"ian %ET+1 order ET Sin$le 6se Pro$ram 0i"ense soft#are1 @ERD2&2)K the information and re,uirements sheet1 @E8P&92K the RS2*2 "onne"tion "able1 !?(&// and the Data Subs"ription1 @ERD2&)2 The re,uirements and information sheet lists the hard#are re,uired and the features of ET

The servi"e tool ET is not needed to determine or "lear servi"e "odes1 but it ma.es the tas.s easier and faster ET "an also displa- servi"e "ode histor- information These features ma.e ET a useful troubleshootin$ tool ET "onne"ts to the datalin. servi"e "onne"tor #hi"h is round and has  "onta"ts The data lin. servi"e "onne"tor is lo"ated next to the .e- start s#it"h 'or more information1 see the Ele"tri"al S-stem S"hemati" in the ma"hine Servi"e Manual To use the ET servi"e tool1 "hoose the MA384NE '6N3T4ONS option from the main menu The next menu is a list of the Ele"troni" 3ontrol Modules %E3M+ installed on the ma"hine 3hoose the menu item SteerICra.eITransmission After determinin$ the servi"e "odes #ith 3AT ET1 see the topi" Troubleshootin$ Dete"ted 'aults that "orrespond to the servi"e "odes

U'= $* 8$-8697 !:*.= ;=.: A=:?C*. P..@@*. (!;AP)

N%$!& The pre"edin$ "hart has "han$ed from the former issue

The E3AP "an be used to: pro$ram the transmission E3M1 "he". "urrent ma"hine operatin$ status1 "he". abusive events and "he". dia$nosti"s "odes from the transmission E3M Prior to "onne"tin$ the E3AP into the servi"e port on the motor $rader1 the servi"e e,uipment must be properl- "onfi$ured The follo#in$ steps #ill "onfi$ure the E3AP 1 4nstall the NE?G)=2* Servi"e Pro$ram Module %"omputer "hip+ into the !?( &!99 3ommuni"ation Adapter as sho#n on pa$es t#o and three of SE8S2)1 6sin$ The !?(&!99 3ommuni"ation Adapter Group 2 4nstall the NE?G)=2& Ma"hine 'un"tions Servi"e Pro$ram Module %t#o "omputer "hips+ into the /T(/! Ele"troni" 3ontrol Anal-Fer Pro$rammer %E3AP+ as sho#n in SE8S*)*1 6sin$ The E3AP NE?G)=2& Ma"hine 'un"tions Servi"e Pro$ram Module 3 3onne"t !?(&)29 3able bet#een E3AP and !?(&!99 3ommuni"ation Adapter as sho#n in SES8*)*1 6sin$ The E3AP NE?G)=2& Ma"hine 'un"tions Servi"e Pro$ram Module N%$!& Ne#er E3AP units #ith a 3aterpillar part number endin$ in (A %ie /T/!(A+ #ill use !?(&/=& 3able instead of !?(&)29 3able 4 4nstall !?(&=!9 3able to !?(&!99 3ommuni"ations Adapter as sho#n on pa$e five of SES8*)*1 6sin$ The E3AP NE?G)=2& Ma"hine 'un"tions Servi"e Pro$ram Module

At this point E3AP is read- to be "onne"ted to the motor $rader N%$!& E3AP re"eives operatin$ po#er from the Ele"troni" 3ontrol Module %E3M+ throu$h the (pin 3AT Data 0in. 3onne"tor

The follo#in$ pro"edure "an be used to pro$ram the transmission E3M as #ell as obtain operatin$ status and dia$nosti"s

%&+ Servi"e port %Remove the "ap+

1 3onne"t the !?(&=!9 3able to the servi"e port %&+ #hi"h is the (pin1 $raplasti"1 Deuts"hL "onne"tor lo"ated on the front of the seat on the drivers ri$ht hand side 2 Either start the en$ine or turn the StartIStop
Ele"troni" 3ontrol Anal-Fer Pro$rammer S"reen

4 'rom the Ma"hine E3M Sele"tion s"reen sele"t Transmission 3ontrol and press Return to obtain the Transmission 'un"tions s"reen At this point the E3AP has been dire"ted to "ommuni"ate #ith the transmission E3M See SE8S*)*1 6sin$ The E3AP NE?G)=2& Ma"hine 'un"tions Servi"e Pro$ram Module1 for further instru"tions re$ardin$ Steps * and ) of this pro"edure

Ma"hine E3M Sele"tion S"reen

5 Sele"t either 4tem & to read or "han$e parameters1 4tem 2 for 3urrent Status of the transmission or 4tem * for transmission Dia$nosti"s and press Return

Transmission 'un"tions S"reen

ReadI3han$e Parameters S"reen

6 4f 4tem & #as sele"ted in Step =1 then the ReadI3han$e Parameters s"reen #ill be displa-ed 'rom this s"reen t#o "hoi"es are available:

4tem & for readin$ or "han$in$ parameters 4tem 2 for printin$ parameters

ReadI3han$e Parameters S"reen

7 4f 4tem & #as sele"ted in Step 1 then another ReadI3han$e Parameters s"reen #ill be displa-ed 'rom this s"reen t#o parameters "an be pro$rammed The Hehi"le 4D is the first option This input field is provided stri"tl- for "ustomer use and does not have another fun"tion

The Transmission 3onfi$uration 3ode is the se"ond option This is a "riti"al parameter #ithout #hi"h the ma"hine #ill NOT operate %see 3hart )+ The Total Tattletale field is not pro$rammable This field indi"ates ho# man- times an- of the parameters in the list have been "han$ed

Print All Parameters S"reen

8 4f 4tem 2 #as sele"ted in Step 1 the Print All Parameters s"reen #ill be displa-ed The transmission parameters #ill print to the lo"al printer if "onne"ted

Displa- Status ( S"reen &

Displa- Status ( S"reen 2

9 4f 4tem 2 #as sele"ted in Step =1 then Status S"reen  & #ill appear The other status s"reen "an be obtained b- usin$ the up and do#n arro#s or b- sele"tin$ a s"reen number and pressin$ Return 'rom the status s"reens all of the status items listed "an be observed #hile the ma"hine is operatin$

 Gear 0ever ( This is a &* #ire input #hi"h provides the shift lever position to the E3M This sho#s the position of the shift lever Positions are Neutral1 'irst 'or#ard throu$h Ei$hth 'or#ard1 'irst Reverse throu$h Sixth Reverse and Par.  Modulator Suppl- Pressure ( This sho#s the value of the modulation supplpressure s#it"h as read b- the "ontrol

On: The dire"tional "lut"hes have pressure Off: The dire"tional "lut"hes so not have pressure  4$nition S#it"h ( This is a sin$le #ire input that provides a batter- volta$e si$nal #hen turned in the Start position

Run:
Normal: Solenoid is Off 8i$h: Solenoid is On  Transmission 0amp ( This is used in "on7un"tion #ith the dia$nosti" "onne"tor to visuall- flash li$ht "ode se,uen"es #hen dia$nosin$ transmission ele"tri"al s-stem faults On: Transmission lamp is illuminated Off: Transmission lamp is not illuminated  Ca".up Alarm ( 5hen the transmission shift lever is Moved to a Reverse speed1 the E3M provides po#er for the ba".up alarm

On: The ba".up alarm is On Off: The ba".up alarm is Off

 Catter- Holt ( This is a t#o #ire input #hi"h provides 2) D3H nominal to drive the ele"troni" "ir"uits #ithin the E3M and all of the external solenoids 4t indi"ates the volta$e the "ontrol measures bet#een Pins @&(& and @&(2 at the transmission E3M "onne"tor

Displa- Dia$nosti"s S"reen

Displa- Dia$nosti"s S"reen

10 4f 4tem * #as sele"ted in Step =1 then Displa- Dia$nosti"s s"reen #ill appear Sele"t either 4tem & for Displa-I3lear Dia$nosti"s or 4tem 2 for Displa-I3lear Events and press Return 11 4f 4tem & #as sele"ted1 then another s"reen #hi"h is also entitled DisplaDia$nosti"s #ill be displa-ed An- of the dia$nosti" "odes "an be listed in this s"reen dependin$ on the operatin$ "ondition of the ma"hine

'rom this s"reen the user "an find:  The number and t-pe of faults #hi"h have o""urred  5hen the parti"ular fault first o""urred  5hen the fault last o""urred  5hether the fault is "urrentl- a"tive

'aults #hi"h are not "urrentl- a"tive ma- be "leared 3hart * provides a "omplete list of the Transmission Dia$nosti" 3odes To "lear faults1 follo# the steps listed:  6se the arro# up or do#n to hi$hli$ht the fault to be "leared E Press Return  >ou #ill be as.ed to "onfirm that -ou reall- #ant to "lear this fault Ans#er >es or No

A"tive faults ma- not be "leared until the problem "ausin$ the fault has been "orre"ted

Displa- Events S"reen

12 4f 4tem 2 #as sele"ted in Step &91 then a s"reen #hi"h is entitled DisplaEvents #ill be displa-ed Either of the t#o events listed belo# "ould be displa-ed here:  3oastin$ in Neutral #arnin$ ( 5hen the transmission "ontrol lever is in neutral #ith the transmission modulator pedal released #ith a $round speed $reater than 2* .mIh %&) mph+  Ma"hine driven #ith par.in$ bra.e on ( 5hen the transmission "ontrol lever is in Par. #ith a $round speed $reater than * .mIh %&/ mph+

'rom this s"reen the user "an find:  The number and t-pe of events #hi"h have o""urred  5hen the parti"ular event first o""urred  5hen the event last o""urred

To "lear events1 follo# the steps listed:  6se the arro# up or do#n to hi$hli$ht the event to be "leared

E Press Return  >ou #ill be as.ed to "onfirm that -ou reall- #ant to "lear this event Ans#er >es or No 13 To remove the E3AP from use1 dis"onne"t !?(&=!9 3able from the servi"e port

%E== $.='@''= D=''F.@ $* $.='@''= !;M W $* U'* % A= !;AP 'rom the transmission E3M the dia$nosti" "odes "an be obtained and "leared %if not a"tive+ #ithout the use of the E3AP The follo#in$ pro"ess #ill entail dis"onne"tin$ a transmission #irin$ harness and 7umperin$ spe"ifi" #ires in order to prompt the transmission E3M to displa- "oded messa$es to the transmission indi"ator lamp %&+ on the EMS panel

%&+ Transmission indi"ator lamp

NOTICE While using this procedure to retrieve transmission diagnostics from the transmission "C#, the machine must be parked with parking brake $pplied.

This pro"ess is not as eas- to use as the E3AP nor is the "apabilit- as "omplete This "apabilit- has been provided for the user #ho does not have read- a""ess to an E3AP 'ollo# the steps to obtain transmission dia$nosti"s from the E3M

N%$!& The pre"edin$ "hart has "han$ed from the former issue

%2+ Dia$nosti" plu$ %*+ E3M

1 The transmission E3M %*+ and the dia$nosti" plu$ are under the ri$ht side of the "ab 2 0o"ate the transmission indi"ator lamp %&+ lo"ated in front of the steerin$ #heel 3 Pla"e the StartIStop
Dia$nosti" 3ode #ill "ause the "ontrol to repeatedl- displa- that "ode Repla"in$ the & to * 7umper resumes s"rollin$ 7 This mode is used to "lear 0o$$ed Dia$nosti"s from memor- To erase a "ode1 put the "ontrol in the 0o$$ed Dia$nosti" S"roll Mode until the desired "ode is displa-ed and then remove the 7umper The E3M #ill "ontinue to displa- the desired "ode @umper re"epta"le so".et & to ) The transmission indi"ator lamp %&+ #ill turn off indi"atin$ the "ode has been erased The lamp #ill remain off until either the 0o$$ed Dia$nosti" S"roll Mode or the A"tive Dia$nosti" S"roll Mode is re(entered The above pro"ess "an be repeated until there are no "odes stored in memor- An a"tive dia$nosti" "ode "annot be erased from memor- 8 Re"onne"t dia$nosti" plu$ %2+ to the re"epta"le #hen servi"in$ is "omplete Transmission indi"ator lamp %&+ #ill stop flashin$

P..@@= $* $.='@''= !;M $.='@''= ;=.= ;/* W A= !;AP

%&+ Transmission indi"ator lamp

%2+ Dia$nosti" plu$ %*+ E3M

1 The transmission E3M %*+ and the dia$nosti" plu$ are under the ri$ht side of the "ab 2 0o"ate the transmission indi"ator lamp %&+ lo"ated in front of the steerin$ #heel 3 Pla"e the StartIStop
$.E:*'= $.E:*'= W A= !;AP %. !;M D='' Operate the ma"hine in ea"h dire"tion and in all speeds Note the noises that are not normal and find their sour"e 4f the operation is not "orre"t1 refer to the follo#in$ problems and pro"edures

The follo#in$ pro"edure has been desi$ned #ithout the benefit of usin$ dia$nosti"s from the transmission E3M 8o#ever1 usin$ an E3AP in "ombination #ith this troubleshootin$ $uide should improve the effi"ien"- in resolvin$ the problem P.E:*@&

Motor Grader 5ill Not * P.*/.*& 1 3he". the transmission "ontrol fuse %&9 amp+ lo"ated in fuse panel at the base of the steerin$ "onsole Repla"e if ne"essar- 2 Remove the transmission E3M from under the "ab and dis"onne"t the )9(pin Deut"hL "onne"tors Measure volta$e bet#een Pins @&(& and @&(2 3 4f the volta$e measured in Step 2 is above 29 D3H1 the transmission E3M is inoperative 4f some volta$e is measured and the volta$e is less the 29 D3H1 the batteries are under"har$ed 4f no volta$e #as measured in Step 21 pro"eed to Step ) 4 3he". Pin @&(& of the )9 pin Deut"hL "onne"tor to determine the volta$e bet#een the pin and frame 4f Pin @&(& has volta$e1 repair 292 Cla". $round #ire in ma"hine harness 4f Pin @&(& does not have volta$e1 repair &2 Pin. #ire in ma"hine harness P.E:*@&

'irst Gear Out Of Neutral Onl- 5or.in$ Gear ;..*>* P.*/.*& 1 Start en$ine and operate the ma"hine in order to determine #hi"h $ears are operable 2 Stop the ma"hine1 en$a$e the par.in$ bra.e and turn off the en$ine 3 @umper the manual modulation pressure s#it"h in order to determine if this pressure s#it"h is #or.in$ The manual modulation pressure s#it"h is lo"ated on the 8-drauli" 3lut"h 3lut"h Modulation Modulation 3ontrol %83M+ Dis"onne"t the 2 pin "onne"tor and 7umper Pins & and 2 of the re"epta"le

4 Start the ma"hine and attempt to operate the ma"hine in all $ears 4f the ma"hine has more than one $ear out of neutral then the manual modulation pressure s#it"h has failed 4f the first $ear out of neutral is still the onl- $ear available1 pro"eed to Step = 5 'rom Step )1 the #irin$ harness bet#een the manual modulation pressure s#it"h and the transmission E3M is suspe"t Remove the transmission E3M from under the "ab and dis"onne"t both )9 pin Deut"hL "onne"tors 3he". "ontinuitbet#een Pins @&(2 and @2(&& of the ma"hine harness 4f "ontinuit- is obtained #hile the 7umper is in pla"e1 the transmission E3M has failed 4f "ontinuit- is not obtained1 the #irin$ harness bet#een the transmission E3M and the manual modulation pressure s#it"h has failed

$.E:*'= $. E:*'= F:' D***/ B? $* !;M N%$!& The transmission solenoids are identified #ith letters %A throu$h 8+ in this publi"ation The solenoids ma- also be identified #ith numbers %& throu$h /+ Solenoid & is Solenoid A1 Solenoid 2 is Solenoid C1 et" N%$!& P is used as an abbreviation for Pin Example: P* is Pin * N%$!& 5hen 8arness #ith a letter %example: 8arness '+ is used1 the 8arness ' "an be identified on the ele"tri"al s"hemati" N%$!& The transmission E3M is seldom the "ause of a problem 4f the Troubleshootin$ 5ith An E3AP $uide dire"ts -ou to repla"e the E3M1 then double "he". -our steps to be sure that no mista.e #as made before repla"in$ the E3M

Dete"ted 'aults

Troubleshootin$ Dete"ted 'aults 6se the follo#in$ "harts to troubleshoot the faults identified in 3hart =

'lash 3odes: 2&(2/1 34D('M4: )&()/ '9=1 Transmission Trans mission Solenoid Open 3ir"uit

'lash 3odes: *&(*/1 34D('M4: )&()/ '91 Transmission Solenoid Short To Ground

'lash 3odes: )&()/1 34D('M4: )&()/ '9*1 Transmission Solenoid Short To Catter-

'lash 3ode: =21 34D('M4: *! '91 Ca".up Alarm Short To Ground

'lash 3ode: =/1 34D('M4: // '91 H8P Solenoid Short To Ground

'lash 3ode: =1 34D('M4: // '9*1 H8P Solenoid Short To Catter-

'lash 3ode: &1 34D('M4: / '921 Shift 0ever 4nput 4nvalid

'lash 3ode: 21 34D('M4: / '9*1 Shift 0ever Open 3ir"uitIShort To Catter-

'lash 3ode: =1 34D('M4: !9& '921 Transmission Output Speed Si$nal 4n"orre"t

'lash 3ode: /1 34D('M4: &/ '9&1 S-stem %Catter-+ Holta$e Celo# Normal

'lash 3ode: !&1 34D('M4: =29 '921 4nvalid Transmission 3onfi$uration 3odeK 'lash 3ode:

!21 34D('M4: 2/ '921 3he". Pro$rammable Parameters

'lash 3ode: !*1 34D('M4: !) '9=1 Transmission 4ndi"ator 0amp Open 3ir"uit

'lash 3ode: !)1 34D('M4: !) '91 Transmission 4ndi"ator 0amp Short To Ground

'lash 3ode: !=1 34D('M4: !) '9*1 Transmission 4ndi"ator 0amp Short To Catter-

'lash 3ode: !1 34D('M4: &!! '9*1 Transmission Oil Temperature Sensor short to Catter- or Open 3ir"uit

'lash 3ode: !!1 34D('M4: &!! '9)1 Transmission Oil Temperature Sensor short to Ground

'lash 3ode: /&1 34D('M4: // '9=1 AutoIManual 0amp Open 3ir"uit

'lash 3ode: /21 34D('M4: // '91 AutoIManual 0amp Short to Ground

'lash 3ode: /*1 34D('M4: // '9*1 AutoIManual 0amp Short to Catter-

Sensor Si$nal Holta$e Test

S*@

U'*&

&2) &28 &2= &)98 &2 &)*8 &A0 &298 2AN &98 2'M &28 ES 2GS &98 ES 28S &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298 ='M &)98 =8M &298 TM &298 NA >N &*=8 !MM &)98 /@M &28 NA /MN &*=8 /5N &98 NA E@ &98 @M &)98 NA TN &298 ES >R &)98 NA ;N &298 A0; &*=8 AM? &28 AM; &)98 APM &)*8 APN &*8 AR0 &98 ASD &*=8 CD@ &2983A' &*=8 3C3 &28 3C< &)98 33A &98 3 3P &)98 ?;8 &28 ?;@ &98 ?;< &298



Cefore -ou be$in the test1 refer to S-stems Operation1 Testin$ and Ad7ustin$1 Ma"hine Preparation for Troubleshootin$

Table 1


Description

Quantity

1U-5481

Pressure auge roup

1

1U-5482


1

Table 2

Transmission -ubrication Pressure $.inimum& Neutral -O# Idle

/I/ Idle

(irst ear (or)ard

28 #Pa !4 psi$

7 #Pa !1 psi$

345 #Pa !50 psi$

207 #Pa !30 psi$ Table 3

Transmission -ubrication Pressure Di0erential -ock in the ON Position Neutral


-O# Idle /I/ Idle Transmission -ubrication Pressure Di0erential -ock in the O(( Position Neutral


-O# Idle /I/ Idle &

Operate the ma"hine until the transmission oil is at operatin$ temperature of =& 3 %&2) '+

2

Stop the ma"hine on a hard level surfa"e En$a$e the par.in$ bra.e Turn the en$ine O''

Illustration 1

!ear o, the machine (1) 8itting (*est)

*

Remove the plu$ from the transmission "ase 4nstall 6+-3965 'ittin$ %Test+ %&+ into the port Atta"h the 8$-0846 Pressure Gau$e %9 to &1999 .Pa %9 to &)= psi++ to fittin$ %&+  Remove the drive shaft

)

Start the en$ine Turn the differential lo". to the ON position Operate the ma"hine in the NE6TRA0 position at lo# idle The pressure on the $au$e should be a minimum of 2/ .Pa %) psi+ Re"ord the $au$e readin$ in Table )

=

Operate the ma"hine in the NE6TRA0 position at hi$h idle The pressure on the $au$e should be a minimum of *)9 .Pa %=9 psi+ Re"ord the $au$e readin$ in Table )



Operate the ma"hine in '4RST GEAR 'OR5ARD at lo# idle The $au$e pressure should be a minimum of ! .Pa %& psi+ Re"ord the $au$e readin$ in Table )

!

Operate the ma"hine in '4RST GEAR 'OR5ARD at hi$h idle The $au$e pressure should be a minimum 29! .Pa %*9 psi+ Re"ord the $au$e readin$ in Table )

/

Repeat Step ) throu$h Step ! #ith the differential lo". in the O'' position Pressures from the transmission lubri"ation that var- #ith the differential lo". in the ON position indi"ate lea.a$e in the differential lo". s-stem



Stop the ma"hine Turn the en$ine O''and install the differential drive shaft Remove the test e,uipment

g00

U'*&

&A0 &298 2AN &98 2'M &28 ES 2GS &98 ES 28S &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298='M &)98 =8M &298 TM &298 NA >N &*=8 !MM &)98 /@M &28 NA /MN &*=8 /5N &98 NA E@ &98 @M &)98 NA TN &298 ES >R &)98 NA ;N &*=8 CD@ &)98 ?;8 &28 ?;@ &98 ?;< &)*8


%ersonal injury can result from spring force released when removing cap screws. &nternal spring force will be released when cylinder assembly cap screws are removed causing injury. $lways restrain cover as cap screws are loosened. 'ollow the established procedure in the Service #anual to service these parts.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. e prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. (efer to Special %ublication, )")*+--, Caterpillar !ealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products. !ispose of all fluids according to local regulations and mandates.

&

Stop the ma"hine En$a$e the par.in$ bra.e and turn off the en$ine

Illustration 1

(1) *ransmission control +al+e (2) 7uar"

2

Remove $uard %2+ from transmission "ontrol valve %&+  This #ill provide a""ess to the "ontrol

g01

Illustration 2

g01

.ressure *a .ort (3) Cas

*

Put blo".s in front of the #heels and behind the #heels of the ma"hine Remove the differential drive shaft

)

Remove "aps %*+ and install 999 .Pa %/!9 psi+ pressure $au$es on pressure tap %D+ and pressure tap %G+ 

=

Operate the en$ine at lo# idle either in the PAR< position or NE6TRA0 position Re"ord the $au$e pressures Pressure tap %D+ is "lut"h / and pressure tap %G+ is "lut"h = Remove the pressure $au$es and repla"e "aps %*+ 



Remove "aps %*+ and install 999 .Pa %/!9 psi+ pressure $au$es on the pressure tap %C+ 1 pressure tap %'+ and pressure tap %8+ 

!

Operate the en$ine at lo# idle in '4RST GEAR 'OR5ARD Re"ord the $au$e pressures Pressure tap %C+ is "lut"h & Pressure tap %'+ is "lut"h  and pressure tap %8+ is "lut"h ! Remove the pressure $au$es and repla"e "aps %*+ 

/

Remove "aps %*+ and install 999 .Pa %/!9 psi+ pressure $au$es on pressure tap %3+ and pressure tap %E+ 



Operate the en$ine at lo# idle in SE3OND GEAR 'OR5ARD Re"ord the $au$e pressure Pressure tap %3+ is "lut"h 2 and pressure tap %E+ is "lut"h ) Remove the pressure $au$es and repla"e "aps %*+ 

&9 Remove "ap %*+ and install a 999 .Pa %/!9 psi+ pressure $au$e on the pressure tap %A+  && Operate the en$ine at lo# idle in the '4RST GEAR REHERSE position Re"ord the $au$e pressure Pressure tap %A+ is "lut"h * Remove the pressure $au$es and repla"e "ap %*+  &2 Refer to Table 2 for the "orre"t pressures 4f an ad7ustment is needed1 refer to S-stems Operation1 Testin$ and Ad7ustin$1 4nitial Pressures ( Test and Ad7ust

Table 1

Test port A-3

-1

.inimum Pressure

$%&

.a1imum Pressure

2145 #Pa !311 psi$

2365 #Pa !343 psi$

2080 #Pa !302 psi$

2275 #Pa !330 psi$

$%&

-2

-8

-4

-6

-5

-7 !1$

2255 #Pa !327 psi$

2445 #Pa !355 psi$

2570 #Pa !373 psi$

2765 #Pa !401 psi$

1855 #Pa !269 psi$

2075 #Pa !301 psi$

2580 #Pa !374 psi$

2760 #Pa !400 psi$

2710 #Pa !393 psi$

2875 #Pa !417 psi$

2525 #Pa !366 psi$

2815 #Pa !408 psi$

All pressures are ta#en at lo. idle and at 51  !123 $,

Table 2

Test port

.inimum Pressure

.a1imum Pressure

A-3 -1 -2 -8 -4 -6 -5 -7 &* Stop the en$ine 4nstall the differential drive shaft and en$a$e the par.in$ bra.e Repla"e all the "overs and the $uards

U'*&

&A0 &298 2AN &98 2'M &28 ES 2GS &98 ES 28S &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298='M &)98 =8M &298 TM &298 NA >N &*=8 !MM &)98 /@M &28 NA /MN &*=8 /5N &98 NA E@ &98 @M &)98 NA TN &298 ES >R &)98 NA ;N &*=8 CD@ &)98 ?;8 &28 ?;@ &98 ?;< &)*8

Table 1

Tools Needed Qty

Part Number

Description

1

139-7050

o+er Plate

1

1U-5482


1

1U-5481


1

8T-0856

Pressure auge !0 to 6"000 #Pa !0 to 870 psi$$ Table 2

Initial Pressures Test Port A-3

-1

-2

-8

Pressure

$%&

380 : 20 #Pa !55 : 3 psi$

375 : 20 #Pa !54 : 3 psi$

405 : 20 #Pa !59 : 3 psi$

335 : 20 #Pa !49 : 3 psi$

-4

380 : 20 #Pa !55 : 3 psi$

-6

360 : 20 #Pa !52 : 3 psi$

-5

385 : 20 #Pa !56 : 3 psi$

-7 !1$

340 : 15 #Pa !49 : 2 psi$

All pressures are ta#en at 2000 &P and 51  !123 $,

Table 3

Initial Pressures Test Port

Pressure

A-3 -1 -2 -8 -4 -6 -5 -7 Table 4

Test Port A-3

Chan2e in pressure for one 3"4 %5,6 'him

88 #Pa !12,8 psi$

Chan2e in pressure for one 7 %83% 'pacer

44 #Pa !6,4 psi$

-1

-2

-8

-4

-6

-5

-7 &

88 #Pa !12,8 psi$

44 #Pa !6,4 psi$

94 #Pa !13,6 psi$

47 #Pa !6,8 psi$

111 #Pa !16 psi$

55 #Pa !8,0 psi$

77 #Pa !11,2 psi$

39 #Pa !5,6 psi$

111 #Pa !16 psi$

55 #Pa !8,0 psi$

116 #Pa !16,9 psi$

58 #Pa !8,4 psi$

61 #Pa !8,8 psi$

30 #Pa !4,4 psi$

Stop the ma"hine En$a$e the par.in$ bra.e Stop the en$ine

Illustration 1

(1) *ransmission control +al+e (2) 7uar"

2

Remove $uard %2+ from transmission "ontrol valve %&+ in order to provide a""ess to the "ontrol

*

Put blo".s in front of the #heels and behind the #heels of the ma"hine Remove the differential drive shaft

g01

Illustration 2

*ransmission Control Val+e (3) 9iring harness (4) $olts

g01

(5) Co+er () $olt (#) Cas

)

Remove fourteen mountin$ bolts %)+ that are used to retain "over %=+ The top three bolts "an not be removed #ithout removin$ the entire valve These bolts should 7ust be loosened Remove bolt %!+ from the transmission "ontrol valve

=

Slide the 139-7050 3over Plate under "over %=+ The 6(shaped slots should be fa"in$ up#ard so that the bolt holes line up #ith the holes in the plate



Ti$hten bolts %)+ and bolt %+ Refer to Spe"ifi"ations1 Transmission 3ontrol Halve for the "orre"t tor,ue

Illustration 3

g01

(%) 4-1#51 acer an" 5:-13 him () A"uster assembly (1) ani,ol" (11) &oc'nut (12) A"ustment screw

!

Remove "aps %!+ 4nstall the 8$-0856 Pressure Gau$es %9 to 1999 .Pa %9 to /!9 psi++ on taps %D+ and %G+ 

/

Operate the en$ine at hi$h idle in NE6TRA0 Re"ord the pressures Pressure tap %D+ is "lut"h / and pressure tap %G+ is "lut"h = Remove the pressure $au$es and repla"e the "aps %!+ 



Remove "aps %!+ and install the 8$-0856 Pressure Gau$es %9 to 1999 .Pa %9 to /!9 psi++ on pressure tap %C+1 pressure tap %'+ and pressure tap %8+ 

&9 Operate the en$ine at hi$h idle in the '4RST GEAR 'OR5ARD position Re"ord the $au$e pressures Pressure tap %C+ is "lut"h & Pressure tap %'+ is "lut"h  and pressure tap %8+ is "lut"h ! Remove the pressure $au$es and repla"e "aps %!+  && Remove "aps %!+ and install the 8$-0856 Pressure Gau$es %9 to 1999 .Pa %9 to /!9 psi++ on pressure tap %3+ and pressure tap %E+  &2 Operate the en$ine at hi$h idle in the SE3OND GEAR 'OR5ARD position Re"ord the $au$e pressures Pressure tap %3+ is "lut"h 2 and pressure tap %E+ is "lut"h ) Remove the pressure $au$es and repla"e "aps %!+  &* Remove "aps %!+ and install a 8$-0856 Pressure Gau$e %9 to 1999 .Pa %9 to /!9 psi++ pressure $au$e on pressure tap %A+  &) Operate the en$ine at hi$h idle in the '4RST GEAR REHERSE position Re"ord the $au$e pressures Pressure tap %A+ is "lut"h * Remove the pressure $au$es and repla"e "aps %!+  &= Refer to Table 2 for the "orre"t pressures 4f an ad7ustment is needed1 follo# Step & and Step &! & 4f the pressures do not a$ree #ith the pressures that are listed in Table 21 use the follo#in$ pro"edure to ad7ust the pressures i

0oosen lo".nut %&&+ on ad7uster assembl- %+ 

i

5hile -ou monitor the pressure1 ad7ust the pressure b- turnin$ ad7ustment s"re# %&9+ To lo#er the pressure1 turn the ad7ustment s"re# "lo".#ise One turn of the ad7ustment s"re# #ill "han$e the pressure approximatel- &*2 .Pa %& psi+

i

Ti$hten lo".nut %&&+ Refer to Spe"ifi"ations1 Sele"tor and Pressure 3ontrol Halve for the "orre"t tor,ue 'or all "lut"hes ex"ept "lut"h %D+ and "lut"h %G+1 shift the transmission to the NE6TRA0 position for a minimum of &= se"onds Then1 shift the transmission ba". to the $ear that is spe"ified in Step ! throu$h Step &= 'or "lut"h %D+ and "lut"h %G+1 shift the transmission to the '4RST GEAR 'OR5ARD for a minimum of &= se"onds and then shift the transmission ba". to

NE6TRA0 Ma.e sure that the pressures a$ree #ith the pressures that are listed in Table 2 i

4f the pressure "annot be ad7usted to the a""eptable limits #ith ad7ustment s"re# %&9+1 stop the en$ine and remove manifold %&2+ This #ill allo# -ou to a""ess the sele"tor spool Remove the sele"tor spool Add shims and spa"ers or remove shims and spa"ers1 as re,uired

i

4nstall the manifold Ad7ust the initial pressure a""ordin$ to the pro"edure that is listed in Steps &a throu$h &"

&! 3ontinue the pro"edure until all the stations %pressure taps+ are "he".ed and ad7usted &/ Stop the en$ine Remove the 139-7050 3over Plate  & 6se ne# 9P-9150 5ashers and install the transmission "ontrol valve on the transmission Ti$hten bolts %)+ Refer to Spe"ifi"ations1 Transmission 3ontrol Halve for the "orre"t tor,ue 29 To verif- the "lut"h pressures1 refer to S-stem Operation1 Testin$ and Ad7ustin$1 Transmission Pressures ( Test 2& 4nstall the $uards and the differential drive shaft

N*& This pro"edure should be follo#ed #henever a transmission "ontrol valve is repaired b- repla"in$ an- of the sprin$s or an- of the spools that are "ontained #ithin the individual "lut"h stations N*& 4f the transmission "lut"h pressure is out of the toleran"e ran$e1 the most li.el- "ause of the failure #ill be a failed modulation sprin$1 debris in the "ontrol valve or a seal failure #ithin the transmission

U'*&

&A0 &)*8 &A0 &98 2'M &98 2'M &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES28S &28 ES 20R &28 ES 20R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA 2;< &)98 ES*AS &)98 ES *AS &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &28 )ER &28)ER &298 NA )M< &298 NA )M< &28 NA )?M &28 NA )?M &*8 NA =A< &*8 NA =A< &298='M &298 ='M &)98 =8M &)98 =8M &28 =;M &28 =;M &298 ES NM &298 ES NM &298TM &298 TM &98 ES 5M &98 ES 5M &*=8 !MM &*=8 !MM &)98 /@M &)98 /@M &)98 ES /


Cefore -ou be$in the test1 refer to Troubleshootin$1 Ma"hine Preparation for Troubleshootin$ Table 1


Description

Quantity

1U-5481


1

1U-5482


1

Table 2

Transmission -ubrication Pressure

Neutral -O# Idle

/I/ Idle


80 : 30 #Pa !12 : 4 psi$

ini/u/ 7 #Pa !1 psi$

558 : 55 #Pa !80 : 8 psi$

241 : 27 #Pa !35 : 4 psi$ Table 3

Transmission -ubrication Pressure Di0erential -ock in the ON Position Neutral


-O# Idle /I/ Idle Transmission -ubrication Pressure Di0erential -ock in the O(( Position Neutral


-O# Idle /I/ Idle &

Operate the ma"hine until the transmission oil is at operatin$ temperature of =2 B *3 %&2= B ='+

2

Stop the ma"hine on a hard level surfa"e En$a$e the par.in$ bra.e Turn the en$ine O''

Illustration 1

!ear o, the transmission (1) *est ort

*

Remove the Remove the plu$ plu$in in test test port %&+ from from the tran transmiss smission ion "ase "ase 4nsta 4nstallll 6+-3965 6+-3965 'ittin$ 'ittin$ %ui". Dis"onne"t+ into test port %&+ Atta"h the 8$-0846 8$-0846 Pressure Pressure Gau$e %9 to &1999 .Pa %9 to &)= psi++ to fittin$ %&+ Remove the differential drive shaft

g01

)

Start the en$in Start en$ine e Turn Turn the diff differen erential tial lo". lo". to the the ON positio position n Operat Operate e the ma"h ma"hine ine in the NE6TRA0 position at lo# idle The pressure on the $au$e should be a minimum of =9 .Pa %! psi+ Re"ord the $au$e readin$ in Table *

=

Operate the Operate the ma"hi ma"hine ne in the NE6TR NE6TRA0 A0 posi position tion at at hi$h hi$h idle idle The The pressur pressure e on the the $au$e should be a minimum of =99 .Pa %!2 psi+ Re"ord the $au$e readin$ in Table *



Operate the Operate the ma"hi ma"hine ne in '4RS '4RST T GEAR GEAR 'OR5 'OR5ARD ARD at lo# idle idle The $au $au$e $e pressu pressure re should be a minimum of ! .Pa %& psi+ Re"ord the $au$e readin$ in Table *

!

Operate the Operate the ma"hi ma"hine ne in '4RS '4RST T GEAR GEAR 'OR5 'OR5ARD ARD at hi$h hi$h idle idle The The $au$e $au$e pres pressure sure should be a minimum 2&= .Pa %*& psi+ Re"ord the $au$e readin$ in Table *

/

Repeat Step Repeat Step ) throu throu$h $h Step Step ! #ith #ith the the differe differentia ntiall lo". in in the O'' posit position ion Transmission oil pressures that var- #ith the differential lo". in the ON position indi"ate lea.a$e in the differential lo". s-stem



Stop Sto p the ma"hin ma"hine e Turn Turn the the en$ine en$ine O'' O'' and insta installll the diffe different rential ial drive drive shaft shaft Remove the test e,uipment 4nstall 5P-4483 5P-4483 Plu$ Plu$ ba". into test port %&+ #ith a tor,ue of *= B * Nm %2 B 2 lb ft+

U'*& &28 8 ES ES 2GS &2 &28 8 ES 20R &2 &28 8 NA NA 25R &2 &28 8 NA NA 25R &)98 2GS &2 NA 2;< &) &)98 98 NA 2;< &) &)98 98 ES *AS &) &)98 98 ES *AS &28 )ER &28 )ER &28 NA )?M &28 NA )?M &)98 =8M &)98=8M &28 =;M &)98 /@M &)98 /@M &)98 ES /
Illustration 1

g00

%&+ 6Y-2300 4nput Shaft Group %2+ 6Y-2301 Transmission 3lut"h 3lut"h %'or#ard+ %'or#ard+ %*+ 6Y-2302 Transmission 3lut"h 3lut"h %Reverse %Reverse and Se"ond+ %)+ 6Y-2303 Transmission 3lut"h 3lut"h %'irst %'irst Gear and Third Gear+ %=+ 8!-9316 Transmission 3lut"h 3lut"h %8i$h %8i$h Gear and 0o# Gear+

Illustration 2

g00

ection A-A

6Y-2300 = S G.

Illustration 3

%A+  &92 B 9 mm %9)9 B 9* in"h+ %C+  =!= B 92= mm %22 B 9&9 in"h+

g00

6Y-2301 $.='@''= ;: (F../)

Illustration 4

%&+ Thi".ness of seven ne# fri"tion dis"s and of six ne# plates  )99 B &9) mm %&/&& B 9)& in"h+

g00

N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of seven ne# fri"tion dis"s and six ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number one "lut"h pa". %'or#ard 0o# Gear+  *9* B = mm %9&&* B 9929 in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 108-5751 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ 4nstall 108-5751 'ri"tion Dis" into the "lut"h pa". so that the $rooved pattern fa"es to#ard the "enter of the "lut"h pa". One of the fri"tion dis"s is lo"ated at the front of the "lut"h pa". and one of the fri"tion dis"s is lo"ated at the rear of the "lut"h pa". Minimum allo#able thi".ness for reusabilit-  *! mm %&)) in"h+ Thi".ness of one ne# 6-8911 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 9U-9995 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %2+ Thi".ness of seven ne# fri"tion dis"s and of six ne# plates  )99 B &9) mm %&/&& B 9)& in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of seven ne# fri"tion dis"s and six ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number t#o "lut"h pa". %'or#ard 8i$h Gear+  &= B ) mm %99= B 992= in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+

%*+ Diameter of shaft in bearin$ area  ) B 999! mm %2!==! B 999* in"h+ %)+ 9U-8815 Sprin$ Test len$th  )&9* mm %&&= in"h+ Test for"e  )= B */ N %&9*2! B /2 lb+ 'ree len$th after test  &=9 mm %=* in"h+ Outside diameter  &99 mm %)&! in"h+

%=+ Diameter of shaft in bearin$ area  ) B 999! mm %2!==! B 999* in"h+

Illustration 5

etail A

%C+ 4nstall 5H-8985 Sprin$ Pin %+ in 6Y-1119 Seal 3arrier %!+ #ith = mm %2 in"h+ maximum protrudin$ out of the "arrier

g00

6Y-2302 $.='@''= ;: (R*>*.'* =/ S*=/)

Illustration 6

%&+ Thi".ness of seven ne# fri"tion dis"s and of six ne# plates  )99 B &9) mm %&/&& B 9)& in"h+

g00

N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of seven ne# fri"tion dis"s and six ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number three "lut"h pa". %Reverse Gear+  &= B ) mm %99= B 992= in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=!9 B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %2+ Thi".ness of four ne# fri"tion dis"s and of three ne# plates  2=99 B 9= mm %/) B 929 in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of four ne# fri"tion dis"s and three ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number four "lut"h pa". %Se"ond Gear+  &&= B =* mm %99)= B 992& in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %*+ Diameter of shaft in bearin$ area  ) B 999! mm %2!==! B 999* in"h+ %)+ 9U-8815 Sprin$ Test len$th  )&9* mm %&&= in"h+ Test for"e  )= B */ N %&9*2! B /2 lb+ 'ree len$th after test  &=9 mm %=* in"h+

Outside diameter  &99 mm %)&! in"h+

%=+ 102-5881 5ave Sprin$ Test len$th  */29 mm %&=9* in"h+ Test for"e  299 B 222 N %)!9 B =9 lb+ 'ree len$th after test  =99 mm %&! in"h+ Outside diameter  &99& B 9 mm %)&!) B 92 in"h+

Illustration 7

etail A

%3+ 4nstall 5H-8985 Sprin$ Pin %/+ in 6Y-1119 Seal 3arrier %!+ #ith = mm %2 in"h+ maximum protrudin$ out of the "arrier

g00

Illustration 8

etail $

%D+ 4nstallation depth for 6Y-1895 Sleeve Cearin$ %+ in 6Y-3854 Gear Assembl%+  9= B 9= mm %92 B 92 in"h+ 4nside diameter of bearin$ after assembl-  2= B 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area  /)2 B 999/ mm %2!)! B 999* in"h+

6Y-2303 $.='@''= ;: (F.' G*. =/ $./ G*.)

g00

Illustration 9

%&+ Thi".ness of six ne# fri"tion dis"s and of five ne# plates  *99 B 9// mm %&=*= B 9*= in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of six ne# fri"tion dis"s and five ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

g00

Runnin$ "learan"e for number six "lut"h pa". %'irst Gear+  && B 2 mm %99!= B 992) in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %2+ Thi".ness of four ne# fri"tion dis"s and of three ne# plates  2=99 B 9= mm %/) B 922 in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of four ne# fri"tion dis"s and three ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number five "lut"h pa". %Third Gear+  &&= B =* mm %99)= B 992& in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %)+ Tor,ue for t#o bolts  == B &9 Nm %)& B ! lb ft+ %!+ 102-5881 5ave Sprin$ Test len$th  */2 mm %&=9 in"h+ Test for"e  299 B 222 N %)!9 B =9 lb+ 'ree len$th after test  =99 mm %&! in"h+ Outside diameter  &99& B 9 mm %)&!) B 92 in"h+

Illustration 10

etail A

%D+ 4nstall 5H-8985 Sprin$ Pin %+ in 6Y-2425 Seal 3arrier %=+ #ith = mm %2 in"h+ maximum protrudin$ out of the "arrier

g00

Illustration 11

etail $

%E+ 4nstallation depth for 6Y-2419 Sleeve Cearin$ %*+ in 6Y-3857 Gear Assembl- %+  9= B 9= mm %92 B 92 in"h+ 4nside diameter of bearin$ after assembl-  2= B 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area  /)2 B 999/ mm %2!)! B 999* in"h+

g00

Illustration 12

etail C

%'+ 4nstallation depth for 6Y-1895 Sleeve Cearin$ %/+ in 6Y-3856 Gear Assembl%&9+  9= B 9= mm %92 B 92 in"h+ 4nside diameter of bearin$ after assembl-  2= B 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area  /)2 B 999/ mm %2!)! B 999* in"h+

8!-9316 $.='@''= ;: (H G*. =/  G*.)

g00

Illustration 13

g00

%&+ Thi".ness of seven ne# fri"tion dis"s and of ei$ht ne# plates  =2= B &*) mm %29 B 9=* in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of seven ne# fri"tion dis"s and of ei$ht ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number seven "lut"h pa". %0o# Gear+  )2! B =2 mm %9&/ B 992& in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6Y-7981 'ri"tion Dis"  )*2 B 9&9 mm %&!9 B 99) in"h+ Minimum allo#able thi".ness for reusabilit-  *= mm %&)) in"h+ Thi".ness of one ne# 3P-0337 Plate  2! B 99/ mm %&9 B 99* in"h+ %2+ Thi".ness of six ne# fri"tion dis"s and of five ne# plates  *99 B 9// mm %&=*9 B 9*= in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of six ne# fri"tion dis"s and five ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".

Runnin$ "learan"e for number ei$ht "lut"h pa". %8i$h Gear+  && B 2 mm %99!= B 992) in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e

Thi".ness of one ne# 6-8912 'ri"tion Dis"  )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit-  *** mm %&*& in"h+ Thi".ness of one ne# 110-7723 Plate  *99 B 99/ mm %&&/ B 99* in"h+ %)+ 8M-4295 Sprin$ Test len$th  2 mm %&9 in"h+

Test for"e  !) B  N %& B & lb+ 'ree len$th after test  ))9 mm %&!= in"h+ Outside diameter  &=2 mm %9 in"h+

%=+ 102-5881 5ave Sprin$ Test len$th  */2 mm %&=9 in"h+ Test for"e  299 B 222 N %)!9 B =9 lb+ 'ree len$th after test  =99 mm %&! in"h+ Outside diameter  &99& B 9 mm %)&!) B 92 in"h+

%!+ Tor,ue for t#o bolts  == B &9 Nm %)9 B ! lb ft+

Illustration 14

etail A

g00

%D+ 4nstall 5H-8985 Sprin$ Pin %/+ in 6Y-2425 Seal 3arrier %+ #ith = mm %2 in"h+ maximum protrudin$ out of the "arrier

Illustration 15

View ($)

%E+ 4nstallation depth for 9W-6467 Sleeve Cearin$s %*+ in 8!-1158 Gear Assembl%+  9= B 9= mm %92 B 92 in"h+ 4nside diameter of bearin$ after assembl-  2= B 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area  /)2 B 999/ mm %2!)! B 999* in"h+

g00

Illustration 16

etail C

%'+ %G+ 4nstallation depth for 9W-6467 Sleeve Cearin$s %&9+ in 8!-1159 Gear Assembl- %&&+  9= B 9= mm %92 B 92 in"h+ 4nside diameter of bearin$ after assembl-  2= B 99* %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area  /)2 B 999/ mm %2!)! B 999* in"h+

P.*/.*  M*'.* R=== ;:*.=*

g00

Illustration 17

g00

*yical 6;amle

6se this pro"edure in order to "he". for proper "lut"h assembl- N*& Do not use a puller to remove rotor %!+ from the "lut"h assembl-

Remove the follo#in$ "omponents from the "lut"h $roup: bearin$ %&+1 dis" %2+1 $ear assembl- %*+1 rin$ %)+1 $ear assembl- %=+1 dis" %+1 rotor %!+1 ra"e and bearin$ %/+ and "arrier %+

Illustration 18

g00

&

2 *

Position the assembled "lut"h $roup #ith the shaft in the verti"al position Position the hub assembl- of the "lut"h that is bein$ measured so that the hub assemblfa"es up#ard Ma.e sure that hub assembl- %&9+ moves freel- Position the tip of a dial indi"ator on the side of the "lut"h pa". of the transmission at lo"ation %C+ ;ero the indi"ator

%ersonal injury can result from applying air pressure without the lock ring securely in place. #ake sure the lock ring /001 is securely in place before applying air pressure to the clutch pack.

)

To "he". the runnin$ "learan"e for the "lut"h pa".s1 appl- approximatel- &)9 .Pa %29 psi+ air pressure to passa$e %&)+ for "lut"h pa". %&2+ 

=

Piston %&*+ and the "lut"h pa". %&2+ should move up Determine the distan"e that the piston and the "lut"h pa". has moved from the dial indi"ator This is the runnin$ "learan"e for the "lut"h pa".

N*& 6se this same pro"edure in order to determine the runnin$ "learan"es for the "lut"h pa". for the existin$ "lut"h assemblies

U'*&

;@=*='

Illustration 1

*he en" +iew o, the transmission ,or the sha,t location (1) 8orwar" sha,t

g01

(2) 0nut sha,t (3) ha,t assembly (4) ha,t assembly (5) ha,t assembly

Illustration 2

(1) 8orwar" sha,t (2) 0nut sha,t (3) ha,t assembly (4) ha,t assembly (5) High<&ow sha,t () 7ear (#) 7ear (%) Co+er () 7ear (1) 7ear (11) No/ 2 clutch (12) 7ear (13) 7ear (14) No/ 3 clutch (15) 7ear (1) No/ 5 clutch (1#) 7ear (1%) 7ear (1) No/ # clutch (2) utut yo'e (21) .ar'ing bra'e

g01

(22) rain (23) *ransmission case (24) No/ % clutch (25) Hub (2) 7ear (2#) 7ear (2%) No/  clutch (2) 7ear (3) 7ear (31) High<&ow sha,t (32) No/ 4 clutch (33) rain (34) No/ 1 clutch (35) 7ear

F.' F../ G*.  !=*/ ;:*' (N 1, N 6 =/ N 7)

Illustration 3

(1) 8orwar" sha,t (2) 0nut sha,t (3) ha,t assembly (4) ha,t assembly (5) High<&ow sha,t () 7ear () 7ear (12) 7ear (1#) 7ear (1%) 7ear (1) No/ # clutch (2) utut yo'e (2%) No/  clutch (3) 7ear (31) High<&ow sha,t (34) No/ 1 clutch (35) 7ear

5hen for#ard No & "lut"h %*)+ is en$a$ed1 po#er is transmitted from $ear %+ on input shaft %2+ to $ear %*=+ on for#ard shaft %&+  Gear %*=+ transfers po#er to for#ard shaft %&+  Gear %+ on the for#ard shaft %&+ drives $ear %&2+ on the shaft assembl- %*+  Shaft assembl- %*+ transfers po#er to $ear %*&+  Gear %*&+ drives $ear %*9+ on shaft assembl- %*9+ 

g01

5hen No  "lut"h %2/+ is en$a$ed1 po#er transfers from $ear %*9+ to shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 the po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

S*=/ F../ G*.  !=*/ ;:*' (N 2, N 4 =/ N 7) 5hen No 2 "lut"h %&&+ is en$a$ed1 the po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&9+ on for#ard shaft %&+  Gear %&9+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard shaft %&+ drives $ear %&2+ on shaft assembl- %*+  5hen the se"ond $ear for No ) "lut"h %*2+ is en$a$ed1 po#er is transferred from shaft assembl- %*+ to $ear %**+  Gear %**+ drives $ear %2!+ on shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

$./ G*. F../  !=*/ ;:*' (N 2, N 5 =/ N 7) 5hen for#ard No 2 "lut"h %+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&9+ on for#ard shaft %&+  Gear %&9+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard shaft %&+ drives $ear %&2+ on shaft assembl%*+  Gear %*2+ on shaft assembl- %*+ drives $ear %&=+ on shaft assembl- %)+  5hen the third $ear for No = "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&=+ to shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

F. G*. F../  !=*/ ;:*' (N 1, N 5, =/ N 7) 5hen for#ard No & "lut"h %*)+ is en$a$ed1 po#er is transmitted from $ear %+ on input shaft %2+ to $ear %*=+ on for#ard shaft %&+  Gear %*=+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard shaft %&+ drives $ear %&2+ on shaft assembl%*+  The $ear %&2+ on shaft assembl- %*+ drives $ear %&=+ on shaft assembl- %)+  5hen the third $ear for No = "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&=+ to shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+ 

5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

F G*. F../  !=*/ ;:*' (N 1, N 6, =/ N 8) 5hen for#ard No & "lut"h %*)+ is en$a$ed1 po#er is transmitted from $ear %+ on input shaft %2+ to $ear %*=+ on for#ard shaft %&+  Gear %*=+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard shaft %&+ drives $ear %&2+ on shaft assembl%*+  Gear %*&+ on shaft assembl- %*+ drives $ear %*9+ on shaft assembl- %)+  5hen No  "lut"h %2/+ is en$a$ed1 po#er is transferred from $ear %*9+ to shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

S G*. F../  !=*/ ;:*' (N 2, N 4, =/ N 8) 5hen for#ard No 2 "lut"h %+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&9+ on for#ard shaft %&+  Gear %&9+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard %&+ drives $ear %&2+ on shaft assembl- %*+  5hen the se"ond $ear for No ) "lut"h %*2+ is en$a$ed1 po#er is transferred from shaft assembl- %*+ to $ear %**+  Gear %**+ drives $ear %2!+ on shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

S*>*= G*. F../  !=*/ ;:*' (N 1, N 4, =/ N 8) 5hen for#ard No & "lut"h %*)+ is en$a$ed1 po#er is transmitted from $ear %+ on input shaft %2+ to $ear %*=+ on for#ard shaft %&+  Gear %*=+ transfers po#er to for#ard shaft %&+  Gear %+ on for#ard shaft %&+ drives $ear %&2+ on shaft assembl%*+  5hen the se"ond $ear for No ) "lut"h %*2+ is en$a$ed1 po#er is transferred from shaft assembl- %*+ to $ear %**+  Gear %**+ drives $ear %2!+ on shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2 + on hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

! F../ G*.  !=*/ ;:*' (N 1, N 5, =/ N 8) 5hen for#ard No & "lut"h %*)+ is en$a$ed1 po#er is transmitted from $ear %+ on input shaft %2+ to $ear %*=+ on for#ard shaft %&+  Gear %*=+ transfers po#er to for#ard shaft %&+  Gear %+ on the for#ard shaft %&+ drives $ear %&2+ on shaft assembl- %*+  Gear %&2+ on shaft assembl- %*+ drives $ear %&=+ on shaft assembl%)+  5hen No = "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&=+ to shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on the hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

F.' R*>*.'* G*.  !=*/ ;:*' (N 3, N 6, =/ N 7)

Illustration 4

(1) 8orwar" sha,t (2) 0nut sha,t (3) ha,t assembly (4) ha,t assembly (5) High<&ow sha,t (#) 7ear (13) 7ear (14) No/ 3 clutch (1#) 7ear (1%) 7ear (1) No/ # clutch (2) utut yo'e (2%) No/  clutch (3) 7ear (31) High<&ow sha,t

5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %*&+ transfers po#er to shaft assembl- %*+  Gear %*&+ on the shaft assembl- %*+ drives $ear %*9+ on shaft assembl- %)+  5hen No  "lut"h %2/+ is en$a$ed1 po#er is transferred from $ear %*9+ to shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

g01

S*=/ R*>*.'* G*.  !=*/ ;:*' (N 3, N 4, =/ N 7) 5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %&*+ transfers po#er to the shaft assembl- %*+  5hen the se"ond $ear for No ) "lut"h %*2+ is en$a$ed1 po#er is transferred from shaft assembl- %*+ to $ear %**+  Gear %**+ drives $ear %2!+ on shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

$./ R*>*.'* G*.  !=*/ ;:*' (N 3, N 5, =/ N 7) 5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %&*+ transfers po#er to shaft assembl- %*+  Gear %&2+ on shaft assembl- %*+ drives $ear %&=+ on shaft assembl- %)+  5hen No  "lut"h %2/+ is en$a$ed1 po#er is transferred from $ear %*9+ to shaft assembl- %)+  Gear %&!+ on shaft assembl- %)+ transfers po#er to $ear %&/+ on hi$hIlo# shaft %=+  5hen the lo# $ear for No ! "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&/+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

F. R*>*.'* G*.  !=*/ ;:*' (N 3, N 6, =/ N 8) 5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %&*+ transfers po#er to shaft assembl- %*+  Gear %*&+ on shaft assembl- %*+ drives $ear %*9+ on shaft assembl- %)+  5hen No  "lut"h %2/+ is en$a$ed1 po#er is transferred from $ear %*9+ to shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on hi$hIlo# shaft %=+  5hen the hi$hIlo# $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

F R*>*.'* G*.  !=*/ ;:*' (N 3, N 4, =/ N 8) 5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %&*+ transfers po#er to shaft assembl- %*+  5hen the se"ond $ear for No ) "lut"h %*2+ is en$a$ed1 po#er is transferred from shaft assembl- %*+ to $ear %**+  Gear %**+ drives $ear %2!+ on shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+ 

S R*>*.'* G*.  !=*/ ;:*' (N 3, N 5, =/ N 8) 5hen reverse No * "lut"h %&)+ is en$a$ed1 po#er is transmitted from $ear %!+ on input shaft %2+ to $ear %&*+ on shaft assembl- %*+  Gear %&*+ transfers po#er to shaft assembl- %*+  Gear %&2+ on shaft assembl- %*+ drives $ear %&=+ on shaft assembl- %)+  5hen No = "lut"h %&+ is en$a$ed1 po#er is transferred from $ear %&=+ to shaft assembl- %)+  Gear %2+ on shaft assembl- %)+ transfers po#er to $ear %2+ on hi$hIlo# shaft %=+  5hen the hi$h $ear for No / "lut"h %2)+ is en$a$ed1 po#er is transferred from $ear %2+ to hi$hIlo# shaft %=+ and to output -o.e %29+

U'*&

&A0 &98 2'M &28 ES 2GS &98 ES 28S &28 ES 20R &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298='M &)98 =8M &28 =;M &298 ES NM &298 TM &98 ES 5M &*=8 !MM &)98 /@M &)98 ES /R &)98 NA ;N &)*8

Table 1

Required Tools

Part Number

Description

Quantity

8T-5096

ial Indi(ator p

1

6se this pro"edure in order to "he". for proper "lut"h assembl- Refer to Spe"ifi"ations1 Po#er Train for runnin$ "learan"es for the "lut"h pa".s

Illustration 1

g01

(1) $earing (2) isc (3) 7ear assembly (4) 9asher (5) 7ear assembly () isc (#) !otor (%) $earing () Carrier

&

Remove the follo#in$ "omponents from the "lut"h $roup: •

Cearin$ %&+

•

Dis" %2+

•

Gear assembl- %*+

•

5asher %)+

•

Dis" %=+

•

Gear assembl- %+

•

Rotor %!+

•

Cearin$ %/+

•

3arrier %+

N*& Do not use a puller to remove rotor %!+ from the "lut"h assembl-

Illustration 2

g01

(1) Hub assembly (11) !ing (12) Clutch ac' (13) .iston (14) .assage

2

* )

Position the assembled "lut"h $roup #ith the shaft in the verti"al position Position the hub assembl- of the "lut"h that is bein$ measured so that the hub assemblfa"es up#ard Ma.e sure that piston %&*+ moves freel- Position the tip of a dial indi"ator on the flat of piston %&*+ at lo"ation %C+ ;ero the indi"ator

N*& Ensure that the tip of the indi"ator is parallel #ith the "enterline of the shaft assembl-

%ersonal injury can result from applying air pressure without the lock ring securely in place. #ake sure the lock ring /001 is securely in place before applying air pressure to the clutch pack.

=

To "he". the runnin$ "learan"e for the "lut"h pa".s1 appl- approximatel- &)9 .Pa %29 psi+ air pressure to passa$e %&)+ for "lut"h pa". %&2+ 



Piston %&*+ and "lut"h pa". %&2+ should move up Determine the amount of piston movement from the readin$ on the dial indi"ator This is the runnin$ "learan"e for the "lut"h pa".

Repeat Step & throu$h Step  in order to determine the runnin$ "learan"es for the remainin$ "lut"h pa".s

U'*&

&2= &)98 &2 &98 2'M &28 ES 2GS &98 ES 28S &28 ES 20R &28 NA 25R &)98 NA2;< &)98 ES *AS &98 NA *GM &28 )ER &28 NA )?M &)98 =8M &28 =;M &98 ES 5M &)98 /@M &)98 ES /
NA /MN &98 NA

E@ &98 @M &)98 NA TN &)98 NA ;N &28 AM; &)98 APM &98 ASD &28 3C< &)98 33A &98 33P &29< @AP &9< @CP &2< @@A &)9< @PA &)9< S;0 &9< S;M &29< S;N &2< S;P &29< 2 S;S &)9< 2 S;5 &)98 ?;8 &28?;@ &98 ?;<

D'''*@E:? P.*/.* Table 1

Required Tools Tool

Part Number

Part Description

Qt

A

138-7575

in# ra(#et

1



154-6181

or(ing ;(re.

2



6<-5221

olt

1



4-8156

i=ture

1



6<-3918

olt

1



4-8157

i=ture

2



1U-6405

T)ree >a. Puller

1



1U-6341

T)readed &od

1

>

5P-7970

'ut

1

?

9U-7479

o/pressing Tube

1



5-0637

ig) Idle 'ut

1

5-7353

@as)er

1

1-4207

ull 'ut

2

5-7369

Puller eg

2

3-0465

Pus)-Puller Plate

2

5-7366

;(re.

1

5P-4808

ap

2

1U-9895

rossblo(#

1

lo(#

2

1-4206

'ut

4

8-7552

olt

2

9;-9151 

'

1U-6343

T)readed &od

1

P

6<-8149

'ut

1



2P-8312

Pliers

1

1P-2326

;(re.

1

1P-2325

ead

1

3-0462

olt and 'ut

4

8-0709

;trap

4

5-7373

>a.

3

ebolt

1

&

;

3-3882

S. B?& &

Remove the transmission "ontrol valve Refer to Disassembl- and Assembl-1 Transmission 3ontrol Halve ( Remove

2

Remove the par.in$ bra.e Refer to Disassembl- and Assembl-1 Par.in$ Cra.e ( Remove

*

Remove the transmission speed sensor

)

Remove the transmission oil pump Refer to Disassembl- and Assembl-1 Gear Pump %Transmission 3har$in$ and S"aven$e+ ( Remove

=

Remove the transmission ma$neti" s"reen base Refer to Disassembl- and Assembl-1 Ma$neti" S"reen ( Remove and 4nstall

Illustration 1

& 2 *

g00

Pla"e transmission %&+ level on the floor Remove &2 bolts %2+1 four "overs1 and the O(rin$ seals from transmission "ase assembl- %*+  Remove )& bolts %)+ from the transmission "ase assembl- %*+ 

Illustration 2

g00

N*& 4dentif- the lo"ation of seal "arrier %=+ in the transmission "ase assembl- %*+ for assembl- purposes ) = 

Remove t#o bolts %+ from seal "arrier %=+  4nstall Toolin$ %A+ %not sho#n+ in seal "arrier %=+ Remove seal "arrier %=+ and the three rin$ seals from the transmission "ase assembl- bore %!+  Repeat Step ) throu$h Step = on the three remainin$ seal "arriers %=+ 

Illustration 3

!

Remove seal rin$s %+ from seal "arrier %=+ 

/

Remove three or four seals %/+ from seal "arrier %=+ 



Remove sprin$ pin %&9+ from seal "arrier %=+ 

&9 Repeat Step ! and Step  for the remainin$ three seal "arriers %=+ 

g00

Illustration 4

g00

&& 4nstall Toolin$ %C+ in the transmission "ase assembl- %*+ Ti$hten Toolin$ %C+ evenlto separate transmission "ase assembl- %*+ from transmission "over assembl- %&&+  &2 Atta"h Toolin$ %A+ to transmission "ase assembl- %*+ Position a liftin$ devi"e to Toolin$ %A+ Se"ure the liftin$ devi"e to a hoist Slo#l- raise the transmission "ase assembl- %*+ from the transmission "over assembl- %&&+ Ce "areful not to bind the transmission "ase assembl- %*+ durin$ separation

Illustration 5

&* Remove three bolts %&2+ from tube assembl- %&*+ Remove tube assembl- %&*+ from the transmission "over assembl- %&&+  &) Remove the O(rin$ seal from tube assembl- %&*+ 

g00

Illustration 6

N*& 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+ must be removed to$ether &= 4nstall Toolin$ %D+ on 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl%&=+ 6se Toolin$ %3+ and Toolin$ %E+ in order to hold Toolin$ %D+ on 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+1 as sho#n 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+ must be removed to$ether & Atta"h a suitable liftin$ devi"e to Toolin$ %D+ 3arefull- remove 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+ from the transmission "over assembl- %&&+ The #ei$ht of the t#o shaft assemblies is &!! .$ %*9 lb+

g00

Illustration 7

g00

&! Pla"e 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+ on Toolin$ %'+ or on blo".s and remove Toolin$ %D+ 3arefull- separate 'irstIThird shaft assembl- %&)+ and 8i$hI0o# shaft assembl- %&=+ The #ei$ht of ea"h shaft assembl- is / .$ %&= lb+

Illustration 8

g00

Illustration 9

g00

N*& Pla"e 8i$hI0o# shaft %&=+ in a modified #or. ben"h or on blo".s Modif- a substantial #or.ben"h b- "uttin$ a &&9 B 29 mm %)9 B 99/ in"h+ "learan"e hole in the top of the ben"h

Illustration 10

g00

Illustration 11

g00

N*& Do not atta"h Toolin$ %G+ to rotor %&!+ 4f pressure is applied to rotor %&!+ #ith Toolin$ %G+1 rotor %&!+ #ill bra.e Atta"h the Toolin$ %G+ to $ear assembl- %&/+  &/ 5ith 8i$hI0o# shaft assembl- %&=+ on the modified #or. ben"h or on blo".s1 use Toolin$ %G+ in order to remove ra"e and bearin$ %&+1 rotor %&!+1 $ear assembl- %&/+1 and t#o sleeve bearin$s %not sho#n+ from 8i$hI0o# shaft assembl- %&=+ Press fit Cearin$ %&+ and rotor %&!+ on 8i$hI0o# shaft assembl- %&=+  & Remove bearin$ %&+1 rotor %&!+1 thrust dis" %&+1 and $ear assembl- %&/+ from 8i$hI0o# shaft assembl- %&=+ Atta"h Toolin$ %G+ to $ear assembl- %&/+ Do not atta"h Toolin$ %G+ to rotor %&!+ 

Illustration 12

29 Remove thrust dis" %29+ and the #asher from 8i$hI0o# shaft assembl- %&=+ 

g00

Illustration 13

g00

2& 4nstall Toolin$ %8+ and Toolin$ %<+ on 8i$hI0o# shaft assembl- %&=+ and "lut"h assembl- %2&+ Ti$hten Tool %@+ on Toolin$ %8+ %not sho#n+ in order to "ompress "lut"h assembl- %2&+ Remove t#o half rin$s %22+ and t#o lo". rin$s %2*+ from the 8i$hI0o# shaft assembl- %&=+  22 3arefull- loosen Tool %@+ on Toolin$ %8+ in order to relieve pressure from "lut"h assembl- %2&+ Remove Toolin$ %<+ and Toolin$ %8+ from 8i$hI0o# shaft assembl- %&=+ and "lut"h assembl- %2&+ The "lut"h assembl- %2&+ is made up of five "lut"h plates1 six fri"tion dis"s1 and the hub assembl- 4dentif- the position of the "lut"h assembl- %2&+ for assembl- purposes

Illustration 14

2* Remove #ave sprin$ %2=+ from 8i$hI0o# shaft assembl- %&=+ 

g00

2) Remove piston %2)+ from 8i$hI0o# shaft assembl- %&=+ 

Illustration 15

g00

2= Remove seal extension rin$ %2!+ and seal rin$ %2+ from piston %22+ 

Illustration 16

2 Position 8i$hI0o# shaft assembl- %&=+1 as sho#n Pla"e 8i$hI0o# shaft %&=+ in the modified #or. ben"h1 or on blo".s The #ei$ht of 8i$hI0o# shaft assembl- %&=+ is =9 .$ %&&9 lb+ 2! 4nstall Toolin$ %0+ and Toolin$ %M+ on 8i$hI0o# shaft assembl- %&=+ and inner bearin$ %2/+ Remove inner bearin$ %2/+ from 8i$hI0o# shaft assembl- %&=+

g00

Remove t#o thrust dis"s %2+1 t#o bearin$ sleeves1 and $ear assembl- %*9+ from 8i$hI0o# shaft assembl- %&=+ 

Illustration 17

g00

2/ Remove thrust dis" %*&+ and the #asher from 8i$hI0o# shaft assembl- %&=+ 

Illustration 18

g00

N*& Toolin$ %<+ is the old st-le tool that is no# modified Toolin$ %<+ %ne# st-le tool+ #or.s #ithout bein$ modified Toolin$ %<+ ma- need to be modified so the hole in the top of the tube #ill have "learan"e for Toolin$ %N+  2 4nstall Toolin$ %N+ and Toolin$ %<+ on 8i$hI0o# shaft assembl- %&=+ and "lut"h assembl- %*2+ Ti$hten Toolin$ %P+ on Toolin$ %N+ in order to "ompress "lut"h assembl- %*2+ Remove t#o half rin$s %**+ and t#o lo". rin$s %*)+ from the 8i$hI0o# shaft assembl- %&=+  *9 3arefull- loosen Toolin$ %P+ on Toolin$ %N+ in order to relieve pressure from "lut"h assembl- %*2+ Remove Toolin$ %<+ and Toolin$ %N+ from 8i$hI0o# shaft assembl- %&=+ and "lut"h assembl- %*2+ The "lut"h assembl- %*2+ is made up of ei$ht "lut"h plates1 seven fri"tion dis"s1 and the hub assembl- 4dentif- the position of the "lut"h assembl- %*2+ for assembl- purposes

Illustration 19

N*& Toolin$ %<+ is the old st-le tool that must be modified Toolin$ %<+ %ne# st-le tool+ #or.s #ithout bein$ modified Toolin$ %<+ ma- need to be modified so the hole in the top of the tube #ill have "learan"e for Toolin$ %N+  *& 4nstall Toolin$ %N+ and Toolin$ %<+ on 8i$hI0o# shaft assembl- %&=+ and balan"e piston %*=+ Ti$hten Toolin$ %P+ on Toolin$ %N+ in order to "ompress balan"e piston %*=+  *2 6se Toolin$ %+ in order to remove retainin$ rin$ %*+ from 8i$hI0o# shaft assembl- %&=+  ** 3arefull- loosen Toolin$ %P+ on Toolin$ %N+ in order to relieve pressure from balan"e piston %*=+ Remove Toolin$ %<+ and Toolin$ %N+ in order to relieve pressure from 8i$hI0o# shaft assembl- %&=+ and balan"e piston %*=+ 

g00

Illustration 20

g00

*) Remove balan"e piston %*=+ and seal extension rin$ %*!+ from 8i$hI0o# shaft assembl- %&=+  *= Remove &= sprin$s %*/+ from piston %*+  * Remove piston %*+1 the seal extension rin$ %not sho#n+1 and a rin$ seal %not sho#n+ from 8i$hI0o# shaft assembl- %&=+ 

Illustration 21

*! Remove seal rin$ %)9+ and seal extension rin$ %)&+ from piston %*+ 

g00

Illustration 22

g00

*/ Pla"e 'irstIThird shaft assembl- %&)+ on the modified #or. ben"h or on blo".s 6se Toolin$ %'+ in order to remove ra"e and bearin$ %)2+1 thrust dis" %not sho#n+1 and $ear assembl- %)*+ from 'irstIThird shaft assembl- %&)+ 

Illustration 23

* Remove thrust dis" %))+ and $ear assembl- %)=+ from 'irstIThird shaft assembl%&)+ 

g00

Illustration 24

g00

)9 Remove sleeve bearin$ %not sho#n+1 thrust dis" %)+ and #asher %)!+ from 'irstIThird shaft assembl- %&)+ 

Illustration 25

)& 4nstall Toolin$ %8+ and Toolin$ %<+ on 'irstIThird shaft assembl- %&)+ and "lut"h assembl- %)/+ Ti$hten Toolin$ %<+ on Toolin$ %8+ in order to "ompress "lut"h assembl- %)/+ Remove t#o half rin$s %)+ and t#o lo". rin$s %=9+ from 'irstIThird shaft assembl- %&)+  )2 3arefull- loosen Toolin$ %@+ on Toolin$ %8+ in order to relieve pressure from "lut"h assembl- %)/+ Remove Toolin$ %<+ and Toolin$ %8+ from 'irstIThird shaft

g00

assembl- %&)+ and "lut"h assembl- %)/+ As -ou remove "lut"h assembl- %)/+ from 'irstIThird shaft assembl- %&)+1 identif- the positions of the five "lut"h plates1 the six fri"tion dis"1 and the hub assembl- for assembl- purposes

Illustration 26

g00

)* Remove #ave sprin$ %=&+ from 'irstIThird shaft assembl- %&)+  )) Remove piston %=2+ from 'irstIThird shaft assembl- %&)+ 

Illustration 27

)= Remove seal extension rin$ %=*+ and seal rin$ %=)+ from piston %=2+ 

g00

Illustration 28

) Position 'irstIThird shaft assembl- %&)+1 as sho#n Pla"e 'irstIThird shaft assembl- %&)+ in the modified #or. ben"h1 or on blo".s The #ei$ht of 'irstIThird shaft assembl- %&)+ is == .$ %&29 lb+ )! Remove the seal rin$ %not sho#n+ from 'irstIThird shaft assembl- %&)+  )/ 6se Toolin$ %R+ in order to remove inner bearin$ %==+1 thrust dis" %not sho#n+1 $ear %=+1 and thrust dis" %not sho#n+ ) Remove $ear assembl- %=!+1 the bearin$ sleeve %not sho#n+1 the thrust dis"1 and the #asher %not sho#n+ from 'irstIThird shaft assembl- %&)+ 

g00

Illustration 29

g00

=9 4nstall Toolin$ %<+ and Toolin$ %8+ on 'irstIThird shaft assembl- %&)+ and "lut"h assembl- %=/+ Ti$hten Toolin$ %@+ on Toolin$ %8+ in order to "ompress "lut"h assembl- %=/+ Remove t#o half rin$s %=+ and t#o lo". rin$s %9+ from the 'irstIThird shaft assembl- %&)+  =& 3arefull- loosen Toolin$ %@+ on Toolin$ %8+ in order to relieve pressure from "lut"h assembl- %=/+ Remove Toolin$ %8+ and Toolin$ %<+ from 'irstIThird shaft assembl- %&)+ and "lut"h assembl- %=/+ As -ou remove "lut"h assembl- %=/+ from 'irstIThird shaft assembl- %&)+1 identif- the position of the three "lut"h plates1 four fri"tion dis"1 and the hub assembl- for assembl- purposes

Illustration 30

=2 Remove #ave sprin$ %&+ from 'irstIThird shaft assembl- %&)+  =* Remove piston %2+ from 'irstIThird shaft assembl- %&)+ 

g00

Illustration 31

g00

=) Remove seal extension rin$ %*+ and seal rin$ %)+ from piston %2+ 

Illustration 32

g00

Illustration 33

g00

== 6se Toolin$ %R+ in order to remove inner bearin$ %+ and $ear %!+ from input shaft assembl- %=+ This is ne"essar- at this time in order to remove the remainin$ t#o shaft assemblies

Illustration 34

= 4nstall Toolin$ %S+ and remove ReverseISe"ond shaft assembl- %/+ from the transmission "over assembl- %&&+ The #ei$ht of ReverseISe"ond shaft assembl%/+ is ) .$ %&)9 lb+

g01

Illustration 35

g00

=! Pla"e ReverseISe"ond shaft assembl- %/+ on the modified #or. ben"h1 or on blo".s =/ 6se Toolin$ %R+ in order to remove ra"e and bearin$ %+1 spa"er %!9+1 and $ear %!&+ from ReverseISe"ond shaft assembl- %/+ 

Illustration 36

= Remove spa"er %!2+ and thrust dis" %not sho#n+ from ReverseISe"ond shaft assembl- %/+  9 Remove $ear assembl- %!*+1 the sleeve bearin$ %not sho#n+1 the thrust dis" %not sho#n+1 and the #asher %not sho#n+ from ReverseISe"ond shaft assembl- %/+ 

g00

Illustration 37

& 4nstall Toolin$ %<+ and Toolin$ %8+ on ReverseISe"ond shaft assembl- %/+ and "lut"h assembl- %!)+ Ti$hten Toolin$ %@+ on Toolin$ %8+ in order to "ompress "lut"h assembl- %!)+ Remove t#o half rin$s %!=+ and t#o lo". rin$s %!+ from ReverseISe"ond shaft assembl- %/+  2 3arefull- loosen Toolin$ %@+ on Toolin$ %8+ in order to relieve pressure from "lut"h assembl- %!)+ Remove Toolin$ %8+ and Toolin$ %<+ from ReverseISe"ond shaft assembl- %/+ and "lut"h assembl- %!)+ As -ou remove "lut"h assembl- %!)+ from ReverseISe"ond shaft assembl- %/+1 identif- the positions of the three "lut"h plates1 four fri"tion dis" and the hub assembl- for assembl- purposes

g00

Illustration 38

g00

* Remove #ave sprin$ %!!+ from ReverseISe"ond shaft assembl- %/+  ) Remove piston %!/+ from ReverseISe"ond shaft assembl- %/+ 

Illustration 39

g00

= Remove seal rin$ %/9+ and seal extension rin$ %!+ from piston %!/+ 

Illustration 40

g00

 Position ReverseISe"ond shaft assembl- %/+1 as sho#n The #ei$ht of ReverseISe"ond shaft assembl- %/+ is )& .$ %9 lb+ ! Pla"e ReverseISe"ond shaft assembl- %/+ on the modified #or. ben"h1 or on blo".s / 4nstall Toolin$ %0+ and Toolin$ %M+ on $ear assembl- %/2+ and ReverseISe"ond shaft assembl- %/+   Remove inner bearin$ %/&+1 the thrust ra"e %not sho#n+1 the t#o thrust dis"s %not sho#n+1 and $ear assembl- %/2+ from ReverseISe"ond shaft assembl- %/+ 

Illustration 41

!9 Remove roller bearin$ %/*+ from ReverseISe"ond shaft assembl- %/+  !& Remove thrust dis" and #asher %/)+ from ReverseISe"ond shaft assembl- %/+ 

g00

Illustration 42

g00

!2 6se a se"ond person in order to "ompress "lut"h assembl- %/=+  !* Remove t#o half rin$s %/+ from ReverseISe"ond shaft assembl- %/+ Release the pressure from "lut"h assembl- %/=+ slo#l-1 until the sprin$ %/+ underneath "lut"h assembl- %/=+ is extended and relaxed

Illustration 43

!) Remove hub assembl- %/!+ from ReverseISe"ond shaft assembl- %/+  != Remove sprin$ %/+ from ReverseISe"ond shaft assembl- %/+  ! As -ou remove "lut"h plates %//+ and fri"tion dis"s %9+1 identif- the lo"ations of "lut"h plates %//+ and fri"tion dis"s %9+ for installation purposes Remove six "lut"h plates %//+ and seven fri"tion dis" %9+ from ReverseISe"ond shaft assembl- %/+ 

g00

Illustration 44

g00

!! Remove valve assembl- %&+ from ReverseISe"ond shaft assembl- %/+  !/ Remove piston %2+ from ReverseISe"ond shaft assembl- %/+ 

Illustration 45

! Remove seal rin$ %*+ and %)+ from piston %2+  /9 Remove the "up plu$ %not sho#n+ from ReverseISe"ond shaft assembl- %/+ 

g00

Illustration 46

g01

/& 4nstall Toolin$ %S+ in 'or#ard shaft assembl- %=+ Remove 'or#ard shaft assembl%=+ from the transmission "over assembl- %&&+ The #ei$ht of 'or#ard shaft assembl- %=+ is ) .$ %&)9 lb+

Illustration 47

/2 Pla"e 'or#ard shaft assembl- %=+ on the modified #or. ben"h1 or on blo".s 4nstall Toolin$ %0+ and Toolin$ %M+ to 'or#ard shaft assembl- %=+ and $ear assembl- %!+  /* Remove ra"e and bearin$ %+1 t#o thrust dis" %not sho#n+1 and $ear assembl%!+ from 'or#ard shaft assembl- %=+ 

g00

Illustration 48

g00

/) Remove roller bearin$ %/+ from 'or#ard shaft assembl- %=+  /= Remove the thrust dis" and #asher %+ from 'or#ard shaft assembl- %=+ 

Illustration 49

/ 6se a se"ond person in order to "ompress "lut"h assembl- %&99+  /! Remove t#o half rin$s %&9&+ from 'or#ard shaft assembl- %=+ Release the pressure from "lut"h assembl- %&99+ slo#l-1 until the sprin$ %&9)+ underneath "lut"h assembl- %&99+ is extended and relaxed

g00

Illustration 50

g00

// Remove hub assembl- %&92+ from 'or#ard shaft assembl- %=+  / Remove sprin$ %&9)+ from 'or#ard shaft assembl- %=+  9 Remove six "lut"h plates %&9=+ and seven fri"tion dis" %&9*+ from 'or#ard shaft assembl- %=+ 4dentif- the positions of the "lut"h plates %&9=+ and fri"tion dis"s %&9*+ for assembl- purposes

Illustration 51

& Remove valve assembl- %&9+ from 'or#ard shaft assembl- %==+  2 Remove piston %&9!+ from 'or#ard shaft assembl- %=+ 

g00

Illustration 52

g00

* Remove t#o seal rin$s %&9/+ from piston %&9!+ 

Illustration 53

) Position 'or#ard shaft assembl- %=+1 as sho#n The #ei$ht of 'or#ard shaft assembl- %=+ is )* .$ %= lb+ Pla"e 'or#ard shaft assembl- %=+ in the modified #or. ben"h or on blo".s = 4nstall Toolin$ %0+ and Toolin$ %M+ to 'or#ard shaft assembl- %=+ and $ear assembl- %&&9+ 

g00

 Remove inner bearin$ %&9+1 the thrust ra"e %not sho#n+1 the t#o thrust dis" %not sho#n+1 and $ear assembl- %&&9+ from 'or#ard shaft assembl- %=+ 

Illustration 54

g00

! Remove roller bearin$ %&&&+ from 'or#ard shaft assembl- %=+  / Remove the thrust dis" and #asher %&&2+ from 'or#ard shaft assembl- %=+ 

Illustration 55

 6se a se"ond person in order to "ompress "lut"h assembl- %&&*+  &99 Remove t#o half rin$s %&&)+ from 'or#ard shaft assembl- %=+ 

g00

&9& Release the pressure from "lut"h assembl- %&&*+ slo#l-1 until the sprin$ %&&+ underneath "lut"h assembl- %&&*+ is extended and relaxed

Illustration 56

g00

&92 Remove hub assembl- %&&=+ from 'or#ard shaft assembl- %=+  &9* Remove sprin$ %&&+ from 'or#ard shaft assembl- %=+  &9) Remove six "lut"h plates %&&!+ and seven fri"tion dis"s %&&/+ from 'or#ard shaft assembl- %=+ 4dentif- the positions of the "lut"h plates %&&!+ and fri"tion dis" %&&/+ for assembl- purposes

Illustration 57

g00

&9= Remove valve assembl- %&&+ from 'or#ard shaft assembl- %=+  &9 Remove piston %&29+ from 'or#ard shaft assembl- %=+ 

Illustration 58

g00

&9! Remove t#o seal rin$s %&2&+ from piston %&29+  &9/ Remove the "up plu$ %not sho#n+ from 'or#ard shaft assembl- %=+ 

Illustration 59

g01

&9 4nstall Toolin$ %S+ in 4nput shaft assembl- %=+ Remove 4nput shaft assembl- %=+ from the transmission "over assembl- %&&+ The #ei$ht of 4nput shaft assembl- %=+ is 2* .$ %=9 lb+

Illustration 60

g00

&&9 Remove t#o seal rin$s %&22+ from 4nput shaft assembl- %=+  &&& Remove inner bearin$ %&2*+ and $ear %&2)+ from 4nput shaft assembl- %=+  &&2 Remove the "up plu$ %not sho#n+ from input shaft assembl- %=+ 

Illustration 61

g00

&&* Remove four bolts %&2=+ from $ear assembl- %&2+ Rotate $ear assembl- %&2+ in order to lo"ate the t#o bolts %not sho#n+ &&) Remove $ear assembl- %&2+ from the transmission "over assembl- %&&+ 

Illustration 62

&&= Position $ear assembl- %&2+1 as sho#n 6se Toolin$ %+ to remove snap rin$ %&2+ from $ear assembl- %&2+  && Position $ear assembl- %&2+ to the opposite side 4n order to drive ball bearin$ %&2!+ off $ear assembl- %&2+1 push a small driver throu$h three small holes %not sho#n+ &&! Remove ball bearin$ %&2!+ from bearin$ retainer %&2/+ 

N*& This is a slip fit

g00

Illustration 63

g00

&&/ Remove five bearin$ outer ra"es %&*9+ from the transmission "over assembl- %&&+  && Repeat Step &&/ for transmission "ase assembl- %*+ 

U'*&

2'M &28 ES 2GS &98 ES 28S &28 ES 20R &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &28 )ER &28 NA )?M &)98 =8M &28 =;M &98 ES 5M &)98 /@M &)98 ES/
R*@>: P.*/.* Table 1

Required Tools Tool

Part Number

Part Description

Qty

A

4-8161

ra(#et

1

A

4-8162

ra(#et

1



5P-9736

in#s

2

S. B?&

&

Remove the radiator Refer to En$ine Supplement1  &281 &)98 and &98 Motor Graders for the "orre"t pro"edure

2

Remove the batteries and batter- boxes Refer to En$ine Supplement1  &281 &)98 and &98 Motor Graders for the "orre"t pro"edure

*

Remove the fuel tan. Refer to Ma"hine S-stems1  &281 &)98 and &98 Motor Graders for the "orre"t pro"edure

)

Remove the differential drive shaft Refer to Disassembl- and Assembl-1 Drive Shaft ( Remove and 4nstall for the "orre"t pro"edure

2ot oil and components can cause personal injury. !o not allow hot oil or components to contact skin.

N*& 3leanliness is an important fa"tor Cefore the removal pro"edure1 the exterior of the "omponent should be thorou$hl- "leaned This #ill help to prevent dirt from enterin$ the internal me"hanism &

Drain the transmission fluid in a suitable "ontainer for stora$e or disposal The "apa"it- of the po#er train s-stem is )! 0 %=9 ,t+

N*& 4nstall "aps and plu$s on all openin$s in order to prevent dirt or debris from enterin$ the s-stem 3leanliness is an important fa"tor Cefore the removal pro"edure1 the exterior of the "omponent should be thorou$hl"leaned This #ill help to prevent dirt from enterin$ the internal "omponents

Illustration 1

2

Dis"onne"t three #ire terminals %2+ from alternator %*+ 

*

0oosen bolts %)+ that hold the alternator 0oosen H(belts %&+ 

Illustration 2

) =

Remove bolt %+ and the #asher from the hose "lip Atta"h a liftin$ devi"e to the fan and alternator assembl- Se"ure the liftin$ devi"e to a hoist Remove four mountin$ bolts %=+ and the #ashers that hold the fan assembl- to the ma"hine frame Remove the fan assembl- from the ma"hine The #ei$ht of the fan assembl- is &99 .$ %229 lb+

g00

g00

&n order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system.

Illustration 3



Relieve air pressure from air tan. %!+ 

!

Put identifi"ation mar.s on four hoses %/+ for installation purposes Dis"onne"t four hoses %/+ from air tan. %!+ 

/

Remove four bolts %+1 the #ashers and shims from t#o mountin$ plates %&9+ Remove air tan. %!+ from the ma"hine frame The #ei$ht of air tan. %!+ is &! .$ %*! lb+

g00

Illustration 4

g00

View ,rom uer right si"e o, transmission



Remove four bolts %&&+1 the #ashers1 and flan$e %&2+ in order to dis"onne"t filter hose assembl- %&*+ 

Illustration 5

&9 Remove four bolts %&=+1 the #ashers1 and flan$e %&)+ in order to dis"onne"t t#o hose assemblies %&+  && Dis"onne"t t#o #ire harness terminals %&!+ from the transmission "ontrol valve

g00

Illustration 6

g00

&2 Remove bolt %22+ and the "lip from transmission hose assembl- %&/+  &* Dis"onne"t the fittin$s of hose assembl- %29+ from filter base %&+  &) Remove t#o bolts %2&+ and the #ashers that hold filter base %&+ to the ma"hine frame Move filter base %&+ out of the #a-

Illustration 7

&= Put identifi"ation mar.s on t#o hose assemblies %2*+ for installation purposes Dis"onne"t the fittin$s of the hoses from the transmission

g00

Illustration 8

g00

& Dis"onne"t shift "ontrol "able %2)+ from the transmission h-drauli" "ontrol valve

Illustration 9

&! Remove four bolts %2+1 the #ashers1 and the flan$e in order to dis"onne"t hose assembl- %2=+ from the transmission

g00

&/ Dis"onne"t the fittin$s on hose assembl- %2!+ from the transmission & 0oosen "lamp %2+ and dis"onne"t hose assembl- %2/+ from hose "onne"tor %*9+  29 0oosen "lamp %*2+ and dis"onne"t hose %*&+ from the differential

Illustration 10

g00

2& 4nstall Toolin$ %A+ to both sides of fl-#heel housin$ %**+ Ad7ust both s"re#s %*)+ in order to "onta"t the ma"hine frame This toolin$ #ill support the en$ine after the rear motor mounts are removed

Illustration 11

g00

Clutch

Recommend Documents