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,2R12R1-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 (1A1-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$s that "ould "ause the No! "lut"h "lut"h to to fail 0isted belo# are some on the obvious items that #ould not onl- appl- to No! "lut"h "lut"h11 but to all "lut"h "lut"hes es &0o# "lut"h "lut"h pressure1 pressure1 "aused b- "ontrol valve problem or "lut"h "lut"h piston piston seal failure 2Slo# "lut"h "lut"h pressure pressure de"a- #hen the "lut"h "lut"h is is disen$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
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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 %9929 in"h+
g00
%A+ Distan"e from "ab floorplate to the bottom ed$e of the pedal = B mm %*! B 92 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 ! Nm %2/ B = lb ft+ %=+ 'inal installation tor,ue / B * Nm %!& 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 /
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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
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(#) $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
•
Release pedal %+
•
8old bolt %!+ in position and ti$hten lo".nut %/+
•
Shut off the en$ine
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 /
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$ine Pla"e blo".s in front of the #heels and pla"e blo".s behind the #heels
Quanti
Illustration 1
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(1) Co+er ,or the transmission control +al+e
*
Remove "over %&+ from the transmission Remove the differential drive shaft
Illustration 2
g01
*ransmission control +al+e (2) *est ort
)
Remove the "over on test port %2+ 3onne"t 8$-0855 Pressure Gau$e %9 to )1999 .Pa %9 to =/9 psi++ to test port %2+
Illustration 3
i"e +iew o, clutch e"al (3) Clutch e"al
g01
(4) .e"al sto bolt (5) &oc'nut
Illustration 4
i"e +iew o, clutch control cable assembly/ (3) Clutch e"al () Clutch control cable (#) Val+e sool
=
Press "lut"h pedal %*+ a$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 999 .Pa %999 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 999 .Pa %999 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$e of 999 .Pa %999 psi+ to /*) .Pa %&29 psi+
i
The spool ma- need to be "leaned if the spool does not move freel- 4f the spool moves freel- and modulation o""urs in Step /1 "lut"h "ontrol "able %+ ma- need to be repla"ed
&9 'or more information on the "lut"h pedal1 refer to theS-stems Operation1 Testin$ and Ad7ustin$1 3lut"h Pedal ( Ad7ust
U'*&
&A0 &)*8 &A0 &)*8 &A0 &298 2AN &298 2AN &298 2AN &98 2' M &98 2'M &982'M &28 ES 2GS &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES 28S &98 ES 28S &28 ES20R &28 ES 20R &28 ES 20R &28 NA 25R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA2;< &)98 NA 2;< &)98 ES *AS &)98 ES *AS &)98 ES *AS &)98 NA *'R &)98 NA *'R &)98 NA *'R &98 NA *GM &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &28 )ER &298 NA )M< &298 NA )M< &298 NA )M< &28 NA )?M &28 NA)?M &28 NA )?M &*8 NA =A< &*8 NA =A< &*8 NA =A< &298 ='M &298 ='M &298 ='M &)*8
M. G./*.& 120H (SN& 2AN1-UP 4MK1-UP 3GR1-UP 5FM1-UP 6NM1-UP 6$M1-UP 9FN1-UP 9YR1-UP) 135H (SN& 3YK1-UP 7MM1-UP 8WN1-UP) 12H (SN& 2GS1-UP 4!R1-UP 5#M1-UP 2R1-UP 2WR1-UP 4"M1-UP 8MN1-UP) 140H (SN& 2#K1-UP 5HM1-UP 8JM1-UP 8KM1-UP 9$N1-UP 9#N1-UP 3FR1-UP 3AS1-UP) 143H (SN& 1A1-UP) 160H (SN& 2HS1-UP 3GM1-UP 9!J1-UP 2FM1-UP 6WM1-UP 9JM1-UP) 163H (SN& 5AK1-UP) Servi"e Ma$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
•
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 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 %+
•
8old bolt %!+ in position and ti$hten lo".nut %/+
•
Shut off the en$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$e the dire"tion of the ma"hine
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Release the transmission modulator pedal in order to re(en$a$e the po#er to the #heels N*& 6se the transmission modulator pedal to in"h the ma"hine
U'*&
&A0 &98 2'M &2 &28 8 ES ES 2GS & &98 98 ES 28S &2 &28 8 ES 20R &28 NA 25R &) &)98 98 NA 2;< &) &)98 98 ES *AS & &98 98 NA *GM &*=8 NA *>< &28 )ER &2 &298 98 NA )M< &2 &28 8 NA )?M &*8 NA =A< &298='M &)98 =8M &28 =;M &2 &298 98 ES NM &298 TM &98 ES 5M &*=8 !MM &)98 /@M &) &)98 98 ES /R &) &)98 98 NA ;N &)*8 &) *8
Illustration 1
chematic o, the Circuit o, the hi,t &e+er
N*& Refer to the Ele"tri"al S-stem S"hemati" in the Servi"e Manual of the ma"hine for the "orre"t s"hemati"
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Problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the ma"hine to respond in"orre"tl- to the a"tions of the lever Some problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the transmission to remain in the present speed and dire"tion #hen a problem is dete"ted Other problems #ith the transmission dire"tion and speed "ontrol lever #ill "ause the transmission to shift to neutral &
+* * '' i
6se the 3aterpillar Ele"troni" Te"hni"ian %ET+ to vie# the status Group & Gear 0ever Parameters
i
A"tuate the transmission shift lever throu$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
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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) )oriontal sur*a(e s)ould not /o+e .)en t)e le+er is in t)e 'UT&A position, Re+erse $,& - o+e t)e le+er to t)e rig)t and pull ba(# t)e le+er to t)e desired speed, T)e /a()ine .ill /o+e in re+erse,
1 ( 'irst Speed 2 ( Se"ond Speed 3 ( Third Speed 4 ( 'ourth Speed 5 ( 'ifth Speed 6 ( Sixth Speed
U'*&
2'M &98 2'M &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES 28S &28 ES 20R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA 2;< &)98 ES *AS &)98 ES *AS &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &298 NA )M< &298 NA )M< &28 NA )?M &28 NA )?M &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &298 ES NM &298 ES NM &298 TM &298 TM &98 ES 5M &298 NA >N &298 NA >N &*=8 !MM &*=8 !MM &)98 /@M &)98 /@M &)98 ES /R &98
Illustration 1
%&+ Tor,ue for *= bolts *9 B ) Nm %22 B * lb ft+ %2+ Tor,ue for pressure s#it"h assembl- *= B * Nm %2= B 2 lb ft+ %*+ Tor,ue for temperature s#it"h assembl- & B * Nm %&) B 2 lb ft+ %)+ Tor,ue for adapter &) B ) Nm %&9 B * lb ft+ %=+ Tor,ue for ei$ht nipple assemblies &) B ) Nm %&9 B * lb ft+ %+ Sprin$ Test len$th &2!9 mm %9=99 in"h+ Test for"e &! B 9& N %9*/ B 992 lb+ 'ree len$th after test &9 mm %9!= in"h+ Outside diameter m %9*/ in"h+
%A+ Position for adapter %)+ /9 B = de$rees
U'*& &9 98 2'M &2 &28 8 ES ES 2GS &28 &A0 &)*8 &A0 &298 2AN &98 2'M & ES 2GS & &98 98 ES 28S & &98 98 ES 28S &2 &28 8 ES 20R &2 &28 8 ES E S 20R &28 NA 25R &2 &28 8 NA 25R &) &)98 98 NA 2;< &) &)98 98 NA 2;< &) &)98 98 ES *AS &)98 ES *AS & &98 98 NA *GM & &98 98 NA *GM &* &*=8 =8 NA *>< &*=8 NA *>< &28 )ER &28 )ER &2 &298 98 NA )M< &2 &298 98 NA )M< &2 &28 8 NA NA )?M &28 NA )?M & &*8 *8 NA =A< &*8 NA =A< &298 ='M &298 ='M &)98 =8M &)98 =8M &28 =;M &28 =;M &298 &2 98 ES NM &2 &298 98 ES NM &298 TM &298 TM & &98 98 ES 5M &98 ES 5M &2 &298 98 NA >N &*=8 !MM &*=8 !MM &)98/@M &)98 /@M &)98 ES /
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Illustration 1
(1) *ransmission control +al+e (2) *ransmission wiring harness
Transmission "ontrol valve %&+ provides the proper flo#s and the proper pressures in order to en$a$e the desired transmission "lut"h "lut"hes es The transmission "ontrol valve is lo"ated on the left side of the transmission "ase The transmission "ontrol valve is "onstru"ted of t#o "ast aluminum valve bodies1 three "ast aluminum manifolds1 three steel plates1 several aluminum spools1 and mis"ellaneous steel parts
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Illustration 2
(3) anual mo"ulation +al+e (4) ain relie, +al+e
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(5) .riority re"ucing +al+e () o"ulating re"ucing +al+es (#) olenoi" +al+es
The transmission "ontrol valve "onsists of the follo#in$ "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
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(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 suppl- pressure 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"ater (2#) .ort ,or temerature sensor
The manual modulation valve is lo"ated in the uppermost portion of the outermost valve bod-
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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 suppl- pressure 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 suppl- pressure 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 suppl- pressure to 9 .Pa %9 psi+ Slo#l- releasin$ the pedal allo#s suppl- pressure 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- 92 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
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M/:= R*/= +:>*
Illustration 7
(#) olenoi"
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(2%) elector sool (2) ecay ori,ice (3) &oa" iston (31) o"ulation ori,ice (32) !e"ucing sool (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 $raduall- redu"e the "lut"h pressure
S:*=/ +:>*'
Illustration 8
(#a) olenoi" (#b) olenoi" (#c) olenoi"
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(#") olenoi" (#e) olenoi" (#,) olenoi" (#g) olenoi" (#h) olenoi" (35) ee" selector sool (3) ee" range selector sool (3#) irection selector sool
Solenoid valves %!+ "onne"t pressuriFed oil from the priorit- redu"in$ 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.' . * $.='@''= ;=.: +:>*
Illustration 9
(3%) .assage ,or clutch 2 (3) &ubrication (4) 6le+ate" "rain (41) .assage ,rom the hy"raulic um (42) .assage to the oil cooler (43) rain (44) .assage ,or clutch % (45) Clutch # at station (H) (4) Clutch 5 at station (7) (4#) Clutch at station (8) (4%) .assage ,or clutch 4 (4) .assage ,or clutch 3 (5) .assage ,or clutch 1 (51) .ilot ressure
U'*&
&A0 &298 2AN &98 2'M &28 ES 2GS &98 ES 28S &28 NA 25R &)98 NA 2;< &)98 ES *AS &98 NA *GM &*=8 NA *>< &28 )ER &298 NA )M< &28 NA )?M &*8 NA =A< &298='M &)98 =8M &298 TM &298 NA >N &*=8 !MM &)98 /@M &28 NA /MN &*=8 /5N &98 NA E@ &98 @M &)98 NA TN &298 ES >R &)98 NA ;N &*=8 CD@ &)*8
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S* U P.*/.*'
Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, do the procedure that follows before testing and adjusting the transmission and power train.
1 Move the ma"hine to a smooth horiFontal lo"ation Move a#a- from #or.in$ 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&92K 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$es t#o and three of SE8S2)1 6sin$ 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 %ie /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$rammed The Hehi"le 4D is the first option This input field is provided stri"tl- for "ustomer use and does not have an- other fun"tion
The Transmission 3onfi$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: )&()/ '91 Transmission Solenoid Short To Ground
'lash 3odes: )&()/1 34D('M4: )&()/ '9*1 Transmission Solenoid Short To Catter-
'lash 3ode: =21 34D('M4: *! '91 Ca".up Alarm Short To Ground
'lash 3ode: =/1 34D('M4: // '91 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: !) '91 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: // '91 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
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
Quantity
1U-5481
Pressure auge roup
1
1U-5482
Pressure Adapter roup
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
(irst ear (or)ard
-O# Idle /I/ Idle Transmission -ubrication Pressure Di0erential -ock in the O(( Position Neutral
(irst ear (or)ard
-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
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.
%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) Cas
*
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
Pressure Adapter roup
1
1U-5481
Pressure auge roup
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 () $olt (#) Cas
)
Remove fourteen mountin$ 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$hten bolts %)+ and bolt %+ Refer to Spe"ifi"ations1 Transmission 3ontrol Halve for the "orre"t tor,ue
Illustration 3
g01
(%) 4-1#51 acer an" 5:-13 him () A"uster assembly (1) ani,ol" (11) &oc'nut (12) A"ustment screw
!
Remove "aps %!+ 4nstall the 8$-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$1 debris in the "ontrol valve or a seal failure #ithin the transmission
U'*&
&A0 &)*8 &A0 &98 2'M &98 2'M &28 ES 2GS &28 ES 2GS &98 ES 28S &98 ES28S &28 ES 20R &28 ES 20R &28 NA 25R &28 NA 25R &)98 NA 2;< &)98 NA 2;< &)98 ES*AS &)98 ES *AS &98 NA *GM &98 NA *GM &*=8 NA *>< &*=8 NA *>< &28 )ER &28)ER &298 NA )M< &298 NA )M< &28 NA )?M &28 NA )?M &*8 NA =A< &*8 NA =A< &298='M &298 ='M &)98 =8M &)98 =8M &28 =;M &28 =;M &298 ES NM &298 ES NM &298TM &298 TM &98 ES 5M &98 ES 5M &*=8 !MM &*=8 !MM &)98 /@M &)98 /@M &)98 ES /
When testing and adjusting the transmission and power train, move the machine to an area clear of obstructions, with safe exhaust ventilation for the exhausts. Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, do the procedure that follows before testing and adjusting the transmission and power train.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. e prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. !ispose of all fluids according to local regulations and mandates.
Cefore -ou be$in the test1 refer to Troubleshootin$1 Ma"hine Preparation for Troubleshootin$ Table 1
Required Tools Part Number
Description
Quantity
1U-5481
Pressure auge roup
1
1U-5482
Pressure Adapter roup
1
Table 2
Transmission -ubrication Pressure
Neutral -O# Idle
/I/ Idle
(irst ear (or)ard
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
(irst ear (or)ard
-O# Idle /I/ Idle Transmission -ubrication Pressure Di0erential -ock in the O(( Position Neutral
(irst ear (or)ard
-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 * Nm %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
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%&+ 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 92= 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 9929 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 99/ mm %&=! B 99* in"h+ 4nstall 108-5751 'ri"tion Dis" into the "lut"h pa". so that the $rooved pattern fa"es to#ard the "enter of the "lut"h pa". One of the fri"tion dis"s is lo"ated at the front of the "lut"h pa". and one of the fri"tion dis"s is lo"ated at the rear of the "lut"h pa". Minimum allo#able thi".ness for reusabilit- *! mm %&)) in"h+ Thi".ness of one ne# 6-8911 'ri"tion Dis" )99 B 99/ mm %&=! B 99* in"h+ Minimum allo#able thi".ness for reusabilit- *** mm %&*& in"h+ Thi".ness of one ne# 9U-9995 Plate *99 B 99/ mm %&&/ B 99* in"h+ %2+ Thi".ness of seven ne# fri"tion dis"s and of six ne# plates )99 B &9) mm %&/&& B 9)& in"h+ N*& The measurement must be made #hen the fri"tion dis"s and the plates are "ompressed N*& This dimension is onl- the thi".ness of seven ne# fri"tion dis"s and six ne# plates This dimension does not in"lude the runnin$ "learan"e of the "lut"h pa".
Runnin$ "learan"e for number t#o "lut"h pa". %'or#ard 8i$h Gear+ &= B ) mm %99= B 992= in"h+ N*& Refer to the pro"edure: Pro"edure to Measure Runnin$ 3learan"e
Thi".ness of one ne# 6-8912 'ri"tion Dis" )99 B 99/ 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 99/ mm %&&/ B 99* in"h+
%*+ Diameter of shaft in bearin$ area ) B 999! 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 &99 mm %)&! in"h+
%=+ Diameter of shaft in bearin$ area ) B 999! 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 %99= B 992= 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 99/ 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 99/ 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 %99)= B 992& 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 99/ 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 99/ mm %&&/ B 99* in"h+ %*+ Diameter of shaft in bearin$ area ) B 999! 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 &99 mm %)&! in"h+
%=+ 102-5881 5ave Sprin$ Test len$th */29 mm %&=9* in"h+ Test for"e 299 B 222 N %)!9 B =9 lb+ 'ree len$th after test =99 mm %&! in"h+ Outside diameter &99& 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 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area /)2 B 999/ 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 %99!= B 992) 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 99/ 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 99/ 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 %99)= B 992& 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 99/ 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 99/ mm %&&/ B 99* in"h+ %)+ Tor,ue for t#o bolts == B &9 Nm %)& B ! lb ft+ %!+ 102-5881 5ave Sprin$ Test len$th */2 mm %&=9 in"h+ Test for"e 299 B 222 N %)!9 B =9 lb+ 'ree len$th after test =99 mm %&! in"h+ Outside diameter &99& 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 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area /)2 B 999/ 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 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area /)2 B 999/ 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 %29 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 992& 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 99/ 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 %99!= B 992) 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 99/ 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 99/ 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$th */2 mm %&=9 in"h+ Test for"e 299 B 222 N %)!9 B =9 lb+ 'ree len$th after test =99 mm %&! in"h+ Outside diameter &99& B 9 mm %)&!) B 92 in"h+
%!+ Tor,ue for t#o bolts == B &9 Nm %)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 99* mm %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area /)2 B 999/ 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 99* %2!=2 B 99&= in"h+ Diameter of shaft in bearin$ area /)2 B 999/ mm %2!)! B 999* in"h+
P.*/.* M*'.* R=== ;:*.=*
g00
Illustration 17
g00
*yical 6;amle
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'*&
&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 /
;@=*='
Illustration 1
*he en" +iew o, the transmission ,or the sha,t location (1) 8orwar" sha,t
g01
(2) 0nut sha,t (3) ha,t assembly (4) ha,t assembly (5) ha,t assembly
Illustration 2
(1) 8orwar" sha,t (2) 0nut 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) utut 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) 0nut 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) utut 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) 0nut 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) utut 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 29 mm %)9 B 99/ 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
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)* 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+
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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- %&)+
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Illustration 29
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=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- %&)+
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Illustration 31
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=) Remove seal extension rin$ %*+ and seal rin$ %)+ from piston %2+
Illustration 32
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Illustration 33
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== 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+
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Illustration 35
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=! 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- %/+
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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
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Illustration 38
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* Remove #ave sprin$ %!!+ from ReverseISe"ond shaft assembl- %/+ ) Remove piston %!/+ from ReverseISe"ond shaft assembl- %/+
Illustration 39
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= Remove seal rin$ %/9+ and seal extension rin$ %!+ from piston %!/+
Illustration 40
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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- %/+
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Illustration 42
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!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- %/+
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Illustration 44
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!! 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- %/+
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Illustration 46
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/& 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 $ear assembl%!+ from 'or#ard shaft assembl- %=+
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Illustration 48
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/) Remove roller bearin$ %/+ 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
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Illustration 50
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// 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- %=+
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Illustration 52
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* 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 $ear assembl- %&&9+
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Remove inner bearin$ %&9+1 the thrust ra"e %not sho#n+1 the t#o thrust dis" %not sho#n+1 and $ear assembl- %&&9+ from 'or#ard shaft assembl- %=+
Illustration 54
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! Remove roller bearin$ %&&&+ 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$s %&&)+ from 'or#ard shaft assembl- %=+
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&9& Release the pressure from "lut"h assembl- %&&*+ slo#l-1 until the sprin$ %&&+ underneath "lut"h assembl- %&&*+ is extended and relaxed
Illustration 56
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&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
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&9= Remove valve assembl- %&&+ from 'or#ard shaft assembl- %=+ &9 Remove piston %&29+ from 'or#ard shaft assembl- %=+
Illustration 58
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&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
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&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
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&&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
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&&* 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
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Illustration 63
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&&/ 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+
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&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+
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Illustration 4
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View ,rom uer 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
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Illustration 6
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&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
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Illustration 8
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& 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$e in order to dis"onne"t hose assembl- %2=+ from the transmission
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&/ Dis"onne"t the fittin$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
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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
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