DOWNLOAD PDF Fiatallis 21-B Crawler Tractor Transmission Engine Service Manual FN 70664062

21-8 crawler tractor

service manual

TRANSMISSION

Form 70664032 English

4/89

AVOID ACCIDENTS Mosl

whether they occur il'l on the farm, at home or on the ere caused by the failure of some individual to follow and fundamental (ules or precautions. For Ihis reasol'! MOST ACCIOENTS CAN BE PREVENTEO by recognizing the real cause and dOing something about II before the accident occurs.

Regardless of the care used 11'1 the design and construction of any type of equipment Ihefe are conditlcms that cannot be completely saleguarded against without Interfering with reasonable accessibllity and efflclent operation.

A ;:;&filM opei"lItot \$ llill.blIslllUlitaM' allllMl all ~ Tho 11_ _' . ol:I$fI",ArnIII 01 <:MlI lfm9ll1 t!lls wcvid prHIII'I! ~

IMUUI'IlI aatioull Inilltlll$ ea::11 }'liar.

Thol wle Ii:

Never attempt to clean, oii or adjust a machine while it is in motion.

WARNING On machines having hydraulically. me~hanicallYI andior cable controlled equipment (such as shovels, loaders, dozers, scrapers, etc.) be certain the equipment is lowered to the ground before servicing, adjusting andlor repairing. If it is nece~sary to have the hydraulically. mechanically, and/or cable controlled equip. ment partially or fully rals.ad to gain accm to certain items, be surs tha ment Ig suitably supported by meens other than the hydraulic 11ft cable andiol' meehamcal devices used for cOl"ltrollirtg' the equiPment.

COPYRIGHT BY FIATALLIS

• All rights reserved. Reproduction 01 lext and illustrations in whole or'in part, is strictly prohibited.

21-8 crawler tractor service manual TRANSMISSION SJN 16001 tbru 16550 SJN 108 16551 • UP FORM 7Q664032 Englin (SAME AS 0664032-0) .

A WARNING

STUDY THE OPERATION AND MAINTENANCE INSTRUCTION MANUAL THROUGH BEFORE STARTING, OPERATING. MAINTAINING, FUEUNG OR SERVICING THIS MACHINE.

A A A A

The Operation and Maintenance Instruction Manual provides the instructions and procedures for starting, operating. maintaining, fueling, shutdown and servicing that are necessary for properly conducting the procedures for overhaul of the related components outlined in this Service Manual.

This symbol is your safety alert sign. It MEANS ATTENTION! BECOME ALERTI YOUR SAFETY IS INVOLVED.

Read and heed all safety instructions carrying the signal words WARNING and DANGER. Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger points.

SUPPLEMENT NO.7 SERVICE MANUAL FORM 70684032 TRANSMISSION

21 .. 8 CRAWLER TRACTOR ( 5-78) ATrENTION: hmert this sheet in the front of publieation as record of in the publieationaecording to instructions below.

Additional copies of this supplement are aveilable. Please irect your request to: Fiat~Allis Construction Machinery. Inc.• Publicat' ns Services Dept., 3(J()(J South 6th Street, Springfield. Illinois 627 U. S. A.

REPLACE the following pages:

61 (Revised) 62 (No change)

75 (Revised) 76 (No change)

REASON:

SUPPLEMENT NO. 6 SERVICE MANUAL FORM 10664032 TRANSMISSION

--

FlAT-AWS

21-8 CRAWLER TRACTOR (11 .. 77)

ATTENTION: Insert this sheet in the front of publicatioo as reco d of uceipt.

Replace or add pages 10 the publication according to instructioos eloW. Additional copies of this supplement au available. Please dire

Flat-ifLUs Constructicm Machinezoy. Inc." '1'echnicaZ PubUcat' 8th Street" Spri:ngjie'td" nUncisM 62?lO U.S.A.

Write in the !oUowmg change: Page 65 Add the followmg note under 8. :3 I IMPORTANT: Before reallSemb. g transmission, make certam aU components a within specifications given 10 Fits and Tolerences.

Replau the following like pages: 89 (Revised) 89A (Revised)

II(ltICE: AU' -ChaZmers CcrpcNticm and FIA'! S.p.,,4. entered into a joint thmture ~ful!tmtt to ~ their ~jact:u:N" saLe and sewics oj constructicm MM'Z'7I ~ts t~1ttrut the wor'td after J'~ 1 .. 1974. n ~ oj the ?tAl enterprise" t.1MNVer in thu rejfiirence is made to AUis-Chalmers or yC'W" AUie-Chalmers such Njfiirence ie in~ to identify FIA'1'..ALlJS COM'Wuction Machine'Z'71 Inc. 0"1' yC'W" FIA!!ALlJS deai.er

Printed in U.S.A.

SUPPLEMENT NO. 5 SERVICE MANUAL FORM 70884032 TRANSMISSION

21@B CRAWLER TRACTOR ATTENTION: Inurt this sheet in the front of publication as record Replace 01' add pages in the publication according to instructions bel Additional copies of this supplement are available. Please direct

Fiat-Attis Con$t~tion MachinePy, Inc., TeahniccZ PubZiaaticns 6th Street, SpringfieZd~ ItZinois# 62710 U.S.A.

Replace the following like pages: 57 (No change) 58 (Revised) 71 (No change) 7l. (Revised) 13 (Revised) 74 (Revised)

75 (Revised) 75A (Added) Reason: New transmisslOD tools for instaUi

Printed in U.S.A.

75B (Added) 75e (Added)

89 (Reviud) 89A (Added) 89B (Added)

90 (No change)

SUPPLEMENT NO.4 SERVICE MANUAL FORM 0664032~O MODULATING CLUTCH. TOROUE CONVERTER. TRANSMISSION. BEVEL GEAR. DRIVE SHAFT U·JOINT

AITENTIQN: Insert this sheet into the front of publication as :recor or add pages in the publication according to instructions below.

Additional copies of this supplement are available.

Write in the following changes (changes are underlined) Page 46

RRIER ••• ; replace CUIDE WHEEL it if I. D. at an point is more than Z.182." {22,. 0 m)

Replace the following like pages: 11 (Revised) 12. (Revised

;; 7 (Revi sed) 38 (Revised)

12A (Added) bnk

47 (No change) 48 (Revised)

13 (Revised) 14 (Revised)

~SA (Added)

Blank

15 (Revised) 16 (Revised)

36E (Added) 36F (Added)

49 (No change 50 (Revised)

2.5 (Revised) 26 (Revised)

360 (Added) 36H {Added)

51 (Revised) 52 (No change)

Reason: This sup ement adds repair procedure for automatic saiety brake and mo lating clutch input shait front nut.

Replace

SUPPLEMENT NO.3 e

SERVICE MANUAL fORM

06>64032~O

MOOULATING CLUTCH, TORQUE CONVERTER, TRANSM ISSION. BEVEL GEAR, ORIVE SHAfT U*JOIN

HD-21 SERIES B ATTENTION: Insert this sheet into the front oi publication as rec

Replace

Or add pages in the publication according to instructions below.

Additional copies of this supplement are available.

Replace

~he following like pages:

11 (Revised) 12 (Revised) 45 (No change) 46 (Revised)

.. .

Relsoft;

This supple ent changes stan speed specification and converter bypass tube rollin procedure, and adds replacement procedure for guidewheel shing.

., "

Printed in U. S. A.

SUPPLEMENT NO.2 SERVICE MANUAL FORM 0884032- 0 MODULATING CLUTCH. TORQUE CONVERTER, TRANSMI BEVEL GEAR. DRIVE SHAFT U-JOINT

HD-21 SERIES B (8 .,,)

AIIENIIQt!: Insert this sheet into the front of publication as re or add pages in the publication according to instructions below.

Additional copies of this supplement are available.

Writl in the following changes (changes a Page 29

Fig. 22

ESSURE REGULAIING VALVE (prior to Ior9,'W Conv,rter SIN 241000)

aeplltt the lollowiog like 71 (Revised) 72 (Revised)

73 (Revised) 74 (No chg.)

Ihis supplement includes a new main pressure regulating valve and two piece friction plates nil the transmission forward/reverse clutch shaft.

Printed in U. S. A.

Replace

NOTICI O' CHANGI TO SERVICE MANUAL FORM 06640n·O TORQUE CONVERTER', TRANSMISSION. BEVEL GEAR and DRIVE SHAFT U-JOINT HD-21 SERIES B CRAWLER TRACTOR

Write in the following changes (changes are underUned): 6. a TRANSMISSION PU

Page 34 Page 5a

(Prior to SiN 11519 thru 1(517578)

Fig. 49

Page 88

Re,ilel the following like pages: 3 (Revised) 4 (No Change)

.'

'<~6A (Added)

36B (Added)

51 (Revised)' 52 (Revised)

19 (Revised) 20 (Revised)

53 (Revised) 54 (No Change)

35 (Revised) 36 (Revised)

69 {Revised} 10 {Revised}

R•• SII: This supplement includes a new ransmission oil pump and changes to t~e. ~rque converter.

.

NOTE: Make appropriate changes this supplement.

INSERT THIS SHEET INTO OF THIS SUPPLEMENT.

dlor additions in ALPHABETICAL INDEX to include

E FRONT OF MANUAL 0664032·0 TO INDICATE RECEIPT

Additional copies f this supplement are available. Please direct your order to the Technical Publi ations .Department. Springfield Plant. "

Supplement No. 1 Issued U-10

GENERAL

SAFETY RULES Do not ues machine to carry lOon ~ by means other

Study tM OperatiOn and Malnt~ t~ Manual before starting, operating, maintaining, fueling, or setvieing machine.

than attad1mants for carrying such objects.

DO NOT CARRY RlDeRS uniaM tM machine Is equipped for csnying people to reduee peraonel exposure to being thrown off.

Read and heed all mach~ted nfeiy sitM before star· tlng, operating, maintaintng, fueling or HMcing machine.

Do not operate machinery In a condition of elltl'el'M fatigue or

Machlf'HH'l'l(M'lted ntety $igM hmt been color coded yellow with black border and lettering tor WARNING and red with white border and lettering for DANGeR pointa.

illneSs. Be especially csreful towards the end of tM shift.

Roll OYer' ProtectiVe Structuru are required on wheet loaders, dozer tractors, trICk type lOaders, gredm and acrepera by ,1Ocs1 or netlonal requirements. DO NOT operate this machine

Never attempt to operate the machine or its tooie from any position other than naIed In the operator's net. Keep head, body, lim!:)&, hands and feet Inside operator's compartment at aU tlmas to reduee ~ to haurds outside the operator's

.withOui a Rotl over Protective Structure.

compartment.

Do not operate a machine without a failing object protactlve structure (FOPS).

Do not allow uneutholimd peraonnel to operate, setvlee or maintain this machine.

Do not operate this machine without a rur caoopy screen when machine is equipped with rear mounted towing winch.

Always eMek work area for dangerotl$ faatIJraa. The fotlowing are examples of dangerous work areas: sfopU, ovemangs, tlmbel', damolitionS. fire, high walls, dropoff, beekfllls, rough terrain, diteMs, ridges, excavationS. hftVy !reffi¢. crowded paril:ing, orowded maln~ and cioHd areu.Un extreme care when in aten such as tMae.

Sest belts ate required to be provided with roll over protective structuru or roll protection cabs by IOcsI or national regula. tlons. Ksep the nfet)' belt fastened around you during 0peration.

Where ooIee exposure excNde 90 dM for S hours, west authorimd ear protective equipment per local or national re. qultel'Mnts thet apply.

An operator must know tM machine's oapabifitles. WHo working on slopfi or near dropoffs be alert to avoid lOon or soft CondtiiOM that coufd csun sudden tipping or ion of con. trot,

Ksep clutctlM and makes on machine and attachments such as power controt unite, wincMs and muter clutcHS edjusled according to Operation and Malntenancs lnalructlon Manuals of the menufacturers at all times. DO NOT edJusl machine with engine roMing except as specified.

Do not jump on or off maehine. Ksep two hands and OM foot, or two fat and OM hand, In contact with steps, grab ralls and handles at all times.

Do not operate a machine with tnkeS out of edjustment. See tM Operation and Maintenance Inslructlon Manus!.

Do not I.IH controls or hOses n hMdhofdS when climbing on Of off machine. Hoses and controle are I'nOVIIbIre and do oot provId$ a soIfd ~ COntrols also may be lnedwrtantly

Move carsfully whan under, in or Mer machine or implements.

Wear required protactlve equipment, such es Mrd hat, nfety gl&_ , salety shoes, eer protectors.

moved esuaIng a.eofdantal machine or equipment movament Ksep operator's compartment, stepping points. ~Is and handiss ciMr of ~ objects, oit, gran. mud or snow a.eoumulatlon to mlnlmim the danger of slipping or ~ing.

Clean mud or grena from shoes before damptlng to mount or operate the maehine.

To move a disabled machine. use a trailer or low boy truck If avatlabfs. If towing Is MCMHrY. provide wsmlng signals as required by IOcsI rulas and regulations and follow Operation and Maintenancs Instruction Manual recommendations. load and unload on a level ares ttlat gives fun support to the trsiier whMIlIl. un temps of adequate strength, low angle and proper halght. Ksep trsllar bed clean of clay, 011 and all materials that become slippery. TIa mactllne down $$Curety to truck or trailer bed and block tracks (Of wheets) as required by the csrrIer.

Be ,carsful of slippery condtIIOne on steppfng points, Mnd ralls, and on the gl'Ollind. West estety boots or shoes that have a high slip realstant sole meterla!.

For your peraonel protactlon, do oot atlempt to climb on or off mactline while machine Is in moIlon.

Never Iaave the machine unettanded with the engine running.

To prevent entrapment In cabs or mounted enclosures, obsetve and !mow the mechanics of alternate exit routes.

Always lock up machine when IMv1ng It uneffendad. Retum keys to autI'torimd saeurity, Heed all shutdown proeadurM of the Operatton and ~ tnelruetton Manual. Always set the parking brake when laeving the machine for any

On machines equipped with suction redfetor fens, be sUte to perIodieally eMek all engine exhaust perts tor IUQ. as exMust gaRS are dangerous to tM operator. Ksep a vent open to ootsIde all' at all timas when operating within a closed cab.

(esson.

STARTING FLUiD IS FlAMMABLe.. Follow the ~a. tlone as outlined In the Operation and Maintenance instruction Manual and as marked on the containers. Store containere In ~, weikentilated p!aes saeure from uneuthorimd of the manutaclurer for storagt· anddiepoesL Wire rope ~ ateal slivers. Use autholimd profactive equipment such as heevy gloves, ntety gissMs when hand-

ling.

I

SAFETY RULES OPERATION

When counterweights heve beatI provided, do not work machine if they have been rerooved unless their equivalent weight hes been replacad. Sea the Operation and Maintenance Instruction Manual.

Before starting machiM, ohaek, adjust and look the operator's seat for maximum oomfort and (l()!'Itrol of the machiM,

Whan operating a machlM know what clearances wIH be encountered, overhsad door'$. wires, pipes, alsles, roadways; also the weight limitations of ground, flcor, and ramps.

00 NOT START OR OPERATE AN UNSAFE MACHINE. Before working the machiM, be sure that any unsafe (l()!'I(fftion has beatI satisfactorily remedied. Chaek brakes, stMl'lng and attachmant (l()!'Itrols before moving. AdvIse the proper maintanance authority of any malfunctioning part or syatem.

Be sure all protaetive guards or panels are in place, and all safety devices provided are in place and In good operating (l()!'Idltion. '

Know bridge and culvert load limits and do not exceed them, Know machine's height, width, and weight. Use a Signal per· son whan clearance is clOsa. Be sure that the exact location of gas !Ines, ut!!!!y liMS,

sewers, overhead and burlad power lines, and other obstruc-

Chack instruments at start-up and frequently during operation,

tions or hazards are koown. Such lOcations should be preciHIy marked by the proper authorities to reduce the risk of accidents. Obtain shut-down or relOcation of any such facilities before starting work, if necessary.

00 oot run the angine of this machlM In cfosed areas without proper vantllatlon to remove deedly exhaust gases, Be sure exposed pereonnelln the area of operation are clear of the machine before moving the machine or Its attachments.

WALK COMPLETELY AROUND machlM before mounting.

Sound hom. Obey flagman. safaty signals and signs.

Be cerlaln to comply with all local, state, and federal regula· tions regarding working in the vicinity of power lines.

Whan roadlng find out what conditions are IIke!y to be mat • olearances, congestion, type of surface, etc. Be aware of fog, smoke or dust elements that obscure visibility.

Know the principles of OroN stMl'lng of orawler tractors. RHd saetion in Operation and Maintanance Instruction Manual on cross stMl'lng.

When backing, always !00k to where the machine is to be moved. Be alert to the position of exposed personnel. 00 NOT OPERATE If exposed peraonnei enter the immediate work

Keap engine axhaust syatem and exheust manlfoids clear of combustible material. equip machine with $Creans and guards when working under COnditions of flying combustible material.

ara Never travel a maohfM on a lob site, in a (l()!'Igested area, or around people without a signal pemm to guide the operator.

If engine hsa a tenctancy to stall for any reason under load or Idle, report this for adjustment to a proper malntanance authorlty immedlatety, 00 oot continue to operate machlM until (l()!'I(f1t1on has beatI correctad.

. In darkness, ehaek area of operation carefully before moving In with machiM. Usa ell lights provided. 00 oot move into area of restricted visiblflty.

Never use bucket es a man-ilft Maintain clear vision of all areas of travel or work. Keep ceb windows clean and repeirad, carry blede low for maximum visibility while traveling. Obtain and usa fan blast deflectors where tractors are ueed as puwr tractors in tendem.

Usa recommended bucket for machiM and material loadabIlity and hsaping characteristics of material, terrain, and other partlnant job condit/OM. Avoid abrupt stsrts and stops when traMPCU'ting a loaded bucket.

Transpori a loaded buckat with the bucket·as far tipped back and in as low a position as possible for maximum visibility, stability, and safest transport: of the maohlne. carry it at a proper speed for the lOad and ground conditions.

Inspect your SMt belt webbing and hardware at lent twice a yaar for signs of fraying, WHr or other weakness that couid lsad to failure.

Cerry the buckat low when traveling with a load.

Use only daslgnated towing or pulling attachment points. Usa cere in making attachment Be sure pins and lOcke as provided are saeure before pulling. Stay cleer of drawi:lers, cables or chainS undar load.

Whan pulling or towing ti'lrough a cebIe or cnstn, dO oot start ~ at full throttta. Take up Slack carefully. Guard egeInet kinking chelns or cable$. IMPact carefully for flawe before using. 00 oot pull through a kinked chain or eab!e due to the high streeses and posSibility of failure of the kinked erea. Awaya WHf heavy gfovas whan handling chain or cable.

Maintain a safe distance from other machines. Provide sufficient clurance for ground and visibtllty (l()!'Idltlons. Yield right. of-way to loaded machirles, ~

Avoid going over obetecles such sa rough terrain, rocks, logs, curbs, ditches, ridges, and railroad tracks whenever pclsaibls.

Whan obettuctlons must be CroHad, dO so with extreme care e. Fl~tlC&speed ., down·$hll!U':;ese up to pus the balance point slowly on the obstruction and eue down on the other side.

Crosa gullies or ditches at an angle with raducad speed after InsuMg ground (l()t'IdiiiOt'ls will permit a safe traverse.

Be sure cables ere anchored and the anchor point Is soong eoougl'l pemmnel clear of T PUI..L OR MACHINES INVOLVED ARE PROPERI..Y GUARDED AGAINST POTENTIAl..

CABI..E OR CHAIN BACKLASH.

Be alert to soft ground conditions closa to newly constructed wails. The fill material and weight of machine may ceuse the well to coilapH under the machiM. Operete at speeds sloW enough to insure complete control at all times. Travel slowly over rough ground, on slopes or nur dropoffs, in congested ereu or on ice or Slippery surfaces.

During operation always carry rtpper in fuji raleect position when oot in usa and lower to ground when parked.

n

FETY

l

Be alert to avoid in Iraction conditions that could cause loss of COntrol, NOT drive On ice or frozen ground condlHons when working the machine On steep slopes or neaf the machine well back from the

of the machine for any reason, ,,.,,,,,,,.,},,,,,..,,,, or chile control to the control securs the machine for brake, If so equippett Never lower attachments or tools from any other than seated in seat Sound the horn. sure the area neaf the is clear. Lower ths attachment slowly., DO NOT USE Heat position te fower hydrauHc equipment

Be care lu! when ,,,,.,,,,,,.,,, tlon in such a way as anchorage on the ground in case of a

oP,erator·'s seat and after lower in a ground tool to positive Place transmls· controls to off pOSI· brake, and open and Consult Operatlon

When across a hl!lside prooeed slowly. Never tum sharply upi'll!! or I'ImNnl,m.

AVOid sidehm travel whenever POiS:>II,,!!>. Drive up and down the slope. Should the machine Slipping sideways on a grade, tum it immediately downhill.

In steep downhill rm'!lratlon. do not allow engine to overspeed.

Select proper gear downgrade.

Always fallow the shut·down instructions as ouWned in the Opera.tion and Maintenance Instruction Manual

There is no subsHtute for good slopes.

MAINTENANCE

The grade of slope you should being h13 ...rll",rl faotors as oond!t!on of the ground, type of machine, speed of machine and vlSlblllty.

00 not perform any worn on MU!J!mn...n that is not authorized.

Follow the Maintenance or Manual Prooedures.

NEVER COAST the machine down grades and slopes with the transmission In neutral on power shift machines, or Clutch disengaged on manually shifted machines,

Maohine should not be serviced with anyone in the operator's to operate the machine and are seat unless they are a"'~liati"" in tha ",,,,,,v,,.,lno

To reduce the danger of an uncontrolled machine, choose a gear speed before down that wil! hold machine to proper speeds for conditions.

diail:l1l11'iOIil: the Power TaKe-Off lever if so

adi!1stm.enl's or service.

Always turn the master switch (key switch if so eql,Jlppe'iJ, the off position before or "'''''',,,,.,, ...... when parn.ing machine to or ,th,,>.i:.M starting.

in virgin hazards is this is done. is acute in these areas.

Dleconnect batteries and TAG all controls to local or national to warn that is In progress.Bleck machine and all attachments that must be raised per local or naUona! requirements.,

When

over trees, the machine must be eqUipped With overhead guarding, Never anow a machine to climb up on root structure particularly while the tree is being felled.

Use extreme care when pushing over My tree with deed branches, Avoid brushplles, logs or rooks. 00 NOT DRIVE THE MACHINE ONTO ElRUSHPILES, LOGS, LARGE ROCKS or other surface irregularities that break traction with the ground especially when on slopes or near dropotfs,

Never h.lbrfcate, service or running, as Maintenance Manuals. 00 not w@al' or jewelry near moving parts.

Do not run engine wh@n and use care if due to the increased possibility of a flre if fue! is

equipment too ciose to an or below the maohlne, Be on the obJeots and aUdes. Beware of undergrowth of these dangers.

near when Always place the fuel nozzle the side of the filler open· ing before and during flow, To reduce the of a static electr ty spark, keep contact unUi after fuel &hut off.

Park in a non·operating and noMrafflc area or as instructed.

Park on IIrm level ground if possible. Where not poSSible, posl· sure there Is tion machine at a right angle to the slope, no danger of uncontroiled movement. the parking brake,

00 no! adjllst

fuel pump whan the machine Is In motion.

Never park on an Incline without carefully blocking the machine to prevent movement

Never attempt to check or adjust fan belts when ning.

If parking in traffic lanes cannot be appropriate barners, flares and qui red. Also advance warning lane for approaching traffic.

of the When equipment checks that engine, have an in the times with the mechanic Place transmission in neutral anoset the brakes KEEP HANDS ANO CLOTHING AWAY FROM MOVING PARTS. '

Move the machine away from overhead power Hnes before

overhangs and the day.

ill

IS run·

SAFETY RULES AVOid rurming engine with open unprotected air inlets, If such running is unavoidable for service reasons, place protective screens over all inlet openings oo!ore Mrvicing engine,

00 not remove hoees or check valves in the hydraulic system without first removing load and relieving pressure on the supporting cylinders.

00 not place head, body, limbs. feet. fingers, or hands near rotating fan Of oolts, Be especially alert around a pusher fan,

Turn radiator cap slowly to relieve pressure oofore removing.

Add coolant only with engll'le stopped or idling if hot. See Operation and Maintenance Instruction Manual.

Keep head, booy, limbs, feet, !'lands, and fingers away from bucket, blade or ripper when In raised position.

Fluid escaping under pressure from a very smaH hole <:sn almost 00 Invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. 00 NOT USE HANDS. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not ad· ministered immediately.

If movement of an attachment by means of machine's hydraulic system or winches Is required for Mrvice or maintenance, do not raise or lower attachments from any pos!· tion other than when seated 11'1 the operator's Mat. Before starting mechine or moving attachments or tools, set brakes, sound hom and call for an all clear. Raise attachments slowly.

Never UM any gas other than dry nitrogen to charge ac· cumulators. See Operation and Maintenance Instruction Manual.

Never place heed, body. limbs, flngars, feet or hands into an exposed portion ootween uncontrolled or unguarded scissor points of machine without first providing secure blocking.

When making pressure checks use the correct gauge for ex· pected pressure. See the Operation and Maintenance Instruc· tlon Manual or Service Manuals for guidance.

Never align holes with fingers or hands· Use the proper align. lng toot

For field service. move machine to level ground If possible and blOCk mechine. If work is absolutely necessary 01'1 an incline, block machine and its attachments securely. Move the machine to level ground as soon as poSSible.

Disconnect batteries before working on electrical system or repair work of any kind.

Check for fuel or battery electrolyte leaks before starting ser· vice or maintanance work. Eliminate leaks ootore prooeeding,

Brakes are inoperative when manually released for serviCing.

Provision must be made to maintain control of the machine by blOCking or other means.

BATTERY GAS IS HIGHLY FLAMMABLE. Leave baUery box open to improve ventilatloo when charging batteries. Never check charge by plaCing metal objects across the posts. Keep sparks or open Hame awey from better!ee. 00 not smoke near battery to guard against the possibility of an accidental explosion,

Block all wheeis oofore bleeding or disconnecting any brake system linea and cylinders.

Never UM makeshift jacks when adjusting track tension.

Foilow the Undercarriage Service Menual.

00 not charge batteries In a closed area. Provide proper 'len· tilation to guard against an aCCidental explosion from an accumulation of explosive gaeas given off In the charging process.

Know your jecking equipment and Its cepaclty. Be sure the jacking point used 01'1 the machine Is appropriate for the load to 00 applied. Be sure the support of the jack at the machine and under the jack Is approprlate end stable. Any equipment up on a jack is dangerous, Transfer load to appropriate block· ing as a safety measure oofore proceeding with service or maintenance work according to local or national requirements.

Be sure to connect the booster cabtes to the proper terminals (+ to +) and (- to -) at both ends. AVOid shorting clamps.

Follow the Operation and Maintenance Instruction Manual procedure.

Due to the presence of flammable fluid, never check or fill fuel tanks, storage battenes, or use starter fluid near lighted smok· ing materials or open flame or sparks.

Always blOCk with external support any !inkage or part on machine that requires work under the raised linkage, parts, or machine per local or national requirements, Never aHow anyone to walk under or be near unblocked raised equipment Avoid working or walking under raised blocked equipment untess you are assured of your Mfety.

Flust inhibitors are volatile and flammable. Prepare parts in well ventilated place. Keap open flame away • 00 NOT SMOKE. Store eontajnsrs in a cool wetl-ventllated place secured against unauthorized personnel.

00 NOT pile oily or greasy rags· they are a fire hazard; Store !n a closed matal container.

When servicing or maintenance requires access to areas that cannot be rasehed from the ground, uee a ladder or step platform that meats local Of national requirements to reach the servlee point. If such ladders or platforms are not available, use the machine handholds and stepe as provided. Perform ail service or maintenance carefully.

Never use gasoline or solvent or other flammable fluid to clean parts. Use authorized commerCial, !lOn·flammable, non·toxic soIventa.

Shop or field service platforms and ladders used to maintain or service machinery should be constructed and maintained ac· cording to local or national requirements.

Never place gasoline Of dieMI fuel In an open pan.

Lift and handle all heavy parts with a lifting device of proper capeclfy. Be sure parts ere supported by proper slings and hooks. Use lifting eyes if provided. Watch out for people in the vicinity.

00 not use en open flama ee a Ifght source to look for leaks or for inspection anywhere 01'1 the machine.

Shut off engine and 00 sure all pressure in system has been relieved oofore removing panels. houalngs. covers, end caps, See Operation and Maintenance Instruction Manual.

IV

SAFETY RULES 11"1 IIfiII"Ig and handling heavy ~. d1gs must be of ~$~ for 1M P41~ in~ and must be in

If 1M ~ or 1M Q»_ operating, stop 1M macl1ine mom sa a possible. lower Ilquipmanl. sat maci1lne ~lurA4\1 untlf Is Cf)fl'·OIId~od or the maclhine oan safely towed. Never !ift lcads in tlx.e&ss of capacity.

good CCII'ldim.

Handle aU parts with extreme care. Keep hands and from between Wear authorized prolll1K.lti'O'e u(~u!pmUlru heavy

Should 1M maci1ine become tWcl< or frozen to the I:l:adI. out to avold rollover.

When IJ$iI"Ig eompreaeed .. for cleanil"lg ~ use safety gIas$U with akIe ahialds 01' ~Ies. Umit 1M presaure tb 201 kPa (SO acoordlng to local or national requirements.

Kaep Ihe maclhine In the same gear going downhill a \.Isae for going uphitl.

Wear weldere prot~ equipment suoh a dark safety glasae. helmets, proteotive clothing. glcMm and safety ~ wihen welding 01' burning. Wear datil safety glasae near weldil"lg. 00 NOT I..OOK AT ARC WITHOUT PROPER EYE PROTECTION.

When roadIing a mil1K.lhitw, know and use Ihe slmmllrlO devices reqt.lired on 1M maci1lne. Provide an roading where required.

RepllllC$: seat belts every two years on open canopy units and every three yeare on macl'linee with oabe 01' at ~

Always use th& raoomm&nded transport devices when roading1M ~.

of~ip.

00 not attempt repairs unless propar trainlng has been provided.

Wear proper protsetive equIpment suoh as safety goggles or sarety glasses with side shields, hard hat. safety shoes. heavy gloves when metal or other particles are apt to tty 01' tall.

Use extremtl caution when removing radialOr caps, drain plugs, grasae 01' presaure tape. Park \he machine ud let It 0001 before opaning a presst.llized

Use only ~ su:dllary power ~ for heaters. ~. ~ps and almi. equipment tb reduoe 1M

com~nI.

hazards of e!ectrloal shocl<.

Release all presaure before working on systems whlclh

have. aooumuiator.

Kaep mainteniil!'lC$ area CLEAN and DRY. Remova water or oH~lmmedia_.

WherI ~ to tow 1M macl1!ne, do not tlx¢$ed 1M reeomm&nded lOwing speed. be sure 1M lOwing machine ha sufflclern braking ~ to stop 1M tbwed !oed. If the towed· machine cannot be braked, a tow bel" must be used 01' i'N\) twolng machines must be used • one In front pulling and one in \he rear to retard. Avoid towing over long

Remove sl'Iarp~ud oorrs from ~~.

Be sure aH mll1K.lhanic& tools are in good CCII'ldition. 00 NOT use tools with mushroomed haads. Always weer safety glasae wilh side shiald$.

~

00 rG £Itr'b hardened stseI ~ with enyitIing olher !han a sol't Iron or~ 1'IImmer.

Ol':lsarw propar m~ and rapsir of atl hydral.Ik eyHnders. hoses, enap rings ud main attachirlO 00its.

Always kHp 1M brakes and stooling systems in good ~ CCII'lditlcm.

FaQ»lhe access system when climbing up and down.

RepilllC$: ail missing. iHagiblis or damaged Koop ail safety signa cle••

Apply Ih&parklng device and piaQ» 1M transmission 11"1 neutral b&fore staling 1M~.

~.

00 not ml the fuel lank to capacity. Allow room for

00 rG bypass 1M st.arter safety switdt, Repair 1M st.arter safety controls if they maifuncifon.

W!p& up spillad fool Immed_.

Faten seat belt b&fore oparating.

Always tighten 1M fuaf lank cap $&Cum!y. Should 1M fuel cap be lost. mpiaQ» it only with the original manufac:tumrs approved cap. Usa of a non..approved cap may result In

Steeling should b& clhE'lCked 10 bolh right and i&it Bmka should be ~ against engIm power. Cll.ltcih and transmission conlrois should be moved Ihrough 01' tb neutral poeitione tb assure ~ent Operate ail controls 10 insure proper oparatlon. If any malfunctions are found, park maclh,lne. shut off angine. report and repalr before using maci1ine.

twer~cf1Mtarlk.

Neverdl'ive 1M maci1ine near open 11-.

v

Always number if making an inquiry to /'I ... <.! .......... l'1>Nf'>f'>t about this machine.

Many equipment owners employ the Department all work other than routine lubrication and minor service. practice is encouraged, as our Dealers are well Informed and equipped to render efficient service by tactory trained mechanics, This manual may not be reprinted or reproduced, either in in part, without written permission of FiataUis ®, Illustrations

or

standard and optional items,

IMPORTANT

The information manual was current at time It is our policy to constantly improve our product and to make available additional These changes may outflned in this manual. It variances are observed, verify the informathrough your Fiatani~ is not responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by Fiatalfis for use in maintaining and/or repairing products manufactured or merchandized by Fiatallis.

In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by ,-,,""1>11•., failures are caused by use of parts and/or components not approved by Fiatallis,

TABLE OF CONTENTS

TOPIC NO.

PAGE NO.

TITLE

............

1

GENERAL DESCRIPTION • • • •

Z

HYDRAULIC SYSTEM LUBRICANT SPECIFICATIONS. CAPACITY AND SERVICE. • • • • • '* • *" "" .. • '*" ,.

10

:3

TROUBLE SHOOTING • • • • • • • * •

11

4

PRESSURE CHECKING. • • • • • • .. .. • *' •

5

FLOW CHECKING • • • • • • • • •

18

(,

HYDRAULIC SYSTEM COMPONENTS.

21

7

MODULATING CLUTCH AND TORQUE CONVERTER

37

8

TRANSMISSION

54

11

BEVEL GEAR AND SHAFT••

10

DRIVE SHAFT UNIVERSAL JOINT

11

FITS AND TOLERANCES

lZ

SERVICE TOOLS • • • • •

..

..

:I:

'* .. ..

..

•

Ii'

*' • • " •

ALPHABETICAL INDEX • • • •

., .. • ..

..

-«-

..

«

. . ..

13

'"

.. .

.. • • *'

'*

,.,

*' *

'*

:3

...

>lO

79 85

87 • .. * * ., • • *'

89

<II

..

..

.,

:I:

90

\i

TOPIC 1 GEN ERAl OESCR IPTION t 1 MECHAN ICAl OPERAT ION Modulatini clutch aod torque converter transmit engine power through drive shaft universal joint to transmission. Multiple plate clutch. located in front part of torque converter housing. is hydraulically controlled. Engine power is transmitted through modulating clutch to the torque converter rotating housing. Rotating housing drives impeller wheel. impeller wheel pumps oil through turbine wheel; turbine wheel drives torque converter output shaft to transmit power to transmission.

Transmission is constant mesh type with three clutch sbafts and a countershaft to provide three forward speeds and three reverse speeds. Viewing transmission from front. top (input) shaft carries forward/reverse clutches. lower left shaft carries second/third speed clutches,lower right shaft carries first speed clutch, center shaft is bevel pinion (ouiput) shaft. and upper right shaft is the countershaft.

Transmission clutches are multiple plate. oil cooled and lubricated. The clutches are hydraulically engaged and spring released; they reqnire no adjustment. The clntches are all identical in design and operation. size of clutch drum gears vary to obtain different speed and power ratios. Enclosed in front part o,f torque converter housing and driven from engine flywheel are gear trains to drive the dozer pump and transmi;ssion pump.

1.2 FUNCTION Of HYDRAULIC SYSTEM COMPONENTS 1. Z. 1 TRANSMISSION OIL PUMP Mounted on rear of torque converter and driven from engine flywheel by ar train in converter housing. Prior to SIN 76l9(except 10817519 through 10S17578).oil pump contains two sets of gears. Front set of gears suppUes oil from sump in transmission case to charge hydraulic system; rear set of gears scavenges oil from engine fly .. wheel housing and returns it to sump in transmission case. SIN lO8116l9 .. up (inelnding 10817519 thru lOS17518)pump contains a single set of gears which function same as front set of gears in duai-type pump. Oil from engine fly... wheel housing returus to sump in trausmission case by gravity, with alulistance fromcentrifngal force created by rotation fo engine flywheel.

1. Z.l SHIFT INHIBITING PUMP Attached to trausmission bevel pinion sbaft front bearing retainer. pump is driven by bevel pinion shaft. Pump draws oil from trausmission lubs circuit throngh check valve on suction side; check valve on pressure side of pump, closes and oil under pressnre is suppUed to flow regulating piston in shift inhibiting valve.

When direction of tractor travel is changed. pump rotation is reversed SERVICE MANUAl. Form 0664031.0

and oil is supplied to flow regulating piston in opposite end of shift inhibiting valve. Function of oil flow is discussed in paragraph 1. 2. 5. 3.

1.2.,3 PRESSURE REGULATING VALVE 1.2.3.1 Located on top left side of torque converter; contains cold oil relief valve and main relief valve. Cold oil relief valve opens only when oil is extremely cold and/or thick; oil is bypassed to sump when valve opens.

1.2.3.2 Main relief valve regulates stepped pressure and main pressure. System is at stepped pressure when modulating clutch is disengaged.

Fig. 1. Because of no oil pressure in modu' lating clutch circuit, booster piston on tOR of main relief valve is at the top of its bore; 5his increases working height of main relief valve spring which in turn reduces pressure required to upen main relief valve. At specified stepped pressure main relief valve opens fully and dumps excess oil to both the torque converter circuit and trausmission lube circuit. When modulating clutch is engaged.

Fig. 2, oil pressure in modulating clutch circuit forces booster piston on top of main relief valve down; this d'ecreases working height of main relief valve spring which in ,turn increases pressure required to open main relief valve. At specified main pressure. main relief valve opens and dumps excess oil to torque converter circuit. no oil is dumped to transmission lube circuit at main pressure.

1.Z.4 SPEED CONTROL VALVE Mounted on top of trausmission. valve contains two plungers which direct oil to engage transmission clutches - one for the direction clutches, the other for the speed clutches. Plungers are mechanically controlled by the operator and are held in position by detents.

L 1. 5 SHIFT INHIBITING VALVE

Mounted on top of trausmission. valve contains three principal components to regulate oil flows to other parts of the system. the components and their functions are:

1.2.5.1 DIRECTION CONTROL PISTON regulates oil flow to trausmission direction clutches. In neutral. Fig. 1. piston is centered in its bore and blocks main oil flow to transmission direction clutches, When a direction shift is made, Fig. 2, piston is f<!rced off-center by oil from speed control valve., main oil flow is directed out to engage desired transmission

3 (Revised Decembsr 1910)

Due riptilH'1 direction dutch. As direction control is forced off-center, an internal oil passage u;;"",u.ug to flow is inoil from control flows this pilt11l11lage to the flow Thi s oil is restricted to assure comof direction dutch before dutcb circuit is with oiL

down. this forces down and main oil flow to engage dutch.

1. 2.8 TORQUE CONVERTER PRESSURE REGULATING VALVE

Located on rear of

converter~

converter circuit. pressure and

1.2,5,2 FLOW SENSING PISTON clutch control is held dosed main oU flow. When a shift is made, • 2, oil from valve forces flow tension; this directs main oil flow to clutch control valve.

to t:ran11lmil~sion

1.2.9 CENTRIFUGAL SENSING VALVE

L;;L 5.3 FLOW REGULATING PISTONS pump oU now and

In I:hi11l top of to hold valve up to 2.2.00 rpm.

1,

1.2.10 OVER-SPEED VALVE

1.2,6 DECELERATING BRAKE SENSING VALVE AND CYLINDERS

unit may converter reach, force created carrier forces valve allows oil born circuit to engage l:Olrrn:le

1.2.11 OVER-SPEED REGULATING VALVE Located in bont end of bore in dutch , valve over valve; at val ve opens and to sump.

o 1,2.1 MODULATING CLUTCH CONTROL VALVE

HOW DESCRIPTION· NEUTRAL

L 3.1 Oil in main circuit is at Sti1!nn;<!'!l:i on is deadheaded in shift valve $en$i the brakes.. Remainder the transmission oil main relief valve to and lubricate and cool transmission clutches.

L 2,1.1 Located on redirects 01.1 in on'Ulaon is enllall~e 4,

6elefll Description

control valve, ahift inhibitins valve, modulating clutch control valve and related oil lines is static.

1.4 Oil flOW DESCRIPTiON ~ SHIFT FROM NEUTRAL TO 3RD FORWARD 1.4.1 Oil in main circuit stays at stepped pressure until just before modulating clutch engages.

Speed plnnser in apeed control valve aligns 3rd speed outlet with incomins main flow and 3rd speed clutch is engaged. Direction plunger in speed control valve aligns forward outlet with incoming main flow and oil flows to end of direction control piston in shift inhibiting valve. This forces direction control piston off center and allows main oil flow entering shift inhibiting valve to engage transmission direction clutch. As direction control piston is forced off-center, an internal oil passage leading to flow sensing piston is opened to oil from direction plunger in speed control valve. This oil forces flow sensing piston open and allows oil in main circuit to flow to modulating clutch control valve.

NOTE: Restrictor in the internal oil line delays oil flow to end of flpw sensing piston to allow complete engagement of transmission direction clutch before oU enters modulating clutch circuit.

Oil flow to modulating clutch control valve piston is slowed by a restrictor on the inlet side of valve. allowins oil to flow first to the back side of main relief valve. Oil pressure in main circuit is now raised from stepped pressure to main pressure; brakes are released through decelerating brake sensing valve and modulating clutch is applied to move the tractor. As soon as tractor starts

mavins. shift inhibiting supplies additional oil to same inhibiting valve direction control piston which Wlita previously forced down by oil from speed control valve; fnnction of this oil is described in the followins paragraph.

1.5

on. flOW DESCRIPTION

* SHIFT FROM 3RD FORWARD TO 3RD REVERSE

'L 5.1 Tran$miuion third speed clutch remains enga'ged because speed plunger in speed control va1v~ is not moved. When direction plunger is moved from forward to reverse, high pressure oil on end of direction control piston and flow senSing piston is dumped to sump, transmission forward clutch remains engaged. however as direction control piston does not move because of hiSh pressure oil from shift inhibiting pump. Flow sensing piston is forced closed by spring pressure when oil preuure drops. This stops main flow to modulating clutch circuit; modulatin~ clutch disengages and pressure in main circuit drops to stepped pressure; brakes are then applied through decelerating brake sensing valve. Shift inhibitirtg pump continues to supply high pressure oil to end of direc~ion control pis,ton until ground speed of tractor drops to 1 to Z mph (t. 6 to 3.2 km Ih). At this speed and lower, pump volume is not high enough to hold flow regulating piston open. piston closes and dumps oU on end of direction control piston to sump. This allows aU which is at stepped pressure on opposite end of piston to force piston off-center; transmission forward clutch disengages and reverse clutch engages. Modulating clutch is engaged and brakes are released in same manner as when shifting from neutral to 3rd forward.

OIL P'USSUR~ cgg~ _

STEPPED OJ NON·CIRCULATING CONVERTER CHARGING I.2Z2l SUMP AND SUCTtON _ MODULATING CLUTCH APPLY !mil TRANSMISSION LUBE

FROM SPEED CONTROL VALVE

fROM SPEED CONTROL VALVE

wi ' ~

..=...

FROM MODULATING CLUTCH CONTRO l VALVE

CD

CIt

FROM

.

a

SHIFT~ INHIBITING

fJ'

::n

..-_..

VALVE

::::: o

=

TORtlUE CONVERTER PRESSURE REGULATING VALVE

C

TO SHIFT INHIBITING VALVE SHIFT INHIBITING PUMP

.]

TO SHIFT INHIBITING VALVE

T-15456

CD

.=-...

PEED CONTRIlL VALVE

CD

a

..a

..-_. ..,= ..._.

D

lID

HOW REGULATING PISTONS

RESTRICTDR HOW SENSING PISTON - -...........- - - - - - - - - - - - - - - - - - - F I G . 1 OIL FLOW SCHEMATIC - NEUTRAL

T-75457

_

Oil 'llllIIE CQOl

MAIN INIISIT CONVERTER eKARGING I[]I NON-CIRCULATING . . MODULATING CLUTCH APPLY l1li1 TRANSMtSSIllN UtlE I2Z2'J SUMP' ANO SUCTION

a

FROM spnD CONTROL VALVE-<:: TO PRESSURE REGULATING VALVE OIL FILTER TRANSMISSION PUM'

fROM SPEEO CONTROL VAL

..... .

FROM MODULATING CLInCH CONTROL VALVE

CD ::II

f

«>

.

CIt

...

-ii' It

....' ::II

OIL SCREEN

TOROUE CONVUTER PRESSURE REGULATING VALVE

T-75540

PRESSURE REGULATING VALVE

IUHllHER PISTON

MODlJlA TlNG CLlJTCIi CONTROL VALVE

COLO OIL

REliEF VALVE

CHERATING BRA

CYliNOERS

OECElERA TlNG BUKE SENSING VALVE

-

TO TRANS LUBE TO TOROUE CONVERTER

SPEED CONTROL VALVE

TO MODULATING

CLUTCH

..0 '""I

TO TRAfiS,J

CLUTCHES

Ttl TRANS, ClIJTCP

F'1'U1M SHIfT INlUSITINS PUMP

DIRECTION COtHRnl PLUNGER I----------------~FIG .

FLnw SENSING PISTON

T -75458 .2 OIL FLOW SCHEMATIC - 3RD F O R W A R D - - - - - - - - - - - - - - - - - J

TOPIC 2 HYDRAULIC SYSTEM LUBRICANT SPECIFICATIONS. CAPACITY AND SERVICE 2.1 LUBRICANT SPECIFICATIONS

~--------------------CAUTION------------------------~

Specified oil is SAE lOW crankcase oil meet~ ing the following specifications:

Do not use "MIL~L~10Z95A OES" if atmospheric temperature remains consistently above - 1OOF • (-23 0 C. )

2.2 CAPACITY ANO SERV ICE

American Petroleum Institute (API) classification "Service MS**,

2.2.1 Capacity of system is 15 gallons (56.7 Its.).

Military Specification "MIL-L~2l04BtI Grade lOW.

2,Z.2 Service consists of changing oil, replacing filter element, cleaning breather element, and cleaning suction line screen. Replace filter element, clean suction line screen, and install dean oil after making major repairs to any part of the system; replace filter element again after first 50 hours of operation. Detailed service procedures and specified service intervals are given in Operating Instructions and Field Maintenance Manual 0664030.4.

Automatic Transmission Fluid "Type A Sufiix At! may he used if desired.

API classification "Service DS" or HSeries 3 11 oil is not recommended.

When atmosgheric temperature is below - H.l<T, (-23 C.) Automatic Transmission Fluid "Type A - Sufiix AH or lubricating oil meeting Military Specification "MIL-L-IOZ95A OES!! must be used.

10

TOPIC 3 TROUBLE SHOOTING IMPORTANT Always make certain hydraulic system is filled tn proper level with specified lubricant before trouble- shooting.

TROUBLE StarterwiH not turn engine

POSSIBLE CAUSE

REMEDY

Transmission speed shift lever not in neutral start position

Lock speed shift lever in neutral start position with safety lock lever

Neutral safety switch out of adjustment or broken

Adjust; or replace neutral safety switch(paragraph 6. 2.4)

AU other possible causes and their remedies are Hsted in Engine Service Manual Tractor will not move

Tractor seems low on power in all speeds

Speed shift linkage out of adjustment or broken

Adjust andlor repair linkage (paragraph 6.2.4)

Failure in hydraulic system

Check all hydraulic system pressures in sequence given in PRESSURE CHECKING

Brakes applied

Visua.lly check decelerating brake cylinder while operating tractor; if pistons are extended brakes are applied.

Remove decelerating brake sensing valve front cover and check for defective spool (refer tn paragraph 6.6) Tractor SIN 10S19110 - up. the autnmatic safety brake may not be funy releasing; see Hauto. safety brake will not release II in Trouble column.

Low engine rpm or malfWlction in modulating clutch or torque converter

Check engine speed at tnrque converter stall. The stall speed is stamped on name plate attached to top of converter housing above the dozer pump on all tractnrs Wlit no.

18579 and up -- also intermittentlyon Wlit nos. 18517 thru U~571. U stall speed is not stamped on name plate the specified stall speed is 1740-1780 rpm. NOTE: All tnrque converter SIN 243460-up have stall speed stamped on name plate.

Check stall speed in the following manner: Warm engine to normal operating tempera.. tore and set engine high idle to specified rpm. Block both (Continued)

SERVICE MANUAL Form 0664032-0

11

Revised April 1913

Trou.lI. Shooting TROUBLE

Automatic safety brake (SIN 10S19110 - up) will not release

'OSSIBLE CAUSE

REMEDY

Low engine rpm or malfunction 10 modulatmg clutch or torque converter ( Continued)

sprockets so they will not turn forward: start engme and move transmission speed shift lever to 3rd forward position. Accelerate engine to full throttle and check engine rpm. Low rpm indt· cates engme trouhle; refer to Engine Service Ml'lllual for further trouble- shooting information. Ii stall speed is high, check torque converter pressure (4. 6).

At high idle. disengage steering clutches and move transmission shift lever to 31' position. Observe safety brake shaft as shift is made. If•..

• •• shaft moves forward but not far enough to fully release the brake check pressure of oil supplied to release the brake. Pressure check point is on top of transmission filter, Fig. 5; cheek pressure at high idle with transmission 10 PTO. Pressure must be 310-340 psi (21. 7.23. 9 kg/cm 2 ). If pressure is low check malo pressure (4.3).

Ii pressure is OK, check the

safety brake Imkage adjustment (6. 13.4).

• •• shaft does not move at all. cbeck for a failure mside the safety brake sprmg cylinder.

Fig. 30b (10) (6.13.2).

Tractor coasts excessively before changing directions when directional shift is made

Fast. hard shift when changing ,,,,.,."tractor speed reduces but direction change is still accomplished above .. V"""'."" ..... k"'''' (see 1.5)

Deceleratmg brake not operating

Visually cbeck decelerating brake cylinders while making a direction shUt. If the cylmder pistons do not extend, brakes are not being applied; disassemble decelerating brake sensing valve and check for a broken or weak sprin! (refer to paragraph .6)

Brakes too loose

Adjust brakes

Stepped pressut'! low

Check pressure and make necessary adjustments; refer to paragraph 4.3

Sbift mhibiting pump worn

Check pump pressure (paragraph 4. 1)

..

SERVICE MANUAL Form 066403,a-O

Revised April 1913

. Trl.llla"Silltlng TROUBLE

POSSIB LE CAUSE

REMEDY

Fast, hard shift when changing directions; tractor speed does not reduce at aU before direction cha.nse is accomplished

Modulating clutch ,~'i-emaining engaged during shift cycle

Check shift inhibiting system pressures and make necessary corrections to raise pressure if low {refer to paragraph 4. i

Modulating clutch wUl not disengage at high , idle; will disengage when engine is decelerated

Over- speed regulator pressure low

Shim over- speed regulator valve {requires removal of torque converter}

Modulating clutch will not disengage at any engine speed

Over-speed valve stuck open or clutch plates dragging

Either of these causes require removal of modulating clutch for necessary repairs

Modulating clutch disengages during operation at high engine speeds

Engine rpm too high

Set engine rpm to specifications

Modulating clutch apply pressure low

Check main pressure and molulating clutch apply pressure; make necessary adjustments (refer to paragraphs 4.3 and 4.4)

SEBVICl£ MANUAL Form 066403l- 0

12A

Added April 1973

TOPIC 4 PRESSURE CHECKING 4.1 GENERAL INFORMATION It is suggested that the test kit shown in Fig. 3

be used to check the system pressures and flows. The kit contains eight pressure gauges

of various capacity, a flow meter, tachometer, and the necessary Hnes and fittings to connect the gauges, A complete description of the test kit and instructions for its use are contained in Power Shift Transmission Test Data Manual.

FIG. 3 *TRANSMISSION TEST KIT (TG-lOO) *Ord~rf:rom

Fiat-Allis World Wide Education Ceuter 1035 Stevenson Drive Springfield. Illinois 62103

If both gauges on cowl indicate some pressure, bring hydraulic oil to operating temperature before pressure checking by running engine for about 15 minutes with transmission speed shift lever in PTO.

SERVICE MANUAL Form 0664032 .. 0

T-15485

Possible causes given for unsatisfactory pressures are listed in order they are most likely to occur and/or order which is easiest to check. Each cause takes for granted that preceding causes have been checked out and found to be OK. Check system pressures after service work has been performed on any system component.

Revised April i 973

,Pressure Check ing

SPECIFICA TIOIS Pressure Check Points

Pressure Being Checked

ulating Engine Speed lutch and Oil Tem All

Fig. 5

Checks At

Fig. 8

*Trans.

Clutch Apply

Fig. 6

*Modulatin Clutch 170-200 Apply

190-225 13.3515.81

Note II

Engaged

High Idle With Oil

3rd.

Forward

Engaged

Temp. At laOoF. (aZoC)

Engaged

Fig. 7

Fig. 9

*Trans.

Clutch Lube Shift *Inhibiting

Pump

130 mil!t.19. 14 m:in.

NOTE II

NOTE 12

Engage clutch being checked * Disengage steering clutches when checking pressure

Clutch being checked in neutral; opposing clutch on same shaft engaged (except first speed)

'1'-75459 ' - - - - - - - - F I O . 4 HYDRAULIC SYSTEM PRESSURE SPECIFICATIONS - - - - - - - Stepped pressure and main pressure both low; transmission lube pressure OK. Main relief valve spring weak; remove spring from pressure regulating valve (paragraph 6. 3) and check tension. Replace spring if weak.

4.3 MAil PRESSURE AID STEPPED PRESSURE 4.3.1 Clean oil fUter area; connect gauge to pressure check point, Fig. 5. Refer to Fig. 4 for pressure check procedure and specified pressures.

Stepped pressure and main pressure both low, transmission clutch lube pressure also low.

Worn 'pump; flow check pump (paragraph 5. Z).

If pump flow is OK. cold oil relief valve may be sticking open and dumping too much oil to sump. Shim(s) Fig. Zl (9) can be added to raise pressure at which cold oil relief valve opens. Minimum opening pressures is 240 psi 06,87 kg/cm2 ).

4.3. a Pressure check results: No pressure. Pump drive train damaged. Remove pump and inspect pump driving shaft in torque converter housing; check pump for damaged drive shaft.

Low and erratic pressure* Suction line screen clogged; remove pressure pump suction tube from front of transmission and clean screen.

4.4 MODULATIIG CLUTCH APPLY PRESSURE

Stepped pressure OK; main pressure reading same as stepped pressure. Malfunction in inhibit ve flow sensing piston or in the main ,re alve; check modulating clutch apply pressure to pinpoint the trouble.

SERVICE MANUAL Form 0664032 .. 0

4 .. 4.1 Remove front floor plates; remove cap from pressure check point, Fig. 6. and install a pressure gauge in its place.

14

Revised April 1973

Pressure Checking

T-75474 FIG. 6 REAR OF TORQUE CONVERTER L Modulating clutch apply pressure

check point 2. Torque cooverter pressure check point

T-77553 FIG.5 MAIN PRESSURE AND STEPPED PRESSURE CHECK POINT 1. Oil filte r Z. Main and stepped pressure check point (Prior to S/NlOS19110) 3. S~ety brake preuure CheCk}S/N pomt 4. Main and Stepped pressure 10519110 check point - up

4.4.2 Refer to Fig. 4 for preuure check procedure.

4.4.3 Pressure eheck results!

No pressure. main pressure same as stepped pressu.re. Flow sensing piston in inhibiting valve stnck in closed position or orifice on front side of piston is clogged. Remove piston andlor orifice and make necessary repairs (refer to paragraph 6. 1).

Low pressure. main pressure same as stepped pressure. Booster piston on top of main relief valve stuck in the up position; remove piston and make necessary repairs (paragraph 6. 3).

4.5 TRANSM ISS ION CLUTCH APPLY PRESSURE AND TRANSMISSION "CLUTCH LUBE PRESSURE 4.5. I Remove £loor plates, Discoonect oil line leading to lube pressure gauge, Fig. 7. and install pressure gauge in its place to check lube pressure.

4.5.2 Remove pipe plugs from oil collectors. Fig. 8, and install pressure gauge{s) to check apply pressures.

NOTE: Units prior to S/NIOS17047 did:n,ot have pipe plugs, Fig. 8 (1) (2) in forwardl reverse oil collector; on these onits a tee must be ins tailed in oil line between shUt inhibiting valve and oil collector.

4.S.l Refer to Fig. 4 for pressure cheek procedure and specified pressures.

4.5.4 Pressure check results:

Low lube pressure; aU other pressures low.

Low pressure. main pressure and stepped 01' OK but on the low end of specifications. pressure OK. Malfunction in modulating Worn pump. flow check pump (paragraph 5.2). clutch control valve or excessive leakage in If pump flow is OK, cold oil relief valve may modulating clutch. Check modulating clutch flow (paragraph SA); if flow is OK disassemble be sticking open and dumping too much oil to sump. Remove and inspect valve (paragraph modulating clutch control valve (paragraph 6.4' 6.3). If cold oil relief valve is OK, excessive and check tension of springs.

SERVICE MANUAL 15 Revised April 1973 Form 0664032-0

Pressure Checking

,.....---=:-.--------------------------...,

leakage is in torque converter. remove converter and check for broken sealing rings or by-pass mbe.

Lube pressure law ex<:ept when a particular transmission dutch is engaged. then is OK. Excessi ve leakage in dutch which is engaged when pressure is OK; remove transmission and make necessary repairs.

Lube pressure OK ex<:ept when a particular transmission dutch is engaged, then is high.

Front sealing rings leaking on shaft which carries clutch which is engaged when pressure is high, or a leak around the clutch separator plate O-ring. Replace sealing rings and/or separator plate O-ring.

"\I

Apply pressure zero at both direction clutches; modulating clutch apply pressure also zero.

Adjust speed shift linkage. particularly the linkage which controls the direction plunger in speed control valve. If linkage is OK and pressures, are still zero, inhibiting valve direction control piston is stuck in neutral position; remove piston and make necessary repairs (paragraph 6.1).

!

I /

T-14952 FIG. 8 TRANSMISSION CLUTCHES APPLY PRESSURE CHECK POINTS

*1. Forward

*2. Reverse

4. 3rd speed 5. 1 st speed

. 3. 2nd speed o

*Units prior to S/NIOS11047 do not have pipe plugs in collector; on these units a tee must be installed in oil line between shUt inhibiting valve and oil collector.

4.1 TORGUE CONVERTER PRESSURE 4.6.1 Remove floor plates; remove cap from pressure check point. Fig. 6, and install a pressure gauge in its place.

4.6.Z Refer to Fig. 4 for pressure check procedure.

4.6.3 Pressure check results!

Torque converter ...... ,,, ...," remove ..n·... ~nl .. tension (paragraph 6.

OK and pressure is still low. heat excruln~1e may be dogged. re~ulal:or spring weak;

T-75415 FIG. 7 TRANSMISSION CLUTCH LUBE PRESSURE CHECK POINT

4.7 SHiFT INHIBITINS PUMP PRESSURE

1. Drive shaft universal gauge

Z.

SERVICE MANUAL Form 0664032-0

4.1.1 install a tee in oil line. to a pressure gauge.

16

9 (2); connect tee

Revised April Itt73

4.7.2

Presslre Checking

~~------------------~----------,

Run engine at high idle and disengage steering clutches. Engage lst forward clutch and observe pressure; shift to lrd forward and observe pressure (refer to Fig. 4 for pressure specifications).

4.7.3 Install tee and pressure gauge in oil line, Fig. '1 (1) and repeat pressure check pro~ cedure in lst reverse and lrd reverse.

\

4.7.4

I

Pressure check results:

('

Low pressure in both directions in first speed: pressure OK in bath directions in third speed.

Inhibitor pump worn; remove and inspect pump (paragraph 6.1).

Low pressure in hoth directions in both speeds, Check pressure regulating spring in shift inhibiting valve (paragraph 6. 1).

Pressure OK in one direction but low in opposite direction. Remove check valve retainer, Fig. 47 (U) and inspect check valves. Fig. 76. in inhibitor pump circuit; valve could be stuck closed on suction side of pump or open on pressure side of pump.

T-15108 FlO. <1 SHIFT INHIBITING PUMP PRESSURE CHECK POINTS 1. Reverse oil line 2. Forward oU line

11

TOPIC 5 FLOW CHECKING 11 GENERAL INFORMATION

5J SPECIFICATIONS

I

TRANSMISSION PUMP PRESSURE SCAVENGER MODULATING CLUTCH APPLY 0

SHIFT INHIBITING PUMP <'

*Check in 3rd reverse 5.2

same

ESSURE

:;. Z. 1 install flow meter on outlet side of rUter, install gauge to check

5.2.2 Check pump flow at in neutral.

idle with all controls

5.2.3 Flow check results:

Flow Ch<ecking ,..-------------------,

No flow. Pump drive shaft broIten; remove and repair pump (paragraph 6. '8).

Low flow; flow meter needle fluctuates during check. Suction line screen clogged; remove and clean screen.

High flow. If flow is high in neutral and is high by the same amount in engaged position, excessive leakage is in torque converter. Ii flow is OK in neutral but high in engaged position excessive leakage is in mndulating clutch; check mndulating clutch apply flow (paragraph 5.4) and make necessary corrections.

T-15415 FIG. 11 TRANSMISSION SCAVENGER PUMP FLOW CHECK POINT

T-1SS36 FIG. 10 FLOW CHECKING TRANSMISSION PRESSURE PUMP

5.4 MODUlATll1 CLUTCH APPLY

*1. Flow bloek (part of TG-IOO test kit) 2. Transmission oil filter 3. Oil line to main pressure gauge *4. Test kit (TG-loo)

5.4.1 Disconnect oil supply line from mndulating clutch control valve, Fig. 12. and install flow meter.

5.4.2 Refer to paragraph 5.1 for flow check procedure and specified flow.

*Order from Flo-Tech Inc. * 410 South Hager.

P.O. Box 514. Barrington. Illinois 60010.

5.3 TRAISMISSIOI StAVElIER PUMP (Uaits witll dU81*111f pump. III 1.2.1 for p., US"I'

5.4.3 Flow check results:

5.3.1 InstalUlowmeteronoutletside of- pump Fig.H. 5.3.2 Refer to para.graph 5. 1 for flow check procedure and speei£led flows.

5.3.3 Flow check results: SERVICE MANUAL Form 0664032-0

No flow; this will of course mean no clutch apply pressure, and main pressure will be same as stepped pressure. Flow sensing piston in inhibiting valve stuck in closed position or orifice on front side of piston is clogged. Remove piston and I or orifice and make necessary repairs.

19 (Revised December 1910)

Flo. Checking 5.6.,Z

Hiih £low andlow main pressure. Indicates oil is leaking past bOoster piston in pressure reiulating valve; repair valve (6.3)

Refer to parairaph 5.1 for flow check procedure and specified flows.

High flow a.nd low modulating clutch a.ppl y , pressure. Indica.tes oil h leaking past spool in molulating clutch control valve; repdr valve(6. 4).

~i~3 check results:

Hiih flow and satisfactory pressures. Indicates leakage in modulating clutch. If modulating clutch apply flow is more than 4 ipm(l5. 1 It/min) it will be impossible to hold modulating clutch fully engaged, even through apply pressure may be O. K. Disassemble modulating clutch and check for worn or broken sealing rings around clutch apply piston or on front end of torque converter output shaft.

Low flow. Indication of low output by pressure pump or excessive l_kage someplace in system. If pump flow (paragraph 5.2) and modulating clutch apply flow (paragraph 5. 4) are both OK. cold oil relief valve may be sticking open and dumping too much oil to sump. Remove and inspect valve (paragraph 6.3). If cold oil relief valve is OK, excess leakage is in torque converter; disassemble converter and inspect for broken sealing rings or a broken bypass tube.

NOTE:Units with a dual-gear transmission pump (see L 2. 1) will have high scavenger pnmp flow if leakage is in the modulating dutch.

6

T-1S47S FIG. 1Z MODULATING CLUTCH APPLY FLOW CHECK POINT

5.5 TORGUE CONVERTER IN It is not necessary to check torque converter in flow; checking the transmission lube flow will rev_l the same troubles, and in addition will rev_l any excess l_kage in the torque converter. Refer to paragraph 5.6 to check lube flow.

5.8 TRANSMISSION lUBE 5.6.1 Install flow meter between oil supply line, Fig- 13 (2) and jumper tube (li.

SERVICE MANUAL Form 0664032.0

T-7SSZ3

FIG. 13 TRANSMlSSION LUBE OIL FLOW CHECK POINT 1. Jumper tube Z. Transmission.l~be oil supply line

5.1 SHIFTINHIBIi'IN6 PUMP It is not necessary to check the shift inhibiting pump flow because the condition of the pump can be determined by checking the pressure.

In addition to this. the small amount of flow involved will be difficult to rpeasure on a flow meter. Refer to paragraph 4.7 for pressure check procedure. . .

20 (Revised December 1970)

TO PIC 6 HY0 R UII C SSE

COMPONENTS

6.1 SHIFT UIHUUliNG NOTE: Refer to and of valve,

L 2.5 for

6. L 1 REMOVAL AND DISASSEMBLY

6. L L 1 seat forward and remove beside seat to access to valve. Disconnect oil Hnes from valve, . 14, and remove valve from top of transmission. Cover ends of oil lines.

T 1 - -_ _

L

2.

21

FIG. 14 TOP OF TRANSMISSION - - - ' valve valve

ie S,ltem Clmplleltl

' - - - - - - - - - - - - FIG. 15 SHIFT INHIBITING VALVE

1'-75469 -----------.;...!

1. Side covel' 2. Inlet from control valve (reverse) 3. Top cover 4. Outlet to transmission direction clutch (forward) 5. Outlet to brake sensing valve 6. Outlet to transmission direction clutch (reverse)

7. Inlet from pump 8. Inlet from speed control valve (forward) 9. Side cover 10. Inlet from shift inhibiting pump 11. Outlet to modulating: clutch 12. Body B. Inlet from shift inhibiting valve

6.1. L Z Remove top cover. Fig. 15, aud slde covers; pull valve components, Fig. 16. from bores in valve body. Identify all pads as they are removed.

and follower piston (4) on washer with drilled side of piston facing: up. Install spring (3) in follower piston.

6. L 3.3 Install springs. Fig. 16 (20) (21) in flow sensing piston install flow sensing piston (22) with drilled end over springs,

6. 1. 2 INSPECTION Clean oil in top cover, side covers. and valve check pistons for freedom o! movement in check bores for excessive wear. Check springs for proper tension (refer to F'ITS AND TOLERANCES). Clean or replace oil screen. Inspect opening in check valve; specified opening is .060 11 (1. 524 mm). Replace neceuary parts.

6.1. 3.

Install side cover. Fig. 16 (lS)with new gasket.

Be certain gasket does not: cover any oil passages in valve body.

6.1. 3 ASSEMBLY AND INSTALLATION

Turn valve body over and install flow regulating piston. Fig. 16 (14) in its bore. small end first. Fig. 17. Install spring. Fig. 16 (19) and the other piston (14) with small end out.

6. 1. 3.5

6.1.3.1 Stand valve body on small end. Install oil Screen. F • 16 (9) and secure with snap ring (10); check valve (11) over screen with orifice side in.

6.1.3.5 Install direction control piston. Fig. 16 (16) in its bore. either end first. InstaU washer (15) and spring (5) on counterbore.

6.1.3.2 Install washer, Fig. 16 (15) on counterbore in direction control piston bore; install spring (5)

6.1.3.6 InstaU spring. Fig. 16 (3) and follower piston 22

Hyd rill lie System Componen ts in drilled

in valve Install new and secure with retainer

16 (1

6.1.3.8 Install valve on top of transmission, and connect oil lines. Check pl"e!l!!l!ures; refer to

--- ---------- ---------------- ----

..-""'" .,-

......

----- ---

---

T-7551S ' - - - - - - - - - - - - - F I G . 16 SHIFT INHIBITING VALVE _ _ _ _ _ _ _ _ _ _ _ _....4

1. Side cover 2. Gasket 3. Follower piston spring 4. Follower piston 5. Direction control piston spring

6. Body 7. Top cover 8. Gasket 9. Oil screen 10. Snap ring 11. Check valve (restrictor.

12. O-ring retainer U. O-ring 14. Flow regulating piston U. Washer 16. Direction control piston 17. Gasket IS. Side cover 19. Flow regulating piston spring 20. Flow sensing piston inner spring 21. Flow sensing piston outer spring 22. Flow sensing piston

' - - - - - - - - - - - - F I G . 17 SHIFT INHIBITING VALVE _ _ _ _ _ _ _ _. . ;;;T;.. -. .;,7;;..,50;;..,S;,. ;9..)

1. Body 2. Gasket 3. Top cover 4. O-ring 5 ,O-ring retainer 6, Follow~r piston spring 7. Follower piston S. Direction control piston spring 9. Washer

10. Direction control piston 11. Flow regulating piston

1.2 SPUD CONTROL VALVE NOTE: Refer to paragraph 1. Z. 4 for description and operation o£valve. ' 6. Z. 1 REMOVAL AND DISAssEMBLY

12. Flow regulating piston spring 13. Check valve 14. Snap ring 15. Oil screen 16. Flow sensing piston 17. Flow sensing piston onter spring 18. Flow senSing piston inner spring 19. Side cover ZOo Gasket 21. Side cover 22. Gasket 6.2.1.1 Tip seat forward and remove plate beside seat to gain access to valve. Disconnect oil lines and control linkage £:rom Fig. and remove valve £:rom top of ~ransmission.

Cover ends of lines.

Hydraulic System Components 6,

1.Z

f:rom bores in valve

Remove of valve

from bottom top side of and ddents after

6. Z. 1.4 Remove 0retainer, o (3) from bottom of

and

6.Z. L 3 Remove

LEGEND FOR FIG. 18 L 2.. Pipe plugs

3.

FIG. 18 SPEED CONTROL VALVE _ _ T_-_15_4_1_1....

6.2,,2 INSPECTION 6,2.2. t Remove all and from and dean all oil passages. freedom of movement in bores; ers if detent notches are rounded to point that detents will not hold plunger in position. Replace ~etents if worn excessively; replace detent spt'lngs if broken or if they have taken a permanent set.

SERVICE MANUAL Form 0664032 .. 0

6.2.2.2 Closely in the control :rod ends, for excessive looseness wear in the rod end and outer race. Excessive wear can result in loss of vehide control or a transmission failure caused mis-indexing of the valves.

Revised April 1913

Hydraulic Sylttfl COflpone nts

.......- - - - - - - - - - - FIG. 19 SPEED CONTROL VALVE _ _ _ _ _ _ _ _. . ;:;T;.. -. . ;.1. :.,5.::;..5::;.,;16;.,J

1. Plug 2. O-ring 3. Body 4. Detent

5. Spring

6. O-ring 7. Plug 8. Direction control plunger

6.2.3 ASSEMBLY AND INSTALLATION 6.2.3.1 Install oil seals, Fig. 19 (9) in front end of plunger bores.

6.2.3.2 Install speed cnntrol plunger. Fig. 19 (12) in proper bore in valve body. Install from plug end of bore; use care to prevent damage to oil seal. Align a detent groove with detent bore in valve body; install a detent (4). spring (5}. and plug (7) in top and bottom of valve body. Install direction control plunger (8),a,nd detent in a similar manner. Use new O-rings with detent plugs.

6.2.3.l Install plugs. Fig. 19 (1) in end of plunger bores; use new O-rings'. Install new' O-ring Fig. 18 (3) and secure with retainer (4).

•

6.2.l.4 Install valve nn top of transmission. Fig. 14. and connect oUlines. Place control valve plungers in neutral position and put transmissinn speed shut lever in NEUTRAL; adjust and connect control rnds to plungers.

9. Oil seal 10. O-ring 1 L O-ring retainer 12. Speed control plunger

6. 2. 4 SPEED CONTROL LINKAGE ADJUSTMENT

6.2.4.1 Disconnect vertical control rnds, Fig. 20 (6) (15) from bellcranks (8) (7).

6.2.4.2 Place speed control valve plungers in neutral (speed control plunger in as far as possible direction control er in center detent position). Posi lcranks as shown in Fig. 20 by adjusting length of horizontal control rnds (12) (13).

Lock speed shift lever (1) in NEUTRAL START with safety lever (l). Adjust length of vertical control rnds (6) (15) so capscrews are easy slip fit through beUcranks and rod ends.

6.2.4.3 Loosen jam nuts, Fig. 20 (15) and move safety switch (5) in or out as necessary to provide .06 1t (1. 52 mm) clearance between lever (4) and end of safety switch threads when speed shut lever is locked in NEUTRAL START.

6.2.4.4 Units with automatic: safety brake. refer to 6. 12. 3 for speed control linkage adjustment.

SERVICE MANUAL Form 0664032-0

Revised April 1973

Hydraulic System CompORllts

r - - - - - - - U N I T S WfTHAUTOMATtC SAFETY BRAKE-------"""l

T-75521 ' - - - - - - - - - - - - FlO. ~o SPEED CONTROL L I N K A O E - - - - - - - - - - - - ' 11. Direction control plunger ll. Direction control plunger horizontal rod 13. Speed control plunger horizontal rod 14. BeHcrank bracket U. Speed control plunger vertical rod ..

16. Jam nuts 17. Yoke 18. Automatic safety brake control valve 19. Yoke 20. Control rod swivel end 6.3.1.2 DIM. uAtI.06 U (1.52mm) Disconnect oil lines from top and front of valve; remove valve from torque coil.verter.

1. Speed shift lever Shifting tower bracket 3. Safety lever 4. Neutral lock bar 5. Safety switch 6. Direction control plunger vertical rod 7. BeHcrank 8. BeHcrank 9. Speed control valve 10. Speed control plunger ~.

1.3 PlESSURE REGULAT•• G VALVE NOTE: Refer to paragraph 1.2.:3 for description and operation of valve.

6.3.1 REMOVAL AND DISASSEMBLY 6.3. 1. 1 Valve is mounted on upper left side of torque converter; remove left front floor plate to gain access to valve.

SERVICE MANUAL Form 0664032-0

6.3.1.3 Remove plugs, Fig_ Zl or ZZ (1) (11) (is) and remove components from valve body. Identi· £y aU parts as they are removed.

27

Revised April 1973

Comptuumts

T~76761

' - - - - - - - - - - - - F I G . 2 1 PRESSURE REGULATING VALVE---------::....;..;..;;:;..:...;::..;;..,J (UNITS WITH TOROUE CONVERTER S/N 241 L

10.

2.

lL i2.

3.

4. Snap

5. Main valve inner 6. Main relief valve outer 7. Washer

8.

9.

relief valve

oil relief valve 13, Cold o:i1 relief valve outer 14. Cold oil re lief va lve inner 15.

16. if. Booster 18. Washer

pressure

6.3.2 INSPECTION Clean oB passages in valve for freedom ofmovement in bores for excessive wear. Check tension to FITS AND 6.3.3 ASSEMBLY AND INSTALLATION 6.3. 3. 1 Install main reHef valve, 22 'Nith end bore.

(11) with new IMPORTANT: (111 (1 5) are the same thread size but cannot be used over the cold oil relier valve must have a solid center; used behind main reHefvalve may have a center.

6.3.3.2 'Units with torque converter to install washer.

22 (7), main relief valve and booster (3 Install 6.3. 3. :3 Units with install washer, valve "TITH''''''' L D. bore in

SE.RVICE MANUAL Form 0664032-0

Z8

Revised

1973

UY.f.aUc System Com olelts·

~

1$

10

13

14

12

------------------.........1

T-75517 ......- - - - - - - - - F I G . 22 PRESSURE REGULATING VALVE (UNITS wrrH TORQUE CONVERTER PRIOR TO SIN 241000) 1. Plug 2. O-ring 9. Main relief valve 3. Booster piston 10. O-ring 11. Plug 4. Pin 5, Main relief valve inner spring 12. Cold oil relief valve 6. Main relief valve outer spring 13. Cold oil relief valve outer spring: 1. Washer 14. Cold oil relief valve inner spring 15. Plug S. Body

8.4 MODULATING CLUTCH CONTROL VALVE NOTE: Refer to paragraph 1. 2. 7 for description and operation of valve.

6.4.1 REMOVAL AND DISASSEMBLY 6.4. L 1 Valve is located on upper left side of torque converter. remove left front floor plate to gain access to valve.

6.4.1.2 4 Disconnect oil line £rom top of valve; cover opening to prevent entrance of dirt. Remove valve from torque converter.

6.4. 1. 3 Mark position of end cap. Fig. 23 (4) and cover (1) before disassembling valve.

6.4.1.4 Remove cover, Fig. 23 (1); lift small oil filter, Fig. 24 (1) from top of valve body.

Remove piston (11), springs (10) (9). spring seat (S). and spool (4) from bore. Remove end cap (1) fro.m body.

6.4.1.5 Remove pipe plug. Fig. 23 (2); remove check ball and spring from plug opening.

6.4.1.5 • Fig. 23 (5); remove orifice Remove pipe p pIng:, Fig. 24 (1 from plug openin:ll

T-7547Z FIG~ 23 MODULATING CLUTCH CONTROL

VALVE 1. Cover 3. Body 2. Pipe plug 4. End cap

5. Pipe plug

6.4.2 INSPECTION Clean oil passages in cover and body, clean or replace oil filter; check spool for freedom of movement in bore; check large bore in body for excessive wear from piston seal ring.

Check springs for proper tension (refer to FITS AND TOLERANCES). Inspect opening in orifice plug; specified opening is .051**-. 056 H (1. 295 - 1. 42Z mmj. Replace necessary parts.

Revised June 1971

H,draulic S,stem Components

M

11

FIG. 24 MODULATING CLUTCH CONTROL VALVE '--_ _ _ _T_._7_50~9~6.....

1. End cap 2. Capscrew 3, Gasket 4. Spool 5. Body 6. Plug

7. Oil filter Ii. Spring seat 9. Inner spring 10. Outer spring 11. Piston 12. Seal ring

6,4.3 ASSEMBLY AND INSTALLATION

13. Gasket 14. Cover 15. Capscrew 16. Orifice plug 17. Check ball 18. Spring

6.4.3.7 Install valve (with new gasket) on torque converter; lubricate attaching caps crews and torque them evenly to 22-24 Ibs. ft.

(3.04-3.:31 kg-m). Connect oil lines to valve and check preuures (refer to PRESSURE CHECKING).

6.4.3.1 Install spring seat. Fig. 24 (8) in body. seating side up; install springs (9) (10) in respective locations. Install oil filter (7) in small counterbore in valve body. install covel' gasket (13) with cut-out over filter.

1.1 TOROUE CONVERTER PRESSURE

6.4.3.2 Install ring. Fig. 24 (12) in piston groove; interlock ends of ring (ring must turn freely in groove). Lubricate ring freely.

REGULATING VALVE NOTE: Refer to paragraph 1.2.8 for description and operation of valve.

6.5.1 Valve. Fig. 25, is located on lower rear side of torque convert.er. Valve can be disassembled without being removed. Remove guard from main frame to reach valve: remove plug, 25 (2) and remove spring and piston from e body.

6.4.3.3 Install piston, Fig. 24 (11) in bore. Hold piston in position; align marks placed at disassembly and install cover (14). If aligning marks were not made. be sure drilled passages in body and cover are properly aligned.

6.4.3.4 Install valve spool. Fig. 24 (4) in bore (spool may be installed either way). Install gasket (3) with cut-out over drilled passage in body. align marks placed at disauembly and install end cap (1). If aligning marks were not made, be sure drilled passage in body and pauage in end cap are properly aligned.

6.5.2 Check piston for freedom of movement in its bore. Check spring tension (refer to FITS AND TOLERANCES).

6.5.3 Install piston (small end first) and spring in valve body. ucure with plug. Fig. 25 (2).

6.4.3.5 Install orifice plug, Fig. 24 (16) in cover; secure with pipe plug. Fig. 23 (5),

NOTE: If valve body must be removed from torque converter; lubricate and torque attaching capscrews to 22-Z4 lbs. ft. (3.04-3.31 kg-m) when installing.

6.4.3.6 Install check ball. Fig. 24 (17) and spring (18) in cover; secure with pipe plug. Fig. 23 (2).

30

Hydraulic System Components 8.8 DECELERATING BRAKE SENSINI VALYE AND CYUNDERS 2

NOTE: Refer to paragraph '1.2.6 for description and operation of valve and cylinder.

6.6.1 REMOVAL AND DISASSEMBLY 6.6.1.1 Sensing valve is attached to bottom of seat frame, Fig. 26. disconnect oil lines and remove attach eapscrews to remove valve.

Remove cover, ig. 21 (101.); pull spool (Ie) and spring «ld) from housing.

T-75473 FIG. 25 TORQUE CONVERTER PRESSURE REGULATING VALVE 1. Body

6.6.1.2 Cylinders are a part of the brake linkage.

Fig. 26; remove yoke pins to disconnect linkage and remove cylinders. Pull piston, Fig. 21 (301.) from barrel (3d); remove seal (3b) and O-ring (3c) from barrel.

2. Plug

FIG. 26 SEAT FRAME AND BRAKE LINKAGE ~. Bra.ke valve spool 2. I)ecelerating brake cylinder - left side 3. Brake control linkage 4. Oil SUpply line to valve 5, OU supply line to cylinder in left brake linkage

T-7S52S

6. Oil return to sump '1. Oil supply line to cylinder in right brake linkage S. Decelerating brake sensing valve

Hydraulic Syatlll CO.,Ot1It1ta 6.6.2.2 Check fit of cylinder piston in the barrel; replace cylinder auembly if piston rough or pitted. Replace O-rings and seals.

6.6.2 INSPECTION 6.6.2,1.

Check sensing valve sponl for freedom of movement in housing. Check spring tension (refer to FITS AND TOLERANCES).

T~14959

L - - - - - - - - - - - - F I G . 1.1 DECELERATING B R A K E - - - - - - - - - - - - - ' 3. Cylinder a. Piston b. Seal c. O-ring d. Barrel 4. Oil return line 5. Oil line to sensing valve

1. Sensing valve a. Cover b. O-ring c. Sp~l d. Spring e. HOWling 2. Oil line to cylinder

6.6.3.4

6.6.3 ASSEMBLY AND INSTALLATION

ID.!~ll O-ring,

Fig. 21 (3c) in groove in cylinder barrel (3d); install wiper se~l (3b) in barrel with sealing lip out. Lubricate O-ring and install piston (Sa) in barrel.

6.6.3.1 Install O-ring. Fig. 27 fIb) and cover (la) on front end of housing (Ie) with finished side of cover against O-ring.

6.6.3.5 Install cylinder assembly in brake linkage.

Fig. 28, piston end toward front.

6.6.3.2 Install spool. Fig. 21 (1c) and spring (1d) from rear oi housing; short land on spool in first. Install 0(lb) and cover (la) on rear oi housing £i.nished side oi cover against O*ring.

6.

3.6

Cheek brake linkage adjustment. is properly adjusted when brake valve spool.

F 8 ca} has .31" (7.a7 mm) free travel it comes up solid against piston in brake valve. AdjWlt length of brake control rod. Fig. 28 (5) to obtain free travel.

6.6.3.3 Install sensing valve on sut frame; connect oil lines to n01ulng

32

'"",

Hydraulic System C'm,,"el~1

1...-_ _ _ _ _ _ _ _ _

FIG. 28 BRAKES AND BRAKE LINKAGE

T-75059 ----------.....!

1. B rake pedal 2. Floor plate 3. Parking brake support bracket 4. Parking brake rod 5. Brake control rod 6. Decelerating brake cylinder assembly

1. Decelerating brake valve S. Brake valve spool 9. Access plug 10. Band adjustment universal drive 11. B rake control valve 12. Brake bands

6.7 SHIfT INHIBITING PUMP

and shaft from stator. Remove snap :iing, Fig. 29 (3) from drive shaft and pun gear (4) from in shaft. Remove and remaining snap ring from shaft; out from front of stator.

NOTE: Refer to paragraph 1.2.2 for description and operation of pump.

6.7.1 REMOVAL AND DISASSEMBLY 6.1.1.4 Remove bearings.

29 {Z} from gear housing and/or stator only if they must be replaced.

6.7.1.1 Pump is mounted on bevel pinion shaft front bearing retainer. Remove transmission guard from main frame to gain access to pump.

Remove.capscrews attaching pump to retainer; remove pump •.

6.7.2 INSPECTION Replace shafts if worn. OOP' (.025 mm) at bearing areas. Replace drive shaft if splines show excessive wear or signs of twisting.

6.7.1.2 Mark pump sections for assembly purposes.

Remove caps crews from gear hOUSing and separate gear housing from stator. Do not pry pump apart.

Replace pump if gear pocket in gear housing is severely scored or if 1. D. is more than '1.170" (29.118 mm).

6.7.1.3

NOTE: Gear housing is not serviced separately.

Mark position of gears and remove idler gear

33

" ' - - - - - - - - - - - - - FIG. 29 SHIFT INHIBITING PUMP _ _ _ _ _ _ _ _ _ _ _....J 8. Idler shail; snap

1. Gear 2. Needle 3. Drive shaft snap 4. Drive shaft gear

5.

6.

9. rdler shaft 10. Pin 11. Idler gear 12..

U. Screws

shaft

7. Stator 6.7.3 ASSEMBLY AND INSTALLATION

on bevel Check pump

6.7.3.1 Ii

were removed, install drive shaft inner and idler shaft flush with inner of chamber in install install dri ve

to SiN lUI TRANSMISSION PUMP tos 7629 except lOS!7519thru lOSl7 NOTE: Refer to paragra .2. 1 for desc Uon and of pump.

6.7.3.2

6.8. 1

Install drive shaft s ide of sta tor. Install f rontsnap , install (5), gear (4), and (

6.8. L 1 The pump is easier to reach from th.e bottom; remove from bottom of main frame to reach pump.

6.7.3.3 Install gear {

in idler

L AND DISASSEMBLY

install

6.8. L 2 Disconnect oil Enes from pump; break sure suction tubeal: hose connection leave with pump. Cover ends of oU lines to prevent entrance of dirt.

(

6.7.3.4

6.8. L 3 Remove the two and remove pump dri.ve converter.

6.7.3.5 If test stand is available, refer to FITS AND TOLERANCES for test

34

capscreW$ from converter in torque

ReviudDecembe.r

970

<

Hydraulic SYltlm Clm,llllts 6.8.1.4 Remove caps crews bom front plate. clamp pump in a vise with drive s~it down. Clean exterior of pump and mark pump sections for assembly purposes, 6.8.1.5 Pull rear plate, Fig. 30 (19). wur plate (I4) and gear housing (18) from dowel pins.

--------"""'11

_ - - - - - - CAUTloN pry pump sections apart.

6.8. 1. 6 Mark position of pump gears. Fig. 30 (16);

10

slide idler gear bom shaft and pull drive gear from woodruff key in shaft. Remove woodruff key, center housing (15). wear plate (14). and gear housing (13).

6.8.1. 7 Mark position of remai.ning pump gears; remove idler shaft and drive shaft from front plate.

6.8.1.8 Remove diaphragms. Fig. 30 (9) diaphragm gaskets (7) (8) and diaphragm seal (6) from center housing and front plate. Remove springs and balls (5) and drive shaft oil seal (1) from front plate.

12111314

15

16

18

19

11

T-75103 FIG.30 TRANSMISSION OIL PUMP (PRIOR TO SIN 10517629 except HiS17519 thru 1(517578)

L Drive shaft oil seal 2. -Capscrew ~ 7 11 (177.8 mm) long 3. Capscrew - 6-3/4" {171.4mm} long 4. Front plate 5. Check balls and springs 6. Seal 7. Gasket - thin 8. Gasket - thick 9. Diaphragm 10. Drive shaft and gear

11. Idler shaft and gear 12. Dowel pins 13. Front hody (housing) 14. Wear plate 15. Center body (housing) 16. Scavenger pump gears 17. W:oodruff key 18. Rear body (housing) 19. Rear plate 20, O-ring (not used prior to S/N162(8)

6.8. Z INSPECTION

"'nJ.... "'''''' back plate, front , and/or center housing if bushing L D. is more than. 877 1t (22. 27mm}.

Wash parts in solvent; dry with compressed air. Remove burrs from gear teeth and mating machined surfaces of gear hOUSings. center hous ing • and!r ont and rea r plate s. Was h afte l' deburring.

Replace shafts if worn .001" (.OZ5mm) at bushing area. Replace drive shaft if rough at oil seal location or if splines show excessive wear or signs of twisting.

6.8.3 ASSEMBLY AND INSTALLATION

NOTE: Oil aU parts prior to assembly.

Replace gear hOIl if I. D. is more than

(s) if severely scored or .108" (53. 54mm) •

Replace' wear scored.

if warped or severely

6.8.3. 1 Install check balls and springs, Fig. 30 (5) in bores in front plate. Install seals (tl), with open side down, gaskets (7) (8) and diaphragms (9), with bronze side up. in front plate and center housing. Use dull tool to "tuck" seals into grooves in front plate and center housing. diaphragms will be flush with outer of seals when properly installed.

Replace drive shaft oil seal. diaphrams. and diaphragm seals and gaskets.

6.8.3. Z Clamp front plate in a vise - diaphragm up and install dowel pins. Fig. 30 (12). Install drive

URVICE MANUAL Form 0664032-0

35 (Revised December 1970)

suction line after up, attach elbow toward the

shaft and idler shaft; gears are

on converter their proper locations; capscrews.

6.8.3. 13 Check pump flow.

6.8.3.4 Insta.l:I wear plate, side gears suction side of gear in ..... '.......Ul(

.

30 (14) with bronze

section on must fit are contained Form 0663850- 6.

Service

6.8.3.5 SIN 162.08 - up, install a-ring. Fig. 30 (20) on each side of center housing OS}; use light grease to hold 0- rings in position. Install ce~nter over dowels against front !budng • side up.

6.10 fRAHSM 188 ION PUM P (81N 10817629· up including 10817519 thru 10817578) 6.10.1 REMOVAL AND DISASSEMBLY 6.10. L 1 is easier to reach from the OOl:tc,m remove hom bottom of main hame to reach pump.

6.8.3.6 Install woodruff key, Fig. 30 (l7) iu drive shaft. slide scavenger pump (16) on shafts. Install rear over with half moon cavities up and hole in of one on pressure side of pump.

6. 10. L 2.

Disconnect oU lines from cover ~ends of oU lines to entrance dirt. Remove 4 .. 1......"U.Ug capsc rews lro.m and remove pump from torque converter. gump drive coupling from shaft in torque converter.

6.8.3.7 Install wear plate, side gears suction side of inside gear

pressures

with bronze section on must fit

mark on cove rand dt.L"-i.H.<:r from cover; tap to cover. Slide adapter use care to to seal and oil seal re- used

6.8.3.8 SIN 16208

6.10. L 4Remove spacer 6.8.3.9 Install drive shaft oll in. Turn drive shaft with will be noticed if pump is Or,(H)I:lrl:V

6. O. L 5 rear seal (11) from bore

6.8.3.10 If test stand is avallable. refe.r to FITS AND T01.ERANCES for tut 5P'IItC14:1.t;;<t.l'1.QQ11J.

seal Mark and re-

30a {7}

(9) {1

6.10. Z INSPECTION 6.10. Z. 1

6.8.3.11 Belore installing pump. check driving shaft bearing and splinu on driving shaft; replace if necessary.

weal" plates if

6.10.2.2 Do not use drive shaft if or if Do not use than.015*'

6.8.3. U Connect pressure pump suction elbow new a-ring) to pump. Prior to SIN 1 elbow securely, but on the final turn, leave elbow toward rear of pump,finish the final turn to elbow with lower part of SERVICE MANUAl. Form 0664032-0

or

NOTE:The adapter, gear and idler shaft are not serviced. if any of these parts are not usable.

36

December 1

score

Hydraulic System CompOlelts

---12

--13

14 T-76331 FIG.30a TRANSMISSION PUMP (SIN 10S17629 - up. including 10S17519 thru 10S17578)---' 1. Dust seal 2. Oil seal 3. Adapter 4. Spacer plate 5. Seal ring

6. Qear Housing 7, Wear plate 8. Formed seal <1. Back - up ring 10. Back - up ring 11. O-ring

6. 10. 3 ASSEMBLY AND INSTALLATION 6.10.3. 1 Lubricate interior of gear housing liberally with light oU. 6.10.3.2 Seat the seal, Fig. 30a (8) in groove around back-up ring (9); place the seal and ring in groove in back side of wear plate (7). Place an O-ring (ll) and back.. up ring (10) around each of the shaft bores on back side of wear plate - put 0- ring in first.

6.10.3.3 Install wear plate in gear housing. Open side of seal, Fig. 30a (8) must be on suction (large port) side of housing and relief pocket in wear plate must be on pressnre side of housing.

Seat wear plate in housing.

6.10.3.4 Install shafts and gears, Fig.30a (12) (13) in housing. align marks placed at disassembly if original gears are used.

SERVICE MANUAL Form 0664032- 0

12. Drive shaft and gear U. Idler shaft and gear 14. Dowel 15. Wear plate 16. O-ring

6.10.3.5 Place wear plate. Fig. 30a (15) against gears with relief pocket in plate on pressure side of pump. Install O-rings (16) around shaft bores in wear plate.

6.10.3.6 Install dowels. Fig. 30a (4) in gear housing and slide spacer plate (4) over them. Install seal ring (5) between spacer plate and wear plate.

6. 10.3.7 Install oU seal. Fig. 30a (2) in adapter (3) with spring side of seal in. Bottom seal in counterbon. Install dust seal (1) with Up side out. Bottom dust seal against oil seal.

Lubricate lips of both seals.

6.10.3.8 Cpver drive shaft splines to protect seal Ups and install adapter on gear bousing; torque attaching capscrews to 120 Ibs. ft. (16. 59 kg-mI. Torque capscrews evenly in small increments; turn pump drive shaft while tightening them to be sure pump does not bind. Shaft will turn with heavy drag after capscrews are fully torqued.

36A (Added December 1970)

Hydraulic System Cam,aRents

" ' " - - - - - - - - FIG. 30b AUTOMATIC SAFETY BRAKE CONTROLS _ _ _ _ _ _ _ _...J 1. Right brake pedal

17. Nuts 18. Yoke 3. Pedal return spring 19. Lever 4. Floor supporting cross channel ZOo Yoke pin .U. Right brake cross shaft 5. Capscrew 6. Supply line bom transmission filter zz.. Yoke (short) 7. Transmission control belle rank bracket Zl. Jam nut Z4. Hose clamp 8. Control valve 9. Outlet to actuating spring cylinder lS. Boot 10. Actuating spring cylinder Z6. Hose clamp Z7. Yoke (long) 11. Capscrews lZ. Drain Une to transmission sump l8. Transmission filter 13. Drain line to transmission sump Z9. Oil line to transmission pressure gauge 14. Hose 30. Check valve 15. Boot 31. Outlet to transmission main relief valve DIM. tlA" -. 030 H --.lZO"(0. 76-16. brake shaft clearance Z. Pedal stop

SERVICE MANUAL Form 066403Z-0

36B

Revised April 1973

HY'rau lie System Camp.nents

T~ 77550

' - - - - - - - - FIO. 30e AUTOMATIC SAFETY BRAKE CONTROL VALVE 1. Hose clamp 2,. Yoke 3. Linkage boot 4. Spool 5. Hose clamp

6. Oil seal 7. Housing 8. Washer 9. Snap ring 10. Yoke

6.12.1.2 Disconnect oil lines and linkage from valve.

Fig. 30b. Remove the two capscrews. (5) attaching valve to bellcrank bracket (7) and remove the valve.

6.10.3.9 Before installing pump. check driving shaft bearing and splines on driving shaft; replace if neces sary.

6.10.3.10 Install coupling on pump driving shaft; install pump (with new O*ring) on converter housing.

'Connect oil lines to their proper locations; tighten pump attaching capscrews and nuts.

6. 12. 1. 3 Remove boots, Fig. 30c (3) from each elld of valve. Disconnect yoke (2) from spool (4); pull spool out other end of housing. Remove snap ring (9). washer (S) and oil seals (6) from housing.

6.10.3.11 Check hydraulic system pressures and/or pump now.

6. LZ.2 INSPECTION AND ASSEMBL Y

8.11 AUTOtIATIC SAFETY BRAKE CHECK VALVE REPLACEMENT

6. 12. Z. 1 Check fit of spool in bore. Replace spool and housing if clearance is more than. 003" (0,07 mm). Be sure all oil passages in housing are clear.

6.11.1 Valve is connected in outlet line of transmission oil fUter. Fig. 30b. Disconnect oil lines to remove it.

6. LZ. 2. Z Install oil seals. Fig. 30c (6) in housing -spring side of seals in. Install washer (8) with chamfered side against oil seal and secure with snap ring (9).

6. 11.2, Valve must provide a pressure dillerentialof 100 +01' -)Opsi (1,0 +01" - 0.1Kg/cmZ) at transmjssion pump flow and pressures.

RemoVe cap from hody. Inspect spring and plunger; replace valve if defective. Use new cap O-ring at assembly.

6.1Z.2.3 Lubricate oil seals and '0. D. of sponl and install spool in housing. Large end of spool must be against washer. Connect yokes, Fig. 30 c (2) (l0) to each end of spool. Yokes are identical; they can be installed at either end of spool.

6.11. 3 InstaU check valve in filter outlet Hne. Small arrow on valve body indicates oil flow and must -point away from filter.

8.12 AUTOMATIC SAFm BlAKE COITROL VALVE. Fig. 30ll

------....1

6.LZ.2.4 Attach linkage boots, Fig. 30e (3) to each end of housing. The two small holes in the first fold from small end of boot must be toward bottom after valve is installed.

'I,

6.12.1 REMOVAL AND DISASSEMBLY 6, 12. 1. 1 Valve is a part of the transmission control linkage;remove leftnoor piate for access to valve.

SERVICE MANUAL Form 0664032-0

36C

Added April 1913

H,drallic System CtUIPlllltl

1..-._ _ _ _ _ _ _ _ _ _ _ _ FIG. lOd

T-77762, BRAKE LINKAGE _ _ _ _ _ _ _ _ _ _ _ _---1

1. Pedal shaft bearings (left side) shaft 3. Keys 4. Left pedal shaft lever 5. Pedal lever pad eye bolt 6. Left pedal pad 7. Right pedal pad 8. Brake pedal levers 9. Right pedal sbaft 10. Automatic safety brake lever U. pedal sbaft lever 12. pedal shaft bearing 13. Bearing mounting bracket 14. Pedal shaft lever rod 15. Yoke

16. Rocker lever bracket 17. Linkage return spring 18. Spring ancbor 19. Decelerating brake c 20. Rocker lever 21. Automatic safety brake cylinder 22. Yoke 23. Yoke pin 24. Pedal retracting spring 25. Bearing mounting bracket 26. Pedal sbaft lever rod 27. Yoke 28. Spacer 29. Pedal shaft ring

Z. Left

SERVICE MANUAL Form 0664032-0

36D

Added April 1913

Hydraulic System Components 6. 13. 1. 5 Turn nut away from out rear of untH 30e (6) (7)

6. 12 • .3 INSTALLATION AND LINKAGE ADJUSTMENT

6. 12 • .3, 1 Attach valve to transmission control bellc rank bracket.:1' 30b ( - - the hose connection point valve housing must be on topside. Torque {5} to 95 -- 105 Ibs. ft.

6.13. L 6 Remove and dition of The moved from main frame to (6.13.2).

6. 1l • .3. Z Install Fig • .301" {ZZ) (27) in ends of valve spool; not tighten jam nuts (23).

Place transmission control valve speed plunger in neutral position (in as far as possible) and transmis s ion control leve r in neutral- start pos ition- - hold brake control valve spool against stop (push yoi<e (27) in as far ~s possible). Adjust yokes (ll) (27) to connect the linkage. Tighten jam nuts (l3) and small damps (24).

6.13 AUTOMATIC SAFETY BRAKE ACTUATING SPRING CYLINDER, Fig. 30b (10)

.....-------WARNING - - - - - - - . . , Do not destroy used piston burning. The fumes are very when inhaled.

6. 13. 1. 7 Heat the new piston ring, Fig. 30e ( in water at 150 0 F. (6S o C) for about IS minutes.

Install new O-ring. Fig. 30e in center groove in piston and install the piston (1) over the 0T a hose around piston ring to seat the ring in groove; leave on about 30 minutes while the ring cools.

6.13.1 SEAL REPLACEMENT NOTE: The piston seals and rear cover 0- ring can be replaced wi.th the cyHnder attached to main frame.

30e in end grooves and 1. D. shaft

6. 13. 1. 1 Remove floor plates and the dozer control valve cover plate on right side of seat.

6. 13. 1. 2 R the automatic brake and remove pin, Fig. 30b (20). If brake cannot be released in the normal manner block the brake aU the way down, remove ( 15) and turn the rear nut (17) in front of This will force the yoke OS} ance for removal of hrake pedal.

6.13,1.9

nect oU line to the rear nut (1)

6.13.1.3 Remove floor supporting cross channel. Re~ move attaching from right brake shaft bearing s, F :3 Od (1) (12) and lift the shaft assembly enough to dear the (lZ).

Remove the yoke and front nut from safety brake shaft.

. JOe (9) in rear eover; oiL marks and in stan rear cove r rews to Conoff

6. 1.3, L 10 Light! y boot, :3 Ob (l to Install front nut (Ion shaft and screw (lSj on shaft until end of is 2" (50, mm) from end of housing, Fig. 30e. Lock the nuts together midway between yoke and

6.13. L 4 Disconnect oil line, Fig. 30b (9) from :rear of housing. Mark rear cover for re-assembly and remove cover from

6. 13. 1. 11 Install brake shaft: and ; attach bearings. Fig. 30d {l) (2) to brackets. Con~ neet right brake

r------------ WARNING - - - - - - . . . . . , The springs and piston will erupt from housing as the rear cover is removed if rear nut, Fig. 30b (1 is not locked against housing.

SERVICE MANUAL Form 0664032~O

re-

36E

Added April 1973

flUI

T· 77563 i . - - - - - - - - F l G . 30e AUTOMATIC SAFETY BEL4..KE SPRING HOtJSING--------J L

HI,

Nuta

t L Rear cover 12. Piston 13. Yoke

2.

3. Shaft 4. Inner 5. Outer 6.13.1.14 Install remainder of to valve.

6. 13. 1. 12 Install noor the left front to locate the rear of slol;: in

remov<i:d for acces a

6.13.2 REMOVAL AND DlS}\SSEMBLY

30b (3) to

anchor it 1;:0 cross

6.13.2.1 is attached to main frame on of transmis sion. Remove rear floor and the dozer control valve cover on right side oJ seat for acce.$$.

brake pedal. in the two nuts the shaft (lor retract the

6.1:1. 2. 2 Release the automatic . 30h

and anow it to warm up. Return to low idle and move transmission lever to 3F to release automatic brake. ,--------WARNING - - - - - - - - ,

r-------- WARNING - - - - - - - - - .

If the trador is to move, be sure the tractor another means of is used before the brake released ..

6,13.2.3 Dhu:onnect oil from rear of and remove three capscrews ( 11) houaing to main frame. Lin housing and disconnect oil tine (12.) ~remove from tractor.

SERVICE ,MANUAL

Form 0664032.0

36F

Added

1973

Nyaha.lie System Compolelts FIRST STEP

SECOND STEP

T-775S2

FIG. 30£ INSTALLING PISTON IN HOUSING 1. Yoke

2. Housing 3. Outer spring 4. Inner spring

5. Piston shaft 6. Guide ring 7. Seal ring (covers 0- ring) 8. Piston

6.13.2.4 Remove yoke, Fig. 30e OJ) and bont nut (l} from piston shaft (3); bottom the rear nut ( 1) against bont of spring housing. Mark rear cover for re-assembly and remove cover bom housing.

SERVICE MANUAL Form 0664032- 0

9. Rear cover 10. O-ring 11. Shaft nuts U. 2.25"(57. Imm) wrench

, . . . - - - - - - - WARNING - - - - - - - - . . , The springs and piston will erupt from housing as the rear cover is removed if rear nut. Fig. 30e (l) is not locked against housing.

36G

Added April 1913

H,.fau

Systefl C,.p,nents

6.13.2.5 Remove nut from shaft to release the spring tension on piston; tension win be fully released just before the nut reaches end of shaft. The piston, shaft and sp can be removed from end of bousing. Fig • .3 • Remove rings from piston. , . . - - - - - - - WARNING-------, Do not destroy nsed piston burning_ Tbe fumes are very when inhaled.

6.13.4.3 Tighten the nut on shaft to pnll piston into housing; gnide the piston rings as they enter honsing. Continue turning nnt until real' of piston is abont . 5*' (12.7 mm) below rear of housing.

6.13.4.4 Install new O-ring. Fig. 30f (10) around rear cover; lubricate O-ring and interior of bousing.

Align marks placed at disassemhly and install rear cover on boulliing. Torque attaching capscrews to no -- 135 Ibs. ft. (1S.1 -- 18.6 m~kg). Back tbe nut away from froAt of housing until it is free on shaft. .'

6. U. 3 INSPECTION 6.13.4.5 Install front nut, Fig. 30b (11) on' sbaft. Lightly clamp boot (15) to housing and screw yoke (I8) on sbaft until end of yoke is 2" (50.8 mm) £:rom honsing. Fig. 30e. Lock tbe nuts togetber midway hetween yoke and housing.

6. 13.3. 1 Cbeck 1. D. of piston bore in housing. Bore must not be rough Or excessively worn. I. D. of bore wben new is 5.000" -- 5.004" (121,0 - - 1Z 7» 1 mm); replace housing if bore I. D. is more than 5. oH) If 027.25 mm).

6. U. 3, 2 Check for broken or weak brake apply springs.

Free beight of outer spring, Fig. 30e (5) is approximately 13. 66 n (346. <) mm); load when c<*npreued to 8.16 11 (207,2 mm) must be at least 2.000 Ibs. (907. 1 kg-), Free heigh!: of inner spring (4) is approximately U. 55" (344,1 mm); load wben compreued to 8. 16" (201. Z mm) must be at lust 540 lbs. (244, 9 Re~ place either spnng if weak.

6.13.3.3 Replace the piston seals and 0- ring; replace rear cover O-ring. See WARNING al: 6.13.2.5 before disposing of rings. Do not attempt to remove piston, Fig_ 30e (12) from shaft (3); tbe shaft and piston are serviced only as an assembly. .

6.13.4.1 Block the right hrake pedal in fully depreued. position. Witb tbe two nuts, 30h (17) locked together tbe shaft (16) can be to extend or retract the yoke (8). Position tbe yoke by turning the nuts to allow installation of yoke pin (20).

Start engine and allow it to warm up. Return engine speed to low idle and move transmission shift lever to :3F position to release automatic safety brake.

6. 13.4 ASSEMBLY. INST ALLATlON. AND LINKAGE ADJUSTMENT 6. U. 4.1 Heat ~e new piston ring. Fig_ 30e (7} in water at 150 F (6S o C) for about 15 minutelli.

, . . - - - - - - - WARNING - - - - - -.....

Apply left brake to hold unit stationary whUe transmission is engaged during adjustment procedure.

InllltaU new O-ring. Fig. 30e (8) in center groove in piston and :l.nllltall the piston ring (7) over the O-ring. Tighten a hose clamp around pilliton ring to seat tbe ring in piston groove; leave clamp on about 30 minutes while the ring cools.

With safety brake released •• 030" -- .120" (O. 16 • - :3.04 mm) clearance must he between yoke and front side of yoke pin.

Fig.30b DIM. "A". Adjnst clearance by turning the s brake shaft in Or out of the yoke. Lock 0 nuts together against real" of yoke after clearance is obtained.

Clamp boot (IS) securely at both ends.

6.13.4.2 Install gnide rings, Fig. 30f(6) in end grooves in piston; stagger the ring gaps. Lubricate rings and 1. D. of housin;. Install springs (3) (4) on shaft and start shaft into housing. Compress springs sligbtly by hand andinstaU one of the nnts (11) on front of shaft. Put a hardened ftatwasher between nut and housing.

SERVICE MANUAL Form 06640:U-0

6.13.4.6 Lay bousing on tranlllmission callie. in its approximate loca.tion along main frame, and connect oil lines to bottom and real" of housing.

Fig. 30b. Install real" capscrew first-then the two front capscrews to attacb housing to main frame. Align yoke with lever. Fig. 30d (10) on right brake cross shaft while positioning housing. Torque attaching capscrews to 110 -135 1bs. ft. US.l -. 18.6 m-kg}.

6.13.4.8 InstaU remainder of parts removed for access to valve.

36H

Added April 1913

"

TOPIC 7 MODULATING CLUTCH AND TORQUE CONVERTER 7.1 REMOVAL NOTE: The following procedures covel' torque converter removal in a general rather than specific way. Specific locations of disconnect points are left to the discretion of the mechanic and are determined to a great extent by the tools which are available to him.

1.1.1 Turn electrical system master switch off.

1.1.2 Remove exhaust stack and engine hood.

Disconnect ail" inlet hose and air cleaner restriction indicator hose from air cleaner.

1.1.3 Disconnect decelerator and governor control rods from lever beneath cowl.

7.1.4 Disconnect instrument panel gauge lines from front of cowl; disconnect wires in wiring harness.

7.1.5 Remove engine temperature gauge tube from water outlet manifold and install a plug to prevent coolant leakage.

7.1. 6 Disconnect steering control vertical rods from bell crank beneath cowl. Remove capscrews attaching bellcraok to bottom of cowl.

Disconnect cowl bracing rod from cowl.

7.1. 7 Attach hoist to cowl; remove capscrews attaching cowl to fenders; remove cowl.

7.1. Ii Remove floor plates and transmission bottom guards. Drain oil from transmission case.

7.1.9 Disconnect parking brake rod from brake cross shaft; remove floor supporting channel (with shims), decelerator pedal, and parking brake lever as an assembly.

1.1.10 Disconnect and remove steering control lower (horizontal) rods and front bellcrank.

1.1.11

NOTE: All the oil in the dozer hydraulic taok will drain from disconnected end of the pump suction line unless the oil outlet opening in hydraulic taok is plugged before the suction line is disconnected. To plug opening, remove suction line strainer and magnet from hydraulic tank and place a 4'* (10 L 6 mm) diameter ball in strainer seat; rest strainer assembly on ball to hold it in place.

7.1.12 Disconnect brake control linkage. Fig. 46; remove brake pedals, shafts, and brackets.

7.1.13 Unlock and remove caps crews attaching front and rear yokes to universal joint, slide front yoke forward and remove universal joint.

7. L 14 Attach suitable hoist to torque converter and remove capscrews attaching torque converter to flywheel housing; carefully lift torque converter from tractor.

1.2 MODULATING CLUTCH D'ISASSEMSLY 7.2. 1 Use a suitable puller to remove pilot bearing Fig. 31 (7).

7.2..1.1 Early units remove both halves of the carrier retaining washer. Fig:. 31 (6).

7.2.1.2 Late units. remove locking screw. Fig. 31 (12) from carrie r retaining nut (11). Use spanner shown in Fig. 44a with suitable extensions to loosen the carrier retaining: nut; remove the nut and locking washer under it.

1.2.2.

Pull clutch carrier from driving flange, Fig. 32; remove woodruff key. Fig. II (4) from flange.

1.2..3 Remove spider. Fig. II (3). hub (1), and friction plates (2) from driving flange; remove hub and friction plates from spider.

NOTE: Gear housing must be disassembled befor" driving flange can be removed.

Disconnect aU oil lines and vent line from torque converter housing; disconnect oil lines from transmission pump and dozer pump. Cover openings to prevent entrance of dirt.

SERVICE MANUAL Form 0664032-0

Revised April i 913

\

Mtdllatint CIiteh And Ttrque Ctnverter

LEGEND FOR FIG. 31 1- Centrifugal sensing valve cap Z. Gear housing 3. Modulating dutch control valve 4. Pressure regulating valve 5. Torque converte~ housing t 6. Retaining washer 7. Pilot bearing 8. Over-speed regulating valve 9. Over-speed valve cap 10. Locking washer 11. Carrier retaining nut 12. Nut locking screw EMU.Y tIIlTS

FIG.31 MODULATING CLUTCH INSTALLED

SERVICE MANUAL Form 066403Z- 0

38

T-7S477 T-77634

Revised April 1973

M.alatinl Clutch And Terque Converter 7.2.4 Remove piston from carrier, Fig. 34. remove sealing rings £rom piston and carrier.

7.2.5 Remove centrifugal sensing valve cap.

Fig. 31 (I); remove oil filter, Fig. 35 (Z), pistnn'(3). spring (4), and shims (5) from bore in carrier. Keep shims intact for use at assembly.

7.2.6 Remove over.speed valve cap. Fig. 31 (9); :r:emove sleeve. Fig. 35 (10), piston (9), spring (8), and washer (7) from bore in carrier.

T·75480 FIG. 32 REMOVING CLUTCH CARRIER 1. Shaft protector

T-75482 FIG. 34 REMOVING PISTON FROM CLUTCH CARRIER 1. Puller screws 2. Piston

T-15481, FIG. 33 MODULATING CLUTCH - CARRIER REMOVED 1. Hu.b 2. Friction plates

3. Spider (back plate' 4. WoodrW'i key

39

3. Clutch carrier

M.41'ltil Clltcis AId Tlr"le C.lverter

- - FIG. 35 CENTRIFUGAL SENSING VALVE AND OVER-SPEED VALVE INSTALLED _ _.",J IN CLUTCH CARRIER 1. Ce~trifugal sensing valve cap 2. Oil filter 3. Piston 4. Spring S. Washers (shims) 6. Clutch carrier

1. Washer S. Spring 9. Piston 10. SIeeve 11. Over-speed valve cap

Modulating Clutch And Tarftul Converter 1,3 SEAR HOUSINS OISASSEMBLY

7.3.4 Remove snap ring. Fig. 37 (11) from dozer pump driving shaft bore in torque converter housing; remove oil seal (9), carrier (lO), and O-ring £rom bore.

7.3.1 Remove caps crews attaching gear housing to torque converter housing. pry gear housing away from torque converter housing.

7.4 TOROUE CONVERTER OISASSEMBLY

NOTE: It may be necessary to tap rear end of pump driving shafts to free the rear bearings from bores in torque converter housing.

7.4.1 Remove accessory drive gear, Fig. 36 (4); remove clutch driving flange from rotating housing.

7.3.a Remove capscrews, Fig. 36 (1). remove idler gear and sbaft from housing. Remove ~plit retaining washer and remove idler gear £rom shaft.

. . . . - - - - - - - CAUTION------......, Do not pry driving flange from rotating housing; gouges made in the rotating housing while prying will affect its balance. If driving flange is difficult to remove, tap it in one direction enough to open a small gap between the flange and rotating housing; place a wedge in the gap and tap the flange in the opposite directioo. Repeat tapping and wedging procedure until driving flange is removed. Do not cock flange too mu ch while removing or the sealing rings in L D. of the flange may be damaged.

7.3.3 Remove pump driving shafts from gear housing; use suitable puller to remove any bearings which must be replaced.

7.4.2 Remo:ve valves, Fig. 37 (I) (2) (lo) from converter housing; refer to paragraphs 6.3, 6.4, and 6. :> for repair procedures.

7.4.3 Slide universal joint front yoke from adapter, Fig. 37 (6); remove retaining capscrew from end washer (4). Remove snap ring, Fig. 37 (3); use pusher screws to remove end washer (4). Remove a-ring behind end washer and slide adapter (6) from torque converter output sbaft.

T-75484

7.4.4 Use pusher screws to remove rear bearing retainer. Fig. 37 (5}; drive rear oil seal out front side of retainer.

FIG. 36 GEAR HOUSING INSTALLED FRONT VIEW 1. Capscrews 2. Idler gear shaft 3. Idler gear 4. Accessory drive gear 5. Clutch driving fIattge 6. Over-speed regulating valve

41

1I'.llatill Cluteh AI. T.rqll C.IYlrtlr

T-75474 FIG. 37 TORQUE CONVERTER ~ REAR VIEW 1. Pressure regulating valve l. Modulating clutch control valve 3, Snap ring 4. End washer 5. Seal carrier (rear bearing retainer) 6. Output shaft adapter 7. Gear housing 8, Torque converter housing 9. Oil seal

10. O-ring carrier 11. Snap ring 12. Dozer pump driving shaft 13. Bearing 14. Transmission pump driving shaft and coupling 15. Snap ring 16. Torque converter pressure regulating valve

1.4.5

not pull oil tube from shaft unless it is 1ooliJe. Place rotating housing on 8 ft (203. Zmm) blocks, Fig. 39. and drive output shaft out of front bearing.

\ .

Support front end of torque conve~r output IiJhaft. drive output shaft and rotattng"bousing assembly. Fig. 38, out front of converter housing.

1.4.6 Remove sealing ring carrier, Fig. 38 (l)t do

IMPORTANT: Output shaft front bearing has a split inner race; identify races so they ,may be reinstalled in original position if reused.

,

Me'ulating Clutch An. Tefque Cenvertlr

T-75546

FIG. 38 OUTPUT SHAFT AND ROTATING HOUSING ASSEMBLY

1. Rotating housing Z. Sealing ring carrier 3. Impeller wheel 4. Output shaft

T.75527 FIG. 39 REMOVING OUTPUT SHAFT FROM FRONT BEAIUNG 43

Medulatinl Clutc' And Tlrque Clnvener

T~75528

FIG. 40 ROTATING HOUSING ATTACHED TO IMPELLER 1. Capscrews w/spedal washers 2. Impeller wheel clamping plate 3. Impeller wheel hub

4. Guide wheel carrier 5. Impeller wheel 6. Rotating housing

7.4.7 Remove caps crews attaching impeller wheel to rotating housing. Fig. 40, use pusher screws to remove impeller wheel. Thrust bearings and races, guide wheel, guide wheel carrier> and turbine can now be lifted from rotating housing.

peller wheel should not be removed ouless replacement of one of the parts is necessary.

1.4.9 Remove sealing rings bom output shaft and front carrier.

7.4.10 7.4.8 The frout bearing carrier attached to rotating housing. the hub and clamping ring attached to turbine wheel, and the hub attached to im-

Pull modulating clutch oil supply tube and O-ring. Fig. 41 (2) from support (1); remove support from housing. Do not remove oil bypass tube (3) unless it has been leaking.

Modulltin, Clutch And Torque CORverter refe-r to FITS AND TOLERANCES. CENTRIFUGAL SENSING VALVE. Check piston for freedom of movement in bore.

Inspect spring; refer to FITS AND TOLERANCES. OVER-SPEED REGULATING VALVE. Check piston for freedom of movement in bore, Clean or replace filter screen, Inspect spring; refer to FITS AND TOLERANCES, Refer to paragraph 7.9 for pressure check procedure.

7. 5, a GEAR HOUSING

T-75481 FIG. 41 INTERIOR OF TORQUE CONVERTER HOUSING 1. Guide wheel carrier support 2. Modulating clutch oil supply tube 3. Oil bypau tube

1.5 INSPECTION 7. 5. I MODULATING CLUTCH PILOT BEARING. Replace if worn, pitted, or chipped.

SEALING RINGS. All sealing rings should be replaced when clutch is rebuilt.

FRICTION PLATES (STEEL). Thickneu of a new plate is .103"-.105** (2.61-2. 66mm); replace if thickneu is leu than. 095" (2.41 mm).

FRICTION PLATES (BI-METALLIC).

Thickneu of a new plate including friction material is .1401*-.145/1 (3.556-3. 683mm); depth of friction material grooves is .012H_ .020" (.304-. 508mm). Replace plate if thickness is leu than. UOH (3.302mm) or if thickness varies more than .002" (. 050mm).

NOTE: If friction plates are severely scored or burned. they must be replaced regardless of wear.

ACCESSORY DRIVE GEAR AND BUSHING. Replace if gear teeth are chipped or worn. or if I.D. of hushing is more than 4.010u (lOl.85mm) OVER-SPEED VALVE. Check piston for freedom of movement in here. Inspect spring;

BEARINGS. Bearings must 1"011 smoothly and be £ree of pitted, cracked, or worn balls, rollers, and races; retainers must not be dented or damaged. Badly worn ball bearings can be detected by presence of excessive end play between outer and inner races. Hold one race steady and move other race endwise; compare difference in movement of used bearing with a new bearing. Check outer and inner ra~es for indications of bearing creepage.

ThIS can be detected by marks on bearing races or on bearing area of bore or shaft where bearing has been used. If bearings are to be reused, keep bearings clean, well lubricated, and wrapped in clean oil proof paper to prevent rusting and entrance of dirt. When installing new bearings, do not remove bearings from package until ready for assembling; do not wash lubricant from new bearings.

OIL SEALS. The sealing lip must not be scratched, folded over, torn. or charred from ~ea~. L~p must be 'flexible; spring located mstde IIp must have proper tension to return lip to its proper position when lip is ~n:~ssed in by band. Before installing a seal m its here. coat bore lightly with liquid&type gasket cement; always lubricate lips of seals with clean oil at assembly.

GEARS. Clean all gears and inspect for worn pitted. chipped, or cracked teeth. check in- • ternal splines for galling. roughness, and wear'.

7.5.3 TORQUE CONVERTER TURBINE WHEEL. IMPELLER WHEEL. AND GUIDE WHEEL. inspect blades for looseness, nicks, burrs or binding. If blades are nicked, burred. or slightly bent. they may be filed or stoned to smooth the edges' if blades are loose. wheel MUST be replac~d. r---------------------CAUTION----------------__ Never attempt to peen or stake any loose blades, OIL SEAL. O-RING. SEALING RINGS. AND SEALING RING CARRIER. It is advisable to

Modulating Clutch And Torque COnYfHfe r replace rear oil seal. O~ring and all suI rings when torque converter is assembled.

Inspect seal ring currier; if ring lands are worn, carrier should be replaced.

BEARINGS AND BEARING RACES. Replace bearings and races if excessively worn, chipped, or pitted.

OUTPUT SHAFT. inspect for rough or twisted splines; dress rough spots with small file.

Clean oil passages in shaft; be certain oil tube is tight.

GUIDE WHEEL CARRIER SUPPORT AND IMPELLER WHEEL HUB. Replace if L D. is severely worn by sealing rings.

GUIDE WHEEL CARRIER. Check 1. D. of bushing; replace it if L D. at any point is more than 2.382" (60. 50 mm}. Bushing replacement notes: a. Use care when removing old bushing to prevent burrs in bore b. Lubricate O. D, of new bushing with light oil. Do not use bonding type sealer. c. Press bushing into bore until flush with outer edge of bore. Remove any burrs from end of bushing after it is installed. d. Check bushing 1. D. after assembly.

Specified I. D. is 2.376"-2.379" (60,3560.42 mm). If I. D. is out of specs at any point remove the bushing and check its bore for an out-oi-round condition. Replace carrier if bore is out~of-round. Do not attempt to ream the wshine.

1'-15496 FIG. 43 GUIDE WHEEL INSTALLED IN IMPELLER WHEEL 1. Impeller wheel 2. Guide wheel 3. Front thrust bearing 4. Guide wheel carrier 5. Thrust bearing race (flat) 7.6.2 Install snap ring. Fig. 45 (30) in groove nearest the rear side (ltimpeller side") of guide wheel. Install carrier (29) - long end first - in guide wheel; seat carrier against rear snap ring and install front snap ring (2'8).

1.6,3 Install sealing ring, Fig. 45 (31) in guide wheel carrier, interlock ends of ring and make certain it turns freely in groove.

7.6.4 Install guide wheel and carrier assembly on impeller wheel, Fig. 43; be certain carrier sealing ring enters impeller wheel hub properly. Install front thrust bearing flat

1.6 TORQUE CONVERTER ASSEMBLY 1.6.1 Install hub on impeller wheel, Fig. 42; secure with damping ring and capscrews, Fig. 40; torque capscrews to 22-24 Ibs. ft. (3.04-3.31 kg~m). Install rear thrust bearing. Fig. 42(3) on impener wheel hub with a race (4) on each side of beaxing.

1'-15488

1'-15491

FIG. 42 IMPELLER WHEEL AND HUB FIG. 44 TURBINE WHEEL READY FOR _ _ _ _ _ _ _ _-"UiSTALLATION ON IMPELLER

1. Impeller wheel Z. Hub SERVICE MANUAL Form 0664032 ... 0

3. Rear thrust bearing 4. Thrust bearing race

1. Turbine wheel Z. Clampmg ring

46

3. Hub 4. Front thrust beal'mg race (ilL" shaped} Revised April 1973

Modulating Clutch And Torque Converter race on guide wheel carrier; install thrust bearing on race, Fig. 43.

,...-------CAUTlON _ _ _ _ _ _ _-, Tube will be damaged if roller is inserted too far into tube.

7.6.5 Install hub, Fig. 44 (3) and damping ring (2) in turbine wheel. Align capscrew holes and i.nstall attaching capscrews; torque capscrews to 24-261bs. ft. (3.31-3.59 ). Install snap , Fig. 45 (42) in 1. • of hub.

1.6.6 Coat flal: side of front thrust race with and install it on turbine wheel hub, with flat side against hub.

7.6.7 Install turbine wheel, Fig. 44, on impeller and guide wheel, Fig. 43; be certain front thrust bearing race, Fig. 44 (4) is seated properly on bearing.

7.6.8 InstaU output shaft front carrier, Fig. ·45 (27) in rotating housing; temporarily install two l" (25. 4mm) long capscrews to hold carrier in position. , . . . . - - - - - - - CAUTlON---------.., Do not tighten capscrews enough to score rotating housing.

7.6.9 Install four guide studs in install rotating housing over wheel, wheel, and impeller wheel assembly. rotating housing down impeller turn the assembly over and install attaching capscrews and flat washers, Fig. 40; torque caps crews to 22-24 1bs. ft.

(3.04-3 . .H kg-m). , . . - - - - - - - CAUTION - - - - - - - , Flat washers used with rotating housing attaching capscrews are hardened for this purpose; use original washers or exact factory replacem ents.

1.6. 10 Install guide wheel carrier support in torque converter housing. Fig. 41; torque attaching capscrews to 52.58 1bs. ft. (7.18-ILOl kg-m).

Install O-ring on modulating clutch oil supply tube; lubricate O-ring freely and install tube in support. Fig. 4l.

7.6. n If bypass tube. Fig. 41 (3) is replaced, it must be roUed into housing at both ends using tool shown in Fig. 90 (Service Tools).

Insert roller. 87" (22. Omm) into tube; apply 48-52 in. Ibs. (55.3-59.9 kg/em) torque to the roller to properly tighten the tube in bore.

Ends of tube must be flush to slightly below the housing surface after being rolled.

SERVICE MANUAL Form 0664032·0

1.0.12 Inst.all rear bearing •. Fig. shaft; bottom bearing land. Install sealing of and make in grooves.

(33} on output sealing ring interlock ends turn freely

1.6.13 Install output shaft in housing; seat rear bearing against guide wheel carrier support.

InstaU oil seal in rear beari.ng retainer, spring side of seal toward front side of retainer. Install rear bearing retainer and torque attaching capscrews to 22-24 Ibs. ft.

(3. 04 - 3. 31 kg - m).

7.6.14 Stand output shaft on rear end; block under torque converter housi.ng to prevent it tipping.

Attach lifting device to front of rotating housing; install rotating assembly over output shaft and into torque converter housing. While installing. align splines on shaft and turbine wheel hub; be certain shaft sealing rings enter guide wheel support properly. Shaft splines will be seated ag~inst snap ring in L D. of turbine wheel hub if parts are properly assembled.

7.6.15 Use suitable driver to install rear half of front bearing inner race, . 45 {43l on output shaft; seat race turbine wheel hub. Install front bearing (44) in carrier and install front half of inner race; bottom front race against rear race.

7.6. 16 Install oil tube, Fig. 45 {4l) in output: shaft; tube i.s a "tap in" fit in shaft. Install front ring carrier, Fig. align holes in side carrier with cross drilled hole in shaft. Torque attaching capscrews 1:0 12-14 1bs. ft. (1. 65- L 93 -mi. Install sealing in carrier; interlock ends of rings.

Rings must turn freely in grooves.

7.6.11 Install modulating clutch driving flange on rotating housing. Fig. 36; be certain front: sealing rings enter properly into the 1. D. of the flange. T ue attaching capscrews to 52-58 Ibs. ft. .18-8.01 kg-m). Install new sealing on over-speed regulating valve; install valve in front end of modulating clutch driving

7.6.18 Slide adapter. Fig. 45 (36) on output shaft: install O-ring (31) and end washer (38), Align ron pi.n holes in shaft and end washer and install roU pin; bottom roll pin in shaft. t?ecure end washer with snap ring (39).

Revised February 1973

, "-

Modulating Clutch And Torque Converter 7.7 GEAR HOUS_NS ASSEMBLY 7.7.1 Install snap rings, Fig, 37 (1l}(l5) in pump bores in torque converter bousing. Install O~ring, Fig. 45 (20) and carrier (19) in dozer pump bore-chamber in I. D. of carrier to~ ward front of housing; seat carrier against snap ring. Coat O. D. of dozer pump oil seal (22) with a suitable sealer and install seal in 1. D. of carrier- spring side of seal toward front of housing. Rear of oil seal should be flush with carrier.

7.7.2 Install bearings on pump driving shafts; install shafts in gear housing. Assemble idler gear, bearing, and shaft, Fig. 45. Install shaft in gear housing. Fig. 36, .with spacer between shaft and housing.

7.7.3

carrier; install spring (4) and piston (3). Be certain piston is seated against spring and is not bound in its bore. Install filter (2) and cap 0); torque attaching capscrews to 22-24 Ibs. ft. (3. 04-3, 31 kg-mi.

7.8.6 Install washer Fig. 35 (7) spring (8) piston (9) and sleeve (10) in over-speed valve bore in carrier.

Be certain spring is properly seated in piston.

Install over-speed valve cap (11); torque attaching capscrews t022-Z4lbs. ft.(3.04-3,31kg-m).

7.8.1 Install new sealing rings, Fig. 45 (3)(7} in hub of carrier and around O. D. of piston; lubricate rings freely. Align holes in piston with dowels in a carrier and install piston in carrier; be careful to prevent damaging sealing rings.

NOTE:Piston can be installed either way over dowels in carrier.

Place a new gasket on torque converter housing; install three or four guide studs in gear housing and install gear housing on torque converter housing. Guide pump driving shafts into their bores while installing gear housing; use care to prevent damage to dozer pump shaft oil seal.

7.8 MODULATING CLUTCH ASSEMBLY 7.8, 1 Late units, install pins Fig. 45 (48) in driv~ ing flange; seat pins fully in holes. Install thrust washer (49) over the pins against driving flange.

7.8.2.

Install accessory drive gear, Fig. 36 (4) on driving flange. in mesh with idler gears.

With snap ring. Fig. 45 (o) installed in back plate (9). install back plate on accessory drive gear.

7.8.3 Late units, install split washer, Fig. 45 (47) in groove behind splines on driving flange chamfer in 1. D. of washer toward rear flange.

Be certain oil baffle. Fig. 45 (5) is securely staked in clutch hub (45); if new baffle is in~ stalled stake it in three places equally spaced around hub. Install clutch .hub on driving be certain split washer is seated in counterhore in rear of hub.

1.8.4 Install friction clutch end with a

sensing

35. Install shims (S) in

SERVICE MAN UAL Form 066403Z~O

T-77633 1..---FIO.44a INSTALLING CARRIER---I RETAINING NUT *1.

2.

3. Wood blocks wrench

*Tool no. 15000S15. Order from FiatAllis dealer.

7.8.S Install woodruff key. :33 (4) in flange; install carrier assembly on driving flange over key.

Revised April 1973

odu

Clutch

Torque

verter

7.9. L,:: DRIVE MEMBER. motor will drive the ratio of the pump pump to turn the

r electric

1.9'.1.3 OIL RESERVOIR. A drum of specified lubricant should be used as the reservoir. Be certain lubricant is dean. Insert pump suction line wen below oil surface, but not on the bottom of drum. oil surface. Warm befo re te sta.

7.9. L 4 PRESSURE TAP. Re-work over~ valve (part r; 70657 to a connector to a pressure gauge.

NOTE: Overvalve used in torque converters S a pressure check This cap is as a service item earEer converters.

1.9 BENCH TEST FOR CENTRIFU GAL SENSING VALVE AND OVER·SPEED REGULATING VALVE 7.9.1 EQUIPMENT REQUIRED PUMP. A minimum 1750 No. , which is power on 545 Wheel Loaders, meets this and is available from any Fiatpump drive shaft to a belt

(,9'L,) PRESSURE GAUGE. 60

(4.2

/

drive.

SERVICE MA.NUAL Form 0664032-0

48A

Added AprU 1973

Modulating

IItch

1 9< L 6 OIL LINES AND FITTINGS. Recommended Hnes and are shown in ,45a and 45b. Variations are the Hnes on front side shut-off valve must be to carry the full to Oil Hnes as the return

d 7.9.3.4 Start test with shut-off valve in open. Below 8.5 {.59 dutch will be on front side of dutch shut-off valve to raise 10 psi max. max.} the

7.9.2; CENTRIFUGAL SENSING VALVE

7.9.2. ~ Place torque converter on a work bench with an oil or other means of oiL

1.9.2.2 dutch pressure with a tee, connect pressure gauge and oil to tee.

valve opens. pressure

r-------- CAUTION ----------r

7.9.2.3 dutch control valve with 1:0 test oil

Do not dose shut-off valve to the converter in

7.9<2.4 Start test with shut-off valve in test Hne When valve opens, will come out the in face of dutch carrier below the valve cap and also near the center of the carrier. shut-off valve to raise test pressure and observe pressure at which r"1'1r.. H'"'' valve opens; re-open shut-off valve and observe pressure at which r .. rU1FHU"'''' valve dosesL test several times Hnecessary to cbtain an accurate pressure

7.9.2.5 shim(s)

sure. wUI (.28

7.9.3. 5

Install atandard overcap (see 1.9. L test to be sure no excessive J.ei(L~·"'If" occurs between cap and carrier.

1.10 INSTAllATION NOTE: Check condition of before installation; :refer to Manual Form 0663850-6 for and converter into tractor and clutch back splines in flywheel secure converter to of

VALVE

7.9. 3 OVER -SPEED

7.9.3.1 Place ..v,.... ""'" converter on a work bench with an oil or other means of oil.

1.9.3.2

Supply test oil torque converter inlet; bolt solid plate and gasket on torque converter outlet.

1.10.2 Install drive sha.£t: universal to bont and rear capscrews with

1.10.3 Install brake pedal and shaft assembly, 46; connect brake control linkage and brake ._.,__''''_

7.9.3,3

_"''''''''0 valve cap with one which Replace 1 9. L 4); connect preshas pressure sure gauge. <

SERVICE MANUAl. Form 0664032-0

49 (Revised December

Modulatinl Clutch" And Torqua Converter

1..-._ _ _ _ _ FlG.

SERVICE MANUAL Form 066403Z-0

T-750S7 45 MODULATING CLUTCH AND TORQUE CONVERTER _________....J 50

Revised April 1973

Torque

Clutch

M LEGEND Fo.R FIG. 45 L 2.

3.

4.

5,

6.

7.

8.

9.

10.

U. 12.

13.

14.

15. Dozer pump shaft 16. Gear 17. Torque converter 18.

42. race

43.

44.

45.

46.

used

47.

used

32, 33, Rear 34. Carrier (rear retaine 1") 35. Oil seal

*48. *49. Bronze thrust washer *50. nut *51-

36.

*52.

* Late

7.10.9 Make certain transmission drain installed and Clean

7.10.4 Connect oil lines and vent line to conve rter; attach AllI'11'101"1tH'ltt oil Hnes to !;ransm Remove baH

transmis ~ with to AULIC LUBRICANT SPECIFICATIONS CAPACITY AND

7. 10.5

7.10,10 Start

Install steer rods and front rods and control valve.

Hoor channel shims) and

for a few rve for leaks . Observe oU pressure if normal readare not indicated a few minutes, stop and determine cause.

7.10.6 [nstan cowl; attach it to rear fenders. Attach cowl rod to front of cowl.

to heat: oil i.n system Check oil on oil oil level must within range marks on gauge rod.

7.10.1 Attach control rod belkrank to hottom of coneecl; control vertical rods to beHcrank.

7. 10.8 Connect wires control and Hnes to of cowl; air inlet and air cleaner restriction indicator hose to air cleaner. Install hood and exhaust stack.

SERVICE MANUAL Form 0664032- 0

37. 038. End washer 39.

40.

41. Oil tube

19.

20.

21.

22. on seal 23.

24. Turbine wheel 25. Guide wheel 26. wheel 27. Front carrier 28. F.ront snap 29. Guide wheel ca.rrter 30. Rear ring 31 ... ""~ •.•u ..

1.10.12 Install floor guards.

51

and transmissi.on bottom

Revised April 1973

Modulating Clutch And Torque Converter 112 HOISE ELECTRIC MOTOR

3/4" IAn YAt.ft ISMUT ·fJff YAI.YE)

9258sa TEE

TO MGOULATI,.G CLUTCH APPLY PRESSURE CHECK POINT

CENTRIFUGAL SEIISI,.6 VALVE CAP

ffi··

T-7556Z FIG. 45a CENTRIFUGAL SENSING VALVE BENCH TEST _ _ _ _ _ _-.....l

SERVICE MANUAl. Form 0664032.- 0

52. (Revised December 1970)

3/4" SAH VALVE {SHUT·OFf VAlVEI

CIlfUU:CT 608305 FlnlNS AND 921217 CI'lNNeCTIlR liEILE

CENflUFUGAL SENSinG VAI.VE CAP

AHAeli TO TIlRI.'WE CONVERTER !NLET

OIl. fLOW liEILE unTil. I'IlESSURE lliiACliES U ' 10 psi(,59·,10 kg/tm

CONNeCT PI EllSU liE GAUGE liEIIE

T-15562

L - . . - - - - - - F I G . 45b OVER-SPEED REGULATING VALVE BENCH TEST _ _ _ _ _ _..J

SERVICE MANUAL

Form 066403~- 0

53 (R.evised December 1910)

TOPIC 8 TRANSMISSION 8.1 REM OVAl. NOTE: Before removing the tresmission, remove floor plates and transmission bottom guards;. clean transmission and surrounding area. When disconnecting hoses, cover hose openings to prevent entrece of dirt. Identify each hose as it is removed to facilitate auembly.

8.1.1 Turn electrical system master switch off; drain oil.from transmission case and bevel gear compartment.

8.1.2 .

Remove seat. Disconnect oil lines from decelerating brake control valve. Fig. 26. disconneCt control linkage from dozer control valve. Remove seat frame and front support angle.

8. L 3· Disconnect decelerator pedal control rod from lever beneath cowl; disconnect parking brake rod from brake cross swt. Remove floor plate supporting channel (with shims on right end). decelerator pedal. and parking brake lever as an assembly.

8.104 Disconnect and remove steemg control lower (horizontal) rods.

8.1. 5 Disconnect brake linkage. Fig. 46; remove brake pedals. shafts. and brackets. Unlock and remove capscrews attaching front and rear yokes to universal joint; slide front yoke forward and remove universal joint.

8.1.6 Disconnect oU lines from top of speed control

valve and shift inhibiting valve. Fig114. disconneCt oil lines from steering control valve. disconnect torque converter vent line from transmission filler tube. Remove supporting lay aU lines and vent line aside for clearance.

'.

8.1.1 Disconnect liokage from speed control Valve.

Remove capscrews attaching bellcraok bracket to top of transmission case; lift bellcraok bracket up and tie it to side of shift tower for clearance.

8.1.8 Disconnect transmission pump suction line and steering pump suction line from lower part of transmission case. Disconnect oil supply line from jumper tube assembly on front of transmission case.

8.1. 9 Remove transmission filler tube and breather housing from top of transmission.

8.1. 10 Attach Ufting chain and hoist to transmission; raise hoist until lifting chain is NOTE: A tapped hole in the left rear corner of transmission case and a cast -hole in front cover are the lifting points. not attempt to support the entire transmission from eye -hole in front cover.

8.1. 11 Remove caps crews attaching transmission to main housing; move transmission forward and carefully remove it from tractor. Cover bevel pinion bore in main housing to prevent entrance of dirt.

Tnnsm

ion

T-75537

FIG. 46 TRANSMISSION INSTALLED 1. Transmission filler tube and l:n.. eather

2.

3.

Munno-,.t:U1,O

front

4.

8 .2 DISASSEMBLY

8.2. L 3

8.2.1 REMOVAL OF COMPONENTS FROM TRANSMISSION CASE

retainer shims to bevel Remove collec-

8 ..2. L 1 and remove all Use suitable of reverse and remove drive shaft: rear capscrew • Pull (1) from shaft.

8.2.1.4 A must be used to remove the reverse shaft oil collector, cause the front oil seal spacer, .000"-.002" (.000-. 050mm) is removed with the oil collector. rear end of shaft while oil

8.2. L 2.

Turn transmission so froni: cover faces block under rear of case so rear of shaft contacts floor. Bevel must be in this manner to prevent it from when the front snap is removed.

55

Trals.issill

T-15498

FIG. 47 TRANSMISSION FRONT VIEW 9. First speed clutch shaft oil collector 10. Connector with .188" (4.115 mm) restrictor 11. Check valve retainer 12. Transmission pressure pump suction line screen 13. Oilleve1 gauge rod tube 14. Second/third speed clutch shaft oil collector 15. Connector with .25011 (6. 350 mm) restrietor

1. Drive shaft rear yoke 2. Capscrew 3. Forward/reverse clutch shaft,oil collector 4. Speed control valve 5, Shift inhibiting valve 6. Counter shaft front bearing retainer 1. Bevel pinion shaft frnnt bearing retainer 8. Shift inhibiting pump

56

Traosmissi 00 , . . - - - - - - - CAUTION - - - - - - . . ,

8.2. L 5 Remove oil sealing rings, Fig. 48 (2) frort:! each clutch shaft. Put several wraps of tape around front part of each clutch shaft to protect sharp edges on sealing ring grooves and oil grooves,

Front sealing ring on clutch shaft passes through a large bore in the oil collector and must re-euter the sealing ring bore while collector is being removed. Sealing ring and/or oil colledor may be damaged if collector is forced over sealing ring.

8.2.1.6 Unlock and remove caps crews attaching: end washer. Fig. 48 (8) to bevel pinion shaft and

T-75529

FIG. 48 TRANSMISSION FRONT VIEW - OIL COLLECTORS AND BEARING RETAINERS REMOVED 1. Forwardlreverse clutch shaft 2. Shaft sealing rings 3. Snap ring 4. End washer

7. Front bearing retaining nut 8. End washer 9. Bevel pinion shaft front bearing 10. Bevel pinion depth adjusting: shims 11. Snap ring 12. Second/third speed clutch shaft

5. Counter shaft 6. First speed clutch shaft 57

Transmission end washer (4) to connter shaft; remove end· washers. Remove snap dng (3)lrom forward! reverse dutch shaft.

8.2. L 1 Use socket, Fig. 49, with suitable extension to remove dutch shaft front nuts, Fig. 48(1).

Lock the gear train by installing a 1/2" cold roll bar, Fig. 49, through hole in front cover and bevel pinion sbaft idler gear.

T-8071Z FIG. 50 REMOVING TRANSMISSION FRONT COVER I. Capscrew l/2HNC x 4~1/2H with

plain washer 2. Stud 1/2!1NC x 11" with nut and plain washer 3. Bars 4. Spacer 2-1/4" diam. x 2~1/Z!! long 5. Capscrew l/2 H NC x 3 .. 1/2 11 with plain washer 8.2.1.9 Cut four bars 9.0" (228.6 mm) long from 1.5" (l8. 1 mm) square bar stock. Drill two. 62 It (15.7 mm) holes in each bar 6. 62 n (168.15 mm) apart. Install bars on transmission as shown in Fig_ 50. Remove capscrews attaching front cover to transmission case.

Alternately turn each capscrew and nut attaching bars to front cover a few turns at a time to pull front cover and bearings from the transmission shafts. Make certain cover does not bind as it is being removed..

T-15499 FIG. 49 REMOVING CLUTCH SHAIi 1.' FRO NUTS *1. Socket; (AC~1051) 2. Gear locking pin (112" cold roU)

* Order £rom Service Tools Inc.

1901 Indiana Ave., Chicago, lllinois 60616

8.2.1.10 Identify and remove spacers and'driving gears from shafts. Fig. 51.

8.2. L 8, Be certain rear end of bevel pinion shaft is supported as described in 8.2. 1. 2; remove snap Fig. 48 (11) from ~e~el shaft front Remove pIUlon shims ( tie shims tOlllet:her for reuse ouru.,>l

SERVICE MANUAL Form 10664032

8.2. L 11 Install Fig. 52 to remove front idler gear and n ..,,,, "'Ina from bevel gear and cones so original position

58

(Revised August 1911)

Tranlmillian

T-75501 FIG. 51 TRANSMISSION .:FRONT COVER REMOVED

L Drive gear 2. Spacer 3. Second and third speed clutch shaft 4. Bevel pinion shaft 5. Forward/reverse clutch shaft 6. Spacer

7. Counter shaft 8. Spacer 9. Drive gear 10. First speed clutch shaft II. Spacer 12. Drive gear

59

TraosMissioo

\f

T~15502

nG. 52 REMOVING BEVEL PINION SHAFT FRONT BEARING AND IDLER GEAR BEARING

1. Hydraulic ram and pump assembly Z. Three leg puller 3. Sha!t protector 4. Bevel pinion sha!t front bearing 5. Idler gear bearing 6. Idlel: gear 1. Secnnd speed gear

T-75503 FIG. 53 REMOVING SECOND I THIRD SPEED CLUTCH SHAFT

*1. Lifting tool (OTC f AC 1055) Z. Clutch sha!t

* Order from Service Tools Inc.

1901 Indiana Ave., Chicago, Illinois 60616

Tran smission

1'-75505 FIG. 55 REAR OF TRANSMISSION CASE 1. Rear bearing plugs l. Rear bearing retainer

3. Forward/reverse shaft rear oil seal 4. Bevel pinion shaft rear oU seal 5. Capscrew 6. Snap ring 7. Bevel pinion shalt rear bearing race 8. Bearing retainer 9. Ciroon lor bearing retaining ball

1' .. 75504

FIO.54

REMOV~Ci BEVEL P~lON SHAFT

8.2.1. lZ Use lifting tool, Fig. 53, to :remove secondl third speed clutch sWt and first speed clutch sWt; use suitable lifting eyes to remove forward/reverse clutch sWt and counter shaft.

8.l.1.15 Remove bevel pinion shaft rear oU seal.

Fi.g. 55 (4) from housing.

8.l.l BEVEL ~ION SHAFT DISASSEMBLY

NOTE: Transmission case weighs approximately 650 lbs. (295 kg). Use a sufficient hoist and chain to support the weight.

oniy two pieces remain on bevel pinion shaft after sWt has been removed from transmisslon case; the rear bearing and first speed gear spacer. Bearing ud spacer may be removed together by using a press ud suitable bearing puller attachment.

8.l. 1. 13 Attach lifting chain .to transmission case.

Fig_ 54, ud lift case Over bevel pinion shaft.

8.l .. 3 COUNTER SHAFT DISASSEMBLY

8.l.1.14 Remove rear bearing plugs, Fig. 55 (1) ud forward/reverse rear bearing retainer (1); remove rear bearings if they must be replaced. If bevel pinion sWt rear bearing must be replaced remove snap ring (7) and pull bearing race (6) from retainer (8,. if retainer mu.st be replaced remove capscrewII (5) and pull retainer from housing.

SERVICE MANUAL Form 70664032

Remove snap ring from rear end of shaft; use a snit&ble puller to remove rear gear, spacer, and rear bearing race from shaft.

61

(Revised May 1(78)

Traftl.issie.

T-75530 FIG. 56 FORWARDI REVERSE CLUTCH SHAFT 1. Rear bearing race 2. Spacer 3. Rear clutch drum and gear (forward) 4. Piston housing

5. Front clutch drum and gear (reverse) 6. Thrust washer 7, Thrust bearing 8. Snap ring

T-15506 FIG. 51 SECOND ITatRD SPEED CLUTCH SHAFT

1. Thrust washer 2. Snap ring

3. Front dutch drum and gear (ncond speed)

4. Piston honsing S. Rear clutch drum and I"r (third speed) 6. Rear bearinl raee . . .

.

Traosa iss itm

T-75501 FIG. 58 FIRST SPEED CLUTCH SHAFT L Spacer 2. Piston 3. Piston housing

4. Clutch drum and gear 5. Real' bearing inner race 6. Piston retaining snap ring

8.2.4: CLUTCH AND CLUTCH SHAFT

8.2.4.2

DISASSEMBLY

Remove spacer, Fig. 60 (5) and capscrews (6). Press clutch hack plate down by hand and remove split retainer (2); slide clutch assembly from shaft. Remove front clutch from forward/ reverse shaft and second/third speed shaft in a similar maoner.

8.2.4.1 Remove snap ring from rear end of shaft.

Attach puller behind teeth of rear clutch drum gear. Fig. 59, to pull rear hearing ioner race from shaft. Slide parts off rear of shaft to expose clutch assembly.

IMPORTANT: SIN 10Sl7746-up the forward/ reverse shaft has split bi-metallic clutch plates; the plates can fall free as clutch drum is pulled from shaft. The plate halves must be kept mated if they are to be re-used.

SERVICE MANUAL Form 0664032-0

Revised June 1911 63

Transm ission

1..-_ _ _ _ _ _ _ FIG.

1. Hydraulic ram and pump

59 REMOVING REAR BEARING INNER RACE

Z. Rear bearing race

T-7550S

3. Rear clutch drum and gear

8.Z.4.3 Remove piston retaining snap ring, Fig. 58(6).

Remove piston housing from piston by bumping housing end of shaft on a soft block; remove piston and housing from shaft.

remove carrier retaining snap rings. Cut through carrier within 19" (5.82mm) of shaft in two places and drive a wedge in one cut to expand the carrier bore; remove carrier from shaft .

8.2.4.4 Remove carrier O-ring, Fig. 61 (5). shaft sealing rings (1). and carrier sealing rings (2).

.......- - - - - - C A U T I O N - - - - - - " " " I

8.2.4.5 Remove stop pin retaining pins. Fig. 61 (9) from carrier; remove piston stop pins (8), Remove valve actnating pistons (6) and valve plates (3) from carrier.

8.2.4.5 If necessary to remove carrier. Fig. 61 (4)

SERVICE MANUAL Form 0664032·0

Do not !'i-ttempt to press carri.er from shaft. as damage to the shaft will result.

8.2.4.6 Depress clutch hub spring retainer, Fig. 62 (2) and remove snap ring (I); remove retainer, springs, and clutch plates from hub.

IMPORTANT: SIN 10517146 -up the forward! reverse shaft has split bi-metallic clutch plates. The plate halves must be kept mated if they are to he re-used.

Trllsmissiel

FIG. 60 FORWARD/REVERSE SHAFT - FRONT DRUM AND GEAR REMOVED 1. Clutch hack plate 2.. Split retainer

3. Thrust washer and hearing 4. Clutch drum bearings

5, Spacer 6. Capscrew

1..-_ _ _ _--'-_ _ _ _ FIG. 61 CLUTCH SHAFT AND CARRIER _ _ _ _ _ _ _ _ _--J

1. Shaft sealing ring 2. Carrier sealing ring 3. Valve plate

4. Carrier 5. O-ring 6. Valve actuating piston

7. Shaft 8. Piston stop pin I). Piston stop pin retaining pin

•.3 INSPECT lOR

pressure. Specified size of orifice is .052"• 055" (1. 320 .. 1. 397mm) ..

IMPOBTANT: Cleaa all parts. thoroughly before inspectioa. Be certain all parts are within specifications (see TOPlC 11) then dip parts in clean oU before reassemhly..

NOTE: Valves in some early uuits had a .062" (1.516 mm) orifice. These should be replaced hy the valves with smaller orifice.

SHIFT INHIBITING PUMP CHECK V ALVES. valves £01' a broken spring or clogged , Spring should hold orifice plate shut but allow it to be opened with only slight SERVICE MANUAL Form 70664032

CLU'.rCH DRUMS AND GEARS. Inspect bearing area in each clutch drum and gear for roughness or wear. Specified 1. D. of bore is 3.3761"-3.3766 11 (85.752.9-85.1656 mm). If (Revised Aprill9il)

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T-15106 I

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LEGEND FOR FIGS. 65, 66. AND 67

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1. Shaft and carrier assembly Z. Fig. 65 - Shaft with orificed rear plug Fig. 66 • Shaft with orificed rear plug Fig. 67 • Shaft with solid rear plug 3. Snap ring 4. Valve plate 5. Valve actuating piston 6. Piston stop pin retaining pin 7. Piston stop pin 8. Carrier assembly 9. Flapper valve 10. Flapper valve guard U. Flapper valve rivet n. Carrier O-ring 13. Carrier sea ling ring 14. Piston housing 15. Shaft sealing ring 16. Clutch hub retainer 17. Cap$crew 18. Spacer 19. Thrust bearing

ZOo Thrust washer 21. Fig. 65 - Clutch drum and gear - third speed Fig. 66 - Clutch drum and gear - fhst speed Fig. 67 - Clutch drum and gear - forward ZZ. Clutch drum bearings - wide 23. Clutch drum hearings - narrow 24. Spacer (Fig. 65 has no item 24) 25. Shaft sealing ring s 26. Fig. 65 - Clutch drum and gear - second speed Fig. 66 - Spacer Fig. 67 - Clutch drum and gear - reverse 27. Snap ring 28. Actuating piston 29. Piston seal 30. Clutch hub 31. Si-metallic friction plate 32. Steel friction plate 33. Clutch hub spring 34. Spring retainer 35. Snap ring

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T ~ 75084

LEGEND ON PAGE 69 FIG. 66 FIRST SPEED CLUTCH SHAFT

I

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FIG. 67 FORWARD/REVERSE CLUTCH SHAFT

T-75107

TrlRs.issioR IMPORTANT: SIN 10Sl1140-up the forward/ reverse shaft has spHt bi-metallic clutch plates. The plates are marked with a dye before being cut; these marks must be matched when plates are installed, Fig.68, to be certain the plates are properly mated. Do not use mis-mated halves and do not use split plates and one-piece plates in the same clutch.

Stagger the spHt in the plates as shown in Fig.71A. 8.4 .. 1.6 Install springs, Fig. 68 (3) in clutch hub. Place spring retainer, Fig. 62 (2) on top of springs with tangs of retainer in slots in hub and dimples centered in each spring; depress spring retainer and install snap ring (l). Measure gap between spripg retainer tangs and top steel plate. Fig. 62 (3); gap must be .020" .085" (. S08-Z.159mm). If gap is more than .085" (2..159mm), replace a flat steel plate with a dished steel plate to decrease gap.

Each plate replaced win change gap approximately. 013" (0.33 mm).

T-76156 FIG. 68 INSTALLING CLUTCH FRICTION PLATES *4. Bi-metalHc~plates 1. Steel plates 5. Match marks (split 2. Clutch hub plates only) 3. Springs

8.4.1.1 Install clutch assembly from rear of shaft spring retainer end first. Press back plate down by hand and install retainer. Fig. 65 (16) in groove in shaft. Align bolt holes in retainers with holes in clutch hub; draw clutch hub up against retainers by tightening capscrews (11). Turn capscrews so that slots in spacer (18) will go over capscrew heads; install spacer on shaft with flat side against clutch hub retainers. Install thrust bearing (19) against spacer; slide thrust washer (20) and bearings (2.3) (22) on shaft. Install proper clutch drum and gear (21) over bearings and

*Split plates used on forward/ reverse shaft eU. SIN 10S11146-up 8.4.1.5 Lay clutch hub, FIg. 68 (2) with splines facing upward. Starting with a bi-metallic plate (4) against clutch hub. alternately install eight bi-metallic plates and eight steel plates on clutch hub; "dish" side of steel plates may .face either direction.

4 5

l ,

c

--.J[::llm!LJ

.1...-_ _ _ _ _ _ _ FIG. 69 SECOND/THIRD SPEED CLUTCH SHAFT _ _ _ _

1. Clutch and shaft assembly 2. Shaft spacer 3. Bearing spacer 4~ Rear bearing SERVICE MANUALForm 70664032.

5. Snap ring 6. Snap ring 1. Driving gear 8. Bearing spacer

12

9. Front bearing 10. Front nut U {GaSket (Original) • Shims (Service replacement)

12" on collector 13. O-ring (Ser" vice replace .. ment)

(Revised August 1911)

Tralsmillill

fO

9

S

7

5

~ " - - - - - - - - - - - FIG. 70 FIRST SPEED CLUTCH SHAFT _ _ _ _ _ _ _T;;..-_7;.. ;,;5..,;;;O.;;;.8;;;,.3. L 1. Clutch and shaft a,uembly Z. Bearing spacer 3. Rear bearing 4. Snap ring

5. Bearing spacer 6. Driving gear 7. Front bearing 8. Front nut

( Gasket (Original)

9. Shims (Service replacement) 10. Oil collector 11. Plug

lZ. O-ring (Service replacement)

11

7

1...-._ _ SERVICE REPlACEMENT

" - - - - - - - - - - FIG. 71 FORW A..IlD/REVERSE CLUTCH SHAFT _ _ _ _ _...;T;;.......;7;,.;:5.;;;.08:;.;5:::.-...J 1. Clutch and shaft assembly Z. Rear spacer

3. Real' bearing 4. Snap ring S. Real' hearing retainer

SERVICE MANUAL Form 7066403Z

6. Rear oil seal 7. Front spacer S. Front bearing 9. Snap ring 10 (Gasket (Original) '\'Shims (Service replacement)

13

ll. OU collector lZ. OU seal spacer 13. Front oil seal 14. O.. ring (Service replacement)

(Revised August 1(77)

ion

T~76757

7lARECOMMENDED POSITIONS OF SPLIT IN BI-METALLIC CLUTCH PLATES SHAFT 10S17746 -

1..-._ _ _ _ _ _ _ _ _ _ _ _

FIG. n COUNTER SHAFT _ _ _ _ _ _ _ _ _ _T.;..-_7.;..S.;..1.;..O.;..S....J

1. Shaft

6.

2.

7. Front gear

3. Rear gear

S.

4.

5.

10. End washer

9.

to clutch washer and n";~.r'i ... a - and spacers, Ul"iluue driver to install DO not install snap

over bearings and clutch. Install washer bearing (1 and another washer (20); snap ring, in groove in shait.

"" ..,,,,v •• nT !.;U4.rn".sw

8.4.2, COUNTER SHAFT ASSEMBLY

8.4. 1.8 Turn clutch shait end for end and install front clutch on shaft; secure with clutch hub retainer Turn capscrews so slots i.n heads; clutch hub XW1kiu,ut::Jr. 65 (l bearings install proper clutch drum SERVICE MANUAL Form 70664032

72 ) and rear gear counterbore in I. D. of gear

8.4.2.2 Install suitable to do not install snap ring

14

(Revised August

Use

Tra8 •• il.ioR

T-41592 FIG.73 INSTALLING BEVEL PINION SHAFT REAR BEARING AND SPACER 1. Sltaft protector 4. Spacer 2. Bevel pinion shaft 5. Plate 3. Rear bearing NOTE: Remainder of the parts are installed after shaft is in transmission case.

8.4.3 BEVEL PINION SHAFT ASSEMBLY Use a suitable press, Fig. 73 to install rear bearing and spacer. Remainder of the parts are installed after shaft is in transmission case.

8.4.4 INSTALLATION OF COMPONENTS IN TRANSMISSION CASE 8.4.4.1 Use suitable drivers to install rear bearings; be certain bearings are seated firmly in counterbore.. Do not install rear bearing plugs until front bearings have been installed.

8.4 .. 4.2 If bevel pinion shaft rear bearing retainer was removed, install O-ring.

75 (8) around retainer.Lubricate 0 ailyand install bearing retainer in case, make certain bearing retaining bail groove is installed to 9:00 o'clock position, Fig. 55. Torque attaching capscrews to 35 ..... 39 Ibs. ft. (4.84 ... 5.39 m-kg).

1. Guide tool (75294235) 2. Setscrew 3. Bevel pinion shaft 4. Spacer 5. Rear bearing 8.4.4.4 Coat O. D. of bevel pinion shaft rear oil seal, Fig. 55 (4) with sealing compound, install seal in ite bore from front side of case.

Lubricate seal lips.

8.4.4.3 Place steel ball, Fig. 75 (3) in bevel pinion shaft rear bearing race. Align steel ball with slot in rear bearing retainer and install bearing race in retainer, Fig. 55. secure with snap ring (6).

SERVICE MANUAL Form 10664032

T-75511 FIG.74 INSTALLING BEVEL PINION SMAF

15

(Revised April 1981)

Transmissicm

\

T-75104

1..-_ _ _ _ _ _ _ _ _ _ _ FIG. 75 BEVEL PINION SHAFT - - - - - - - - - . . : : . - - - - '

1. Shaft 2. Snap ring 3. Steel ball 4. Rear bearing 5. Spacer 6. O-ring 7. Rear bearing retainer 8. O-ring 9. Rear oil seal 10. Fint speed gear 1 L Third speed gear 12. Sleeve

13. Second speed gear 14. Idling gear 15. Snap ring 16. Idler gear bearing 11. Front bearing U. Pinion depth adjustment shims 19. Snap ring 20. End washer 21. Caps crew 2Z. Lock plate 23. Bearing adjustment shims 24. Front bearing retainer

NOTE: Transmission case weighs approximately 650 Ihs. (Z95 kg). Use a hoist and chain of sufficient capacity.

8.4.4.7 Install guide tool, Fig.75B {5} on end of couutershaft. Install countershaft. Fig. 51 (7), be certain guide tool is seated on block as in Fig. 75B.

S. 4. 4. 5 Stand bevel pinion shaft on rear end on a ZH (50.8mm) block. Install guide tool Fig. 74 (1) over bevel pinion shaft rear bearing retainer; tighten setscrews (2) to hold guide tool in place. Attach hoist to transmission case and lower case over bevel pinion shaft; guide bevel pinion shaft through rear oil seal to prevent damage to seal. Lower case uutil it bottoms on shaft. then raise case sHghtly and block it in position. Position blocks uuder rear bearing plug holes, flush with rear case, to support shafts after are installed.

8.4.4.6 Install fint speed 75 (I 0). third gea'r (1), IZ} on bevel shaft. Install first ei.ther way; install third speed gear long hub toward rear of ease.

SERVICE MANUAl. Form 7066,4032

75A

8.4.4.8 Install guide tool. Fig. 75B {6} over rear of forward/reverse clutch shaft. against bear. ing race; secure with setscrew (7). Use lifting tool, Fig. 53 U) and a one ton capacity hoist to install clutch shaft. Guide shaft through rear bearing; mesh rear gear with couutershaft gear.

8.4.4.9 Install guide tool. Fig. 15B (9) on rear end of first range clutcn shaft and guide tool (10) on rear end of range clutcn shaft.

Use lifting tool to install clutch shafts in housing. Mesh rear gear on clutch shafts with on bevel pinion shaft; be certain guide are seat,ed on block.

(Added August 1977)

Tralsmissill 8.4.5 INSTALLATION AND ADJUSTMENT OF FRONT BEARINGS 8.4.5.1 Heat bevel pinion shaft front bearing cones in oil to 275°F. (135 0 C); install rear cone and spacer on shaft; seat cone against idler gear bearing. Install bearing cup (w/snap ring) in front covel" and install remaining bearing cone on shaft.

A WARNING It is unsafe to strike hardened steel parts with an other than a soft iron or noruer ammer. When installing such parts weal" heavy gloves and safety glasses with side shields to reduce the possibilty of injury.

8.4.5.2 Install end washer and locking plate on bevel pinion shaft. Fig. 48; torque attaching capscrews to 95-105 Ibs. ft. (13.13-14. 51m-kg).

Hit capscrew heads with a soft hammer several times to be certain that shaft components are properly seated; re-torque capscrews to specified torque. Repeat this until capscrew torque does not change when capscrews are hit. Lock capscrews with locking plate.

'1'-80639 FIG. 7SA SERVICE R.EPLACEMENT BEARING (InstaUed)

1. Outer race plate Z. Inner race chamfer (toward front)

3. Inner race radius (toward rear) 4. Outer race

8.4.5.3 Remove block under rear nf bevel pinion shaft and force bevel pinion shaft front bearing snap ring against front cover. Hold bevel pinion shaft front bearing retainer (without shims) firmly against front bearing; measure distance between bearing retainer and transmission front cover. Make shim pack equal to measurement plus. 0011' (.025 mm) to obtain specified bearing end play; remove bearing retai.ner and tie to shim pack for.Jater use.

8.4.4.10 Install second speed gear, Fig. 15 (13)on bevel pinion shaft-long hub toward rear nf case.

8.4.4.11 Install snap Fig. 15 (15) and bearing cups in idler gear (14). Heat idler gear bearing cones in oil to 215 0 F. (135 0 C); install rear cone and spacer on shaft; seat bearing cone against shoulder on shaft. Install idler gear (either end first) and front cone.

8.4.5.4 Raise bevel pinion shaft slightly and remove snap ring. Fig. 75 (19) from Iront bearing.

Install pinion depth adjustment shims, Fig. 75 (18) which were removed at disassembly. or a shim pack approximately ,120 11 (3', 048mm) thick. Install snap ring (19); push shaft down until snap ring is against shims.

NOTE: If bearing is being re-used. cups and cone assemblies must be installed in their original positions. However, if a new bearing is being installed, either cup may <be used with either cone assembly, regardless nf any marking that may be on the bearing.

8.4.4.12 Install bearings. snap rings. driving gears, and spacers on shafts, Fig. 51.

8.4.5.5 Original Bearing (Ball)

8.4.5.5.1 8.4.4.13 Install front cover (with new gasket) on transmission case. Secure front covel" with attaching capscrews; install hose supporting clips under proper capscrews.

SERVICE MANUAL Form 70664032

Support rear end of forward/reverse clutch shaft with a hydraulic jack. This will prevent rear bearing damage during front bearing instaUation. Install bearing over shaft; use bearing drivers shown in Fig. 75B to drive bearing into place. Make certain bearing is seated on shaft and in counterbore of front cover. Install remaining bearings with. the 7SB

Transmission

2 _ __

"'--- SECOND/THIRD RANGE--....

CLUTCH SHAFT

fiRST RANGE CU.lTCH SHAFT

-.1

__ - 1 . . - - - '

r--_ _ 6

7

8

T-80640 .......- - - - - FIG. 75B INSTALLING SERVICE REPLACEMENT BEARINGS _ _ _ _ _ _--' SERVICE MANUAL Form 7066403Z 15C (Added August 1911)

LEGEND FOR FlG. 75B 1.

*2.

3* Front "'.,," .. "ncr 4. Transmission table *5. Guide and Guide tool 7. Setscrew

tool

8. *9. *1\).

tool tool

>l:See SERVICE TOOLS same drivel".

NOTE: frist second/third range shaft will tools installed on rear end of 8.4.4.7 and 8.4.4.9.

T-80652 FlG.75C DETERMINING THICKNESS OF SHIM PACK 1. Oil collector 2. Measure gap 3. Front cover

4. Seat collector

8.4.5.£> SERVICE REPLACEMENT BEARING 8.4.5.5.3 mstall end washer and on end of 48; torque capscrews to OZ.4 ... B.8 Lock

8.4.5.

1 Support rear end of TDT"'''',"tr shaft with a over ,-,u,,,,,.,,,,,,,,,,. """""'.Tn front of must also be 7S-A

8.4.5.5.4 mstall shaft "'.,,""" .....'" lock ends of clean be grooves.

IMPORTANT: New assembled and w"".."",,,,,,,,,,,,u installed. Outer race over rollers so outer race chamfer side of the inner race. be installed as a \,;VIUIWJ,t:t,., assernlDJ,V

8.4.5.5. :; mstall oil seal, reverse shaft oil side in. mstall oil seal spacer on shaft; bottom it shoulder on shaft.

NOTE: Support rear end of shaft while in· spacer.

bearing down with a soft hammer until outer race plate is started into cover bore. Use bearing driver.

75-B to drive the reUliil.unnl);l\ certain is seated on shaft and in counterbore of covel". Install the remain.. bearings in the same manner ..

8.4.5.5.6 mstall oil collectors new clutch shafts and in proper Fig. 47. Use care to to sealing and H",."",,, ... ,,,,, shaft front oil seal. mstaU countershaft front retainer and gasket. attaching capscrews to go ... 1001bs.

44 •• 13.83 m .. kg).

SERVICE MANUAL Form 70664:032

driver must be used to inner and outer raCes first range

75D

Traumission shaft and second/third range shaft will be supported by the guide tools installed on rear end of shafts in 8.4" 4" 7 and 8.4.4.9.

8.4.5.6.2 Lock transmission gears by.installing a cold roll barf Fig. 49 througb hole in front cover and bevel pinion shaft idler gear. Lubricate threads of front bearing retaining nuts and threads on shaft with graphite base grease; start nuts on their respective shafts. Use socket, Fig_ 49 with torque wrench and sui.table extensions; torque front: bearing retaining nuts to 500 ... 550 Ibs. ft. (69.12 ....

76.04m .. kg). Install snap ring, Fig. 48 (3) on forward/reverse shaft.

8.4.5.6.3 Install end washer on end of countershaftt Fig. 49; torque capscrews to 90 .... 1001bs. ft. (ll.4 .... 13.8 m-kg). Lock capscrews with lock wire.

8.4.5.6,,4 Install aU collectors and countershaft bearing retainer without O-rings or shims. Install three capscrews evenly spaced around collectors and retainer; tigbten capscrews evenly to 10 Ibs. ft. 0.38 m-kg).

Measure distance between collectors and retainer, Fig. 75<: and transmission front cover. in at least three equally spaced locations around collectors and retainer.

Make a sbim pack equal to the average measurement MINUS .. 001 II .. - .004" (0.025 .... o. 10 mm) to obtain the proper clamp on bearing. Repeat this procedure for all collectors and tbe countershaft front bearing retainer.

8.4.5.6.5 Install shaft sealing rings, Fig. 48 (2) interlock ends of rings. Coat sealing rings witb clean aU; be certain they turn freely in grooves.

8.4.5.6.6 Install oU seal. Fig. 71 (13) in forward! reverse sbaft aU collector .. - spring side in.

Install oU seal spacer on forward/ reverse shaft; bottom it against shoulder on shaft.

NOTE: Support rear end of sbaft wilUe installing spacer..

T-75512 FIG. 76 SHIFT INHIBITING PUMP CHECK VALVE RET AlNER 1. Retainer

3. Check valve

s. 4.5.7 Install drive sbaft rear yoke on forward/ reverse clutch shaft; install retaining washer and capscrew. Use suitable holding tool on rear of shaft and torque capscrews to 250 .. 300 Ibs. ft.. (34.55 .- 41.47 m-kg).

IMPORTANT: Use nylok capscrew or apply sealer to threads before installing capscrew.

8 .. 4.5.8 Install retaining ring and 0- r bore in check valve retainer, 76: install check valves (3) and O-rings (2). Install cheek valve retainer on bevel pinion shaft front bearing retainer. tigbten capscrews enongb to bold cbeck valves in place.

8.4.5.6.7 Install new O-rings in grooves around collectors and countershaft bearing retainer.

Install collectors (with correct sbim pack determined in 8.4.5.6.4) over clntcb shafts NOTE: Some units may not have a retaining and in propel' position on front cover, Fig. ring for the inner O-ring; install new retain..

47. Use care to prevent damage to shaft sealing rings in these units. ing s and forward/ reverse shaft front oU seal.. countershaft front bearing retainsr .. Torque all attacbing capscrewl'il to 90 -- 100 Ibs. ft.. (lZ.44 -- 13.83 m-kg).

SERVICE MANUAL 76 (Revised August 1977) Form 7064403Z

Transmission and check bearing end play by positioning a dial indicator throngh power take-off access hole (if unit has rear mounted equipment, work. through bevel pinion bore), Pry bevel gear m both directions (not too hard), if any end play is shown on dial indicator, refer to BEVEL GEAR AND SHAFT and adjust bevel gear shaft bearings preload.

8.4.5.9 .

Install bevel pinion shaft front bea.ring retamer (with shim pack determined in 8.4.5. 3} on front cover. Tighten capscrews attachmg check valve retainer to bearing retainer.

8.4.5.10 ., Clean suction oil screen and retnstall tn transmission case; (replace if necessary). Ins.tal~ bottom cover (with new gasket) on tranSmU>lHOn case.

NOTE: Transmission weighs approximately 2500 Ibs. (1134 kg). Use a holst and chain of sufficient capacity.

8.4.5.11 " Remove guide tools from rear of shafts, Install snap rings on rear end of countershaft and clutch shafts. Install O-rings around rear bearing plugs, Fig. 55 (1); lubricate O:-rings liberally and install plugs in bores agamst rear bearings.

8.5.2 Install two guide studs in main housing; place new transmission mounting gasket over guide studs. Attach hoist to transmi.ssion and install transmission on guide studs; secure transmission to main housing with proper attaching capscrews; remove hoist,

8.4.5. 12 Install oil seal, Fig. 71 (o) in rear bearing retainer (5) - spring side in. Install bearing retainer in rear bearing bore. Fig. 55.

NOTE: A tapped hole in the left rear corner of transmission case and a cast eye-hole in front cover are the lifting points. Do not attempt to support the entire transmission from eye-hole in front cover.

8.4.5.13 Install speed control valve and shift inhibiting valve (with new gaskets) on top of transmission; tighten caps crews evenly. Install shift inhibiting pump (with new gasket), Fig. 47.

8,5.3 Check backlash between bevel gear and bevel pinion; also be certain tooth contact pattern is correct. Following procedure is to be used only when bevel gear is in good condition and was not removed; if bevel gear was removed, refer to BEVEL GEAR AND SHAFT for complete procedure.

8.4.5.14 Connect all oil lines, Fig. 47, except the three lines to speed control valve; leave these dis~ connected to provide clearance for lifting chain.

IMPORTANT: Lube 011 line connectors in the bottom two 011 collectors are restricted so the other shafts wlll receive sufficient lubrication; connectors must be installed in proper location, Fig. 47, or transmission will be damaged. "

a. Position dial indicator as shown in Fig. 78.

Block bevel pinion solid. Insert a small pry bar and rotate bevel gear back and forth; total gear movement, as indicated by reading on dial indicator, is backlash. Check backlash at several points around bevel gear; block bevel pinion solid each time.

8.4.5.15 Cover all openings in oil lines, fittings, or transmission case to prevent entrance of dirt.

IMPORTANT: Several attempts may be necessary to hecome accustomed to the IIfeel" in order to obtain correct backlash readings, Do not hurry this step!

8.5 INSTAllATION (Witll bvel lear aad pinien adjustment cl1ech) check bevel for end As it is raC~l'<;';d>J. to bearing pre -load as described in BEVEL GEAR AND SHAFT .. r .... '· ..... clutches refer to 77

SERVICE MANUAL Form. 7066403Z

17

(Revised August 1977)

backlash is ,012" - . 018" . If backlash is

b.

remove shims

Ii

backlash cannot be obtained in this manner, refer to BEVEL GE.AR AND SHAFT for

c. Check bevel gear-to-bevel contact T-70854 FlG. 77 CHECKING FOR BEVEL GEAR END PLAY

1, Bevel 2. Power

-off access hole 3. Dial indicator 4. Small pry bar

8.5.4 Install oU fiUer tube and breather transmission new

d. Re%check bacldash! If backlash is not within refer to BEVEL GEAR AND

SERVICE MANUAL Form 10664032

18

on

Transmission val.ve, and control valve; toroue converter vent Hne to transtube. Attach

8.5. Hl install seat frame and front Connect oil Hnes to valve; connect dozer control

8.5.11 Make certain transmission drain stalled and • Fill with filter to SYSTEM LUBRICANT SPECIFICATIONS CAPACITY AND SERVICE).

T -70855 FIG. 78 CHECKING BACKLASH BETWEEN BEVEL GEAR AND BEVEL PINION 1. Bevel gear 2. Power take-off access hole 3. Bevel 4. Small 5. Dial

8.5.12 Start minutes to and correct any gauges for normal 1."<::'''-'''''')<,11> are not indicated within a and determine cause.

8.5,5 suction line to lower Connect oil line on front of trans8.5.6 InstaU drive shalt universal bracket, and brake "U'~'5~

oil

"'Y"''''''n",''' on oil within rod); oil level must range marks on gauge rod.

brake 46,

sure checks and all parts are in this

8.5.7 bellcrank bracket connect to """""'5'" if ne ce s sary,

8.5.14 Install floor

and transmission bottom

8.5.8 Connect oil Hnes to

control

shift

TOPIC 9 BEVEL GEAR AN 9.1 REMOVAL ANO INSPECTtON

move nuts bevel gear shaft,

9. L 1 Before bevel gear and sbaft can be is necessary to remove clutches, , and clutch throwout assemblies. Refer to Clutches and Brakes Service Manual, Form for detailed information.

9. L:3

9.1.2 R.emove bevel gear

SHA

cover; re-

19

bevel gear to

on

Bevel Geaf Aad Shaft

T-7057Z ' - - - - - - - - - - - - FIG. 19 BEVEL GEAR AND SHAFT --------~---I 1. CapscreW' Z. Bearing adjWltment shims 3. Bearing cone 4. Lncking ring

5. Bevel gear 6. Shaft 7. Bearing cup 8. Bearing cage

9. Stop nut 10. Capscrew

NOTE: Left bearing cone will be pressed from bevel gear shaft as shaft is pulled from bevel gear.

9.1.4 Auemble split sleeve. Fig. SO (Z) a:round bevel gear shaft with one end against bevel gear and the other end against wall of bevel gear compartment.

9.1.6

Remove puller tools. remove bevel gear shaft (with right cone) through right steerh compartment; remove bevel g:ear. ring cone. capscrew locking ring. and wooden block from bevel gear compartment.

9.1. S Turn puller screw' all the way into tapped hole in right end of bevel gear shaft. Install puller tube. tube end plate. thrust washer, and hex-nut over puller screw; tighten hex-nut over puller screw; tighten hex ..nut to bevel gear shaft from bevel gear.

9.1.7

Remove right bearing cone from bevel gear

&0

Bevel Gear And Shaft shaft. remove bearing cups Fig. 79 (1) from bearing cage assemblies.

bevel gear is properly located 00 shaft.

9.1. 8 Clean and inspect all parts for damage or excessive wear. replace parts where necessary.

:;

~

?

9.2.3 Lubricate other bearing cone, Fig. 81 (3) and start it on short end of bevel gear shaft with large O.D. of -bearing toward bevel gear.

Install forcing screw, Fig. 82, in tapped hole in end of shaft and place tube against iuner race of bearing cone. Install tube end plate, thrust washer, and hex-nut; tighten hex-nut until bearing cone is tight against shoulder on shaft; remove tools.

NOTE: Installation of bearing cones on bevel gear shaft will be much easier if bearing cones are heated in oil to approximately 27S o F. (13S o C) before installation •

~,

0 .~

;:

9.2.4 Press bearing cups. Fig. 81 (7) into beating cages (8); be certain cups are seated firmly in cages. Lubricate bearings with clean oil and install each bearing cage (with original bearing adjustment shims) in bore from which it was removed. Make certain locating pins l I Fig. 81 (11) are in vertical position; start bearing cage attaching caps crews (1) but do not tighten.

0

~

l

T-41600 FIG. 80 PULLING BEVEL GEAR SHAFT

j

9.2.5 Torque nuts, Fig. 81 (3), on bevel gear attaching capscrews to 290 to 315 Ibs. ft.

(40.09-42.92 kg-m).

1. Bevel gear

*2. ~1it sleeve (OTC f AC - 692 3. Wrench 4. Brake drum hub *5. Forcing screw (OTCIAC - 972) *6. He" nut (OTC f AC - 938 P - 3) *7. Thrust washer (OTC lAC - 938 P - 4) *8. Tube end plate (OTC f AC - (74) *9. Tube (OTC' AC - 973)

9.2.6 Tighten bearing cage attaching capscrews; bump cages to be certain bearings are properly seated, retighten cage attaching caps crews if necessary.

* Order from Service Tools loc.

1901 Indiana Avenue Chicago, Illinois 60616

1.3 ADJUSTM ENTS

1.2 INSTAllATION

IMPORTANT: Adjust bearing pre-load before installing transmission.

9.3.1 BEARING PRE-LOAD

9.2.1 Press bearing cooe, Fig. 81 (3) on long end of shaft with large O. D. of bearing tight against shoulder 00 shaft. Place bevel gear 00 suitable work bench {with teeth of gear downward), Positioo caps crew lOCking ring (4) on bevel gear anq install capscrews (10) in bevel gear; turn caps crew heads as necessary to clear locking ring as capscrews are installed.

9.3. L 1 Install caps crew in end of bevel gear shaft and tighten until it bottoms.

9.3. L 2 Turp bevel gear shaft with torque wrench.

Fig. 83. t<:> determine pre-load; specified preload is 20-40 Ibs. in. ('23.04 - 46.08 kgem).

9.2.2 Remove locking ring and position bevel gear in bevel gear compartment with teeth of gear facing right steering clutch compartment.

Install bevel gear shaft through right steering clutch compartment and align capscrews in bevel gear with boles in bolting flange of shaft. Bump or drive bevel gear sbaf.t into bevel gear until elastic stop nuts can be started on capscrews. Install locking ring.

Fig. Sl (4) and tighten nuts evenly until

NOTE: This is approximately. 002" - .004/1 (. OSO - • 101 mm} tight.

9.3.1.3

Add or remove bearing adjustment shims (equally) under bearing cages to obtain specified preload. When adjusting. bump bearing cages to be certain bearings are properly seated.

81

ft

1..-_ _ _ _ _ _ _ _ _ _ _

FIG. 81 BEVEL GEAR AND SHAFT _ _ _ _ _ _ _ _ _ T_-_4_14_9_4..J

L

5. Bevel gear 6. Bevel gear shaft 7. Bea cup 8, cage

2.

3.

4.

9.3.2

AND GEAR TOOTH CONTACT PATTERN

9.3.2.1 Install transmissinn (refer to

9.

10.

U.

1/2 of the tooth toward heel. and be centered between and bottom of tooth, . 84. Area of contact when gears H.'~'.ne,n should increase in as shown in 85.

9,3.2.2 Check backlash between bevel Mount dial indicator, can be taken from backlash at four block

so . Check

9.3.2,3 backlash is .012" - . 018" . 304backlash shims from under one cage to the othe.r; is moved, but

NOTE: Each. 005" win (.07imm . shown in

transmission case and snap shaft front This iNCREASE backlash ,.,,,,j-,,,,,,, .. , , and bevel lash is .012" - . 018" • DECREASE backlash TOWARD bevel liU.HU"" " .. tw .. ",.n

or tooth conuu:;:z on bevel gear teeth. must favor toe of gear

. 87 win re-

Bevel Gea r Ali Sha't NOTE: Several adjustmeots of both the bevel pinion and bevel gear may be necessary before the correct tooth contact pattern and correct backlash are obtained.

T~13056

FIG. 82 INSTALLING BEVEL GEAR SHAFT BEARING CONE

'1'-25132 FIG. 83 CHECKING PRE-LOAD OF BEVEL GEAR SHAFT BEARINGS

*1. Tube (OTC I AC .. (75) 2. Bearing cone *3. Tube cap (OTC lAC .. (76) *4. Thrust washer (OTC I AC .. 938 P .. 4) *5. Nut (OTC lAC - 938 P - 3) *6. Forcing screw (OTCIAC - 972) 7. Wrench

1. Torque wrench 2. Adapter 3. Socket

4. Bevel gear shaft 5. Bearing cage'

* Order fram Service Tools, Inc.

1901 Indiana Ave., Chicago, Illinois 60616

pinion by transferring bevel gear shaft bearin'g adjustment shims fram bearing cage on flat side of gear to bearing cage on tooth side of gear.

9.3.2.7 SHORT TOE CONTACT as shown in Fig. 88 will result in chipped tooth edges and excessive wear due to small contact area. To ·correct short toe contact move bevel pinion AWAY fram bevel gear by adding pinion depth adJustshims between tranemission case and snap ring on bevel pinion shaft front bearing.

This adjustment will INCREASE backlash between bevel pinion and bevel gear. Specified backlash is • eHZ" - • OU n (.304 ... 457 mm).

DECREASE backlash by moving bevel gear TOWARD bevel pinion. Move gear toward pinion by traneferring bevel gear shaft bearing adjustment shims from bearing cage on flat side of bevel gear to bearing cage on tooth side of bevel gear.

13

'1'-31450 FIG. 84 SATISFACTORY TOOTH CONTACT NO LOAD

Bevel fiear And Shaft

--A

_ACT

8

T-3l449 FIG. 85 SATISFACTORY TOOTH CONTACT GEARS LOADED

T-26963 FIG. 87 LOW CONTACT - NO LOAD

A

--B

T-71900 FIG. 86 HIGH CONTACT .. NO LOAD

9.4 FINAL INSTALLATION 9.4.1 Clean interior of bevel g_l" cO'Irnpal"itm'ent steler'lna clutch compartments. UUJ""""LI, gur compartment cover.

T-7

9.4.2 Install steering cluteh throwout buriag assembUes. steering clutches, and steering brakes, fill hydraulic system with specified lubricant.

Refer to Steering Clutches and Brakes Service Manual. Form 645549 for detailed information.

88 SHORT TOE CONTACT - NO LOAD

TOPIC 10 ,1

RIVE S

ERS L J

REMOVAL, OISASSEMBl Y,

ANO

remove floor

ION

10. L 1 Turn electrical

unlock and remove caps crews to front and rear

master switch

I

~ _ _am T-14951

1-._ _ _ _ _ _ _ _ _ _

FIG. 89 DRIVE SHAFT UNIVERSAL J O I N T - - - - - - - - - - - - '

Universal

9.

Capscrew

10.

1L 12.

n . J...tO'<';AU'It

14. Washer 15. Capscrew Locking wire

to to yokes)

VI Sliaft UniVlfSl1 froo,t yoke forward and remove Remove front from torque converter output shaft.

secure with attaching capscrews (4). capscrews with wire.

10.1 • .3 Refer to Fig. 89. unlock and remove capscrews (4); remove front and real' spider assemblies (6) from coo,necting plate (3).

NOTE: Install spider assemblies on connecting plate with lubricating fiI::tings in line. This will allow both fittings to be lubricated without turning drive shaft.

10.2.2 Slide front yoke all the way forward on torque converter output shaft. If rear was retorque .attaching Fig. 89 to 250.300 lbs. ft. (34. .47 kg-m).

10.1.4

assemblies from .. ,.."n ..,r identify bearing so they may be installed in original position if re-used.

IMPORTANT: Use nylok capscrew 01' apply sealer to threads before installing caps crew.

10. 1. 5 Wash all components in dean solvent. Inspect for excessive wear or damage.

10.2.3 Place universal jOint assembly on real' yoke (with lubrication fittings aligned: with lubrication fitting in front yoke) and install attaching capscrews, lock caps crews with wire.

10.2 ASSEMBLY AND INSTALLATION NOTE: If bearings or bearing journals on spiders show damage 01' excessive wear, it will be necessary to replace spider and bearings as a complete assembly.

10.2.4 universal joint with front yoke, move rearward and install attaching capscrews. Lock capscl'ews with wire.

10.2.1 Install new dust shields, Fig. 89 (7) and sealing washere (8) in each bearing cup; lubricate bearings with light coat o£ grease and install bearing cups on spider journals from which they were removed. Be certain bearings are fully nated on spider journals. Install front and rear spider assemblies (6) on connecting

10.2.5 Lubricate univel"$al joint.

10.2.6 Install floor plates; turn electrical system master switch on.

86

TOPIC 11

FITS AND TOLERANCES

11.1 SHIFT IN HIS fliNG VALVE 11. L 1 FOLLOWER PISTON SPRINGS .24 mm}

- - - - - - - -

- - - - - - - - - 3.78" 2. 8S - 3. 15 lbs. (L

.01 -1.42

11. L 2 DIRECTION CONTROL PISTON SPRINGS free - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.46" 88mm) when to2.165" (54.991 - - - - - - - - - - 3.20-3.S01bs. (1. .1.58 Load when compressed to .965" (24. 511 mm)- - - - - - - - - - - - 6,10-6.75 lbs. (2.76-3.05 1 L L 3 REGULATING PISTON SPRING Approximate free length - - - - - - - - - - - - - - - - - - - - - - - - - - - --6.07'" 154.17 mm} Load when compressed to 3.78" {96. 01 mm} - - - - - - - - - - - - - - 55-60 Ibs. ( 9 -27.2.

1 L L 4 FLOW SENSING PISTON OUTER sPRING Approximate free length - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. 58" (90.93 mm} Load when compressed to 2." (50.8 rom} - - - - - - - - - - -- - - - 9. 5-10. 5 Ibs. (4.30-4.75 11. 1.5 fLOW SENSING PISTON INNER SPRING Approximate free length - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. 48" (62.99 mm) Load when compressed to L 36" (34.54 mm) - - - - - - - - - - - 6,60-7.30 Ibs. (2. 98-3.30 kg) 1 L L 6 F LOW SENSING PISTON CHEC K VALVE Size of. orifice - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

.060 11 { 1. 524

11.2 SPEED CONTROL VALVE 11.2.1 DETENT SPRINGS Approxi.mate free length - - - - - - - - - - - - - Load when compressed to .560" (14. 22 mm)

,706" (17.93 mm) 6 Ibs. 72 kg)

11.3 PRESSURE REGULATING VALVE 1 r. 3.1 MAIN RELIEF VALVE INNER SPRING Approximate free - - - - - - - - - - -- - - - - - - - - - - - - - 2,97" 75.43 mm Load when to 2.55" (64.77 mm) - - - - - - - - - - - 1I:l. 5-2.0. 5 Ibs. {S. .28 1 t. 3. 2 MAIN RELIEF VALVE OUTER SPRING Approximate free - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.95" (14. 93 mm) Load when to 2.55" (64.77 mm)- - - - - - - - - - - - - - 27.30 Ibs. (12. 24-13,60 11. 3. 3 COLD OIL RE LI EF VALVE INNER SPR ING Approximate free length - - - - - - - - - - - - - - - - - - - - - - - - - -- - 4. 06" (103. 12 mm) Load when compressed to 3.26" (82.80 mm)- - - - - - - - - - - - - 57-631hs. .85-28.57 1 L 3. 4 COLD OIL REUEF VALVE OUT ER SPRING Approximate free length - - - - - - - - - - - - - - - - - - - - - - -- ~ - - .. - 3.17" (80.51. mm) Load when compressed to 2.33" (59. 18 mm) - - .. - .. - - -- - - 82.7-91. 3 Ihs. (37.46-41. 35 kg)

11.4 MODULATING CLUTCH CONTRDt VA l VE 1 L 4. 1 INNER SPRING .

Approximate free length - - - - - - .. - .... - .. - .. .. .. - - .......... - - .. - - 2. 26 II (51. 40 mm) Load when compressed to 1.26" (32.0 mm) - .. - - .. - - - - - .. 22.8-25.2 Ibs. (lO,32-1L41 kg) 11. 4. Z OUTER SPRING .. - - - .......... - - ........ - ........ - ............ " 2.38" toO. 45 mm) Approximate free Load when compress to 1.38" (35.05 mm) .. - .... - - - ........ - 57-63 lbs. (25.S5-28.57 kg) 11.4.3 SIZE OF ORIFICE - .. - ...... - .. - ..

87

Fits And Tolerances 11.5 TOROUE CONVEITER PRESSURE REGULATING VALVE U. 5.1 REGULATING SPRING Approximatefreelen,th ~ ~ ~ ~ ~ ~ ~ :3.94" (100.01mm) Load when compressed to 2.33" (59. 18 mm)- - - - - - - ~ - - 42.75-41.25 I'Os. (19.46-21.40 $

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

n.6 DECELERATING BRAKE SENSING VALVE 1 L 6.1 REGULATING SPRING Approximate free length - - - - - - - - ~ - - ~ - - ~ - ~ - - - - - - - ~ - - - 5.95" {1 5 L 13 mm j Load when comprused to 4.28" (108.11 mm) - - - - - - - - - - - - 90-110 I'Os. (40. 8Z~49. 89

11.1 SHIFT INHIBITING PUMP 11. 7.1 Replace if I.D. of ,ear. housing is more than - - - - - - - - - - - - - 1.110" (29.118 mm)

11.1.2 Bench test specifica.tions: Oil: SAE lOW Oil Temperature: 175 0 - 185°F. {79° - 85 0 q Tut Pressure: 200 psi ( 14.06, kg - cm 2 ) Pump Output: .54 gpm (2.04 Its/min)@ 500 rpm 4.3 gpm (16.251ts/min)@2740 rpm 1 L 7.:3 Size of check valve(s) orifice- - - - - - - - - - - - - - -

.052"-.055" (L 320-1. 397 mm)

11.8 TRANSMISSION PUMP (Prior to SIN 10511629 except 10S17519 thru 10S17578) ll. 8.1 Replaee gear housing(s) if L D. is more than - - - - - - - - - - - - - -2.108" (5. 354 mm)

1 L 8. 2 Replace back plate, front plate, and/or center housing if LD. of bushing is more than - - - - - - - - - - - - - - - - - - - - -

.811" (2.227 mm)

11. 8. 3 Bench test specifications; Oil: SAE lOW on Temperature: 1200 - 130o F. (480 - 54°C) Test speed: 2050 rpm Front (pressure) pump output: 30 gpm @ 300 psi (113.56 It/min @ 21. 09 kg-cm2l Real" (scavenging)pumpoutput:2L5 gpm@60psi (81.381t/min@ 4.21 kg-cm Z)

11.9 MODULATING CLUTCH 11. 9. 1 FRICTION PLATES (STEEL) Replace if thicknen is less than - - - - - - - - - - - - - - - - - - - - - - - - - .095" (2.41 mm) 11.9.2 FRICTION PLATES (BI-METALLIC) Replace if thickness is less than - - - - - - - - - - - - - - - - - - - - - - - - - .130" (3.302 mm) Replace if thickness varies more than - - - - - - - - - - - - - - - - - - - - - - .002" (.050 mm) 1 L 9.3 ACCESSORY DRIVE GEAR ReplaceifLD. of hushing is more than - - - - - - - - - - - - - - - - - - - 4.010 ff (101.8S0mm)

11.9.4 OVER-SPEED VALVE SPRING Approximate free length - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1.09" (27.08 mm) Load when compressed to .81" (22.09 mm) - - - - - - - - - - - - - - 1.0-1.11bs. (.45-.49 kg)

11.9.5 CENTRIFUGAL SENSING VALVE SPRING Appr'oxi,mlate free - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. OS" when to .81'* 09 mm) - - - - - - .. - - .. - - .. 6.9-1.6 lba. (3.

67mm .44

11.9.6 OVER -SPEED REGULATING VALVE SPR!NG An,nroxiim,ate free .. - - - - .. - .... - - - .. - .......... - .. - .. - .... - .... 1. 10" to.63 11 (l6.0mm;- - ................ - - - 0.50-1.251b$.

94mm) .26 kg}

88

Revised December 1910

F

And

11.10 TRANSI\USSION 1 FRICTION PLATES i.I tnickness is less than .. - - - - - .. - - - - .... - .... - .. - ............ - - .. .... • UH" if "disn" is less than. !H2" {. or more than. 022" {. "''''''IT",n

565

Ii. 10.2 FRICTION PLATES if tn ickne ss i. s !. e s s than ...................... .... - -- .. - - .. .. .. .. .. .. .. .. .. -- • 13 0" {.3 • .3 () 2 if tnickness varies more tnan .... - - ............ - ...... -.......... .. ...... .... .002" (.050 U. lO.:3 SHIFT INHIBITING PUMP CHECK VALVES Size oi orifice ...................................- .... - .... - ..................... 05Z"-. 055" (1.320.-1.397

11.10.4 CLUTCH HUB SPRINGS g;V;""'"''''.''' free .......................... - .................. - .......... - - ........ - 1.61" • 41 to 1.34" (:34.()3 - - - - - - - - - - - - - - - - - - 12-13 lhs. (5.4-5.

11.10.5 BEVEL PINION

GEAR BACKLASH .. - - .. - ...... - .... 012"-.018" (.304-.457

11.10.6 FRONT COVER 11. 10. 6. 1 Bore diameter Bevel shaft ~---------- .. - .. -- .. --------3763"-6.3773" {161.96-161.98 shail; .......... - - ...... - -.- ............ - .. 5.511.3"-5.5123" (139.99-140.01

1i. 10. 6. Z Bo re depth - measured at 4 locations - - - - - - - - - - - - - - - - - - - - - - .. 2.265"-Z.Z75" 53-57.78 MAX. Variation ... 003" (.076

D.1O.7 CASE 11. 10.7.1 Bore diameter First s'haxt .... _ .... _ .. - - -- ........ _..... - .. - - ...... _ .. 5.5113"-5.512.5" (139.99-140. OZ sna;it - .... ---------_ .. ------- 4.7244" .. 4.7253" (119.99-120.02 snaft----------- 4. 92.06"-4.9Z18" (124.98-125.01

11. 10.8 SHAFTS 11. 10.8. 1 Bevel shait Diameter at rear - ...... - _ .. - ............ - - - - - .. - - 4. 1350 l l w4. 1359" (l05. 03-105.05 Diameter at iront inner - - - - .. - .. - - - .. - - .... - ........ 3. 509" .. 3. 510" 13 .. 8 9. 15 Diameter at front outer - - - - - - - - - - - - - - - - - 3.5015"-3.50Z5" 94 ..

11.10.8.2 Countershaft Diameter at rear Diameter at front

- _ .... - - ............ - - ........ -_ .. - - -2.7567"-2.7574" .... - ........ - - ...................... - .. 2. 559Z"-Z. 5597'"

02-70,04 00-65.0Z

11. 10. 8. 3

shaft - ............ - - - ............... - .. - ...... 2. 7567"-2. 7574" 70. OZ-70. 04 Diameter at: front .. - .. - .......... -- - - - .. _ ........ - .... 2. 559Z"-2. 5597" 00-65.0Z Diameter at gear od drum s - ........ - .............. - .... 2.9994"-3.000" (76. HI-76. 20 Diameter at carrier .......... - ............ - ........ - ...... -3.

370 0 en-85.59 mm) 11.10.8.4 roge snaft Diameter at rear .......... _ .. _........... - ...... - .......... 2. 5598"-Z. 5605" Diameter at iront ...... _ .... - .. - _ .......... -- .. - - .. -- Z. 5592"-2.5597" Diameter at gear and drum ...... _ .. - .. -- -- .... - ...... 2.9994"-3.000" Diameter at carrier .. _ .. - ...... _ ........ ~ .... - ...... - .. -3. 369 H -3. 370" 11.10,8.5 First range Diameter al: .rear .. _ ...... - .. - .. - .......................... Z. 5598"-2.5605" Diameter at front .............. - .. -- .... -- - - ............ 2.559Z"-2.5597" Diameter at gear and d.rum - .. - - - - ...... - .. - .. .... Z. 9994"- 3.000" Diameter at carrier .... - - _ ...... - .................... - .. -3.369"-3.370"

SERVICE MANUAL Form 70664032

OZ-65.04 00-65.02 18-76.20 57-85.59

Novemher 1

ALPHABETICAL INDEX PARAGRAPH

SUBJECT ADJUSTMENTS Bevel gear shaft bearings pre-load Bevel pinion/bevel gear backlash Brake control linkage Speed control linkage

9.3,1

9.3.2 6.6.3 6.Z.4

BEVEL GEAR AND SHAFT Adjustments ••• Repair •• DRIVE SHAFT UNIVERSAL JOINT Repa.ir ., * ., • ~ .. • .. ft

10.1,10.2

...

FLOW CHECKS Modula.ting clutch.

Specifications . • • Torque converter.

Transmission lube Transmission. pump ••

5.4

5.1 5.5

5.6

5.2,5.3

HYDRAULIC SYSTEM Capacity . '" . .. '* .. .. ., * Description and oil flow schematics.

Flow checking_ • • • • • Flow specifications ••••• Lubricant specifications • • • • • Pressue checldng • • • • Pressnre specifications Repair . • • • • • Trouble shooting ••• «<

•

..

II

•

..

..

•

2.2

•

1.2 thru 1.5 5.2 thru 5.7

5.1 2.1 • 4.:3 thru 4. '1 4.2 • 6, I thru 6.9 3.0

MODULA TING CLUTCH Assembly ••• Bench test Description. • DiAssembly Fits and tolerances.

Installation. • Removal

7.8 7.9 1.1 1.2 11.9 1.10 7.1

...

PRESSURE CHECKS Main . . • . . ., . '" . ,. '" • .. • . ., .

Modula.ting clutch apply (in tractor), Modula.ting clutch apply (bench test) Over regulator (bench test) • • Shift g pump • Specifications. • • Stepp.e<1 ., .. ,. *' .. • • ..

.. .. • ..

...

...

It'

•

•

,.,

...

•

Torque converter • • • • • • • • • • • • • Transmission. clutch apply.

Transmission. lube

•

,

•

>iii

...

,.

4.6

..

4.5 4.5

PUMPS Shift Inhibiting Bench test ·specifications.

Description. • Repair ""

•

•

..

11.7 1.2.2

6.7

4'

Transmission Bench test specification.s, Description. • Repair ,

.

4.3 4.4 7.9 7.9 4.7 4.2 4.3

.. .

.. .

...

. . .. .

...

..

B.8 • • • • • 1.2. 1

6.8

Alphabetical Index SUBJECT

PARAGRAPH 2.1 5.1 2.2

Capacity. h.ydraulic Flows Lubricant, Modulating Pressures. . . . , . .

Shift pump bench. test.

Transmission pump bench. test.

Pressures. • • . . • . • . . . • Shift inhihiting pump be.nch test Transmission pump bench test .•

7.9 4.2 11.7 11 8

4.

11. 7 11.8

TORQUE CONVERTER Assembly . • • Description • Disassembly.

Installation Removal • . •

7.6 1.1

1.4 7.10 7. 1

TRANSMISSION Description Fits and tolerances Repair . • . • . .

. . . •.

1. 1 11. 10 . 8. 1 thru 8. 5

TR 0 UB LE SHOOTING .....••..••......••...•..••.....••.....••.....•.....•.•... 3. 0 VALVES Centrifugal Sensing Description . • • • Fits and tolerances.

Repair . . • . . . • .

Decelerating Brake "'''''''''''U14 Description • • • . .

Fits and tolerances.

Repair . . . . • • • . • Modulating Clutch Control Description • . . . .

Fits and tolerances. .

Repair . . ~ * ~ .. .. ....

Over-speed Description . • • • • • Fits and tolerances .• Repair . . • . . . • .

Over-speed Regulating Description. . • • .

Fits and tolerances.

Repair • • • . . . . . • Pressure Regulating Descripti.on . . • . . . • Fits and tolerances. • • Repair . . . . • . . , Shift Inhibiting Description. . . . .

Fits and tolerances • Repair . . . • , • . .

Speed Control Description . . . . .

Fits and tolerances.

Repair . . . . . . . .

Torque Converter Pressure Regulating Description • . . . . .

Fits and tolerances.

Repair. . . , . • . . . • . . . . • . •

1. 2. '1 · 11. 9

1.2

L 2. 6

11.6 6.6 · L 2. 7 11. 4

6.4 L 2.10 · . 11. 9

1.2,7.8

· 1. 2. 11 • . 11.'1 7.2,7.8 , .1.2.3 • 11.:3

6.3

.1. 2.5 ILl 6,1 , .1.2.4 lL2

6.2 .1. 2. 8 · . U.5

· .6.5

91