Service Manual - Allied Systems Company
Contents
1. TR 01 1 DESCRIPTION Piston Stop Piston Stop O Ring Pressure Spring Piston Stop Roll Pin Valve to Housing Screw Valve to Housing Screw Lockwasher Pressure Tap Pipe Plug Pressure Regulating Valve Body Piston Stop Roll Pin Pipe Plug Regulating Valve Piston Piston Stop O Ring Piston Stop Gasket Regulator Spring CHECK POINTS CLUTCH PRESSURE CONVERTER INLET CONVERTER OUTLET CONVERTER TEMPERATURE CONNECTION LUBE PRESSURE COOLER INLET PRESSURE COOLER OUTLET PRESSURE COOLER OUTLET TEMPERATURE zOmmonov r FITTINGS ON TRANSMISSION CONV HSG OR INTO CONV DRAIN TO TRANS High Pressure low Pressure DRAIN MUST HAVE CONTINUOUS SLO EEE Suction Drain FROM CONVERTER TO TRANSMISSION OVERHAUL INSTRUCTIONS FOR TORQUE CONVERTER The following instructions will cover the disassem bly and reassembly of the torque converter in a se quence that would normally be followed after the unit is removed from the machine and is to be com pletely overhauled CAUTION Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit Before attempting any repairs the exterior of unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism DISASSEMBLY OF THE TORQUE CONVERTER Figure 1 Remove pump stud nuts and washers Figure 2 Remove pump assembly and drive sleeve Figure2. lt gt SPICER Off Highway Products Service Manual Converter C8000 CSM 0006 Allied Form 80 900 Rev 2 2011 July 1998 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten ance and repair of the CLARK HURTH COMPONENTS product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principal of operation trouble shooting and adjustments it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Clark Components approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Clark Hurth Components does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied by or approved by Clark Hurth Components IMPORTANT Always furnish the
3. 20 Figure 80 Install impeller cover to turbine hub front bearing Figure 81 Install turbine hub dowels Figure 82 Position impeller to impeller cover O ring Figure 83 Install turbine and lock up cover on turbine shaft Figure 84 Align holes in impeller with holes in impeller cover Install bolts and lockwashers Tighten bolts evenly and securely Figure 85 Install bearing retainer plate on turbine shaft Figure 86 Install bearing plate retainer ring e Figure 87 Install bearing plate oil sealing ring Figure 88 Position new O ring see arrow on impeller cover bearing cap Install bearing cap on impeller cover See Figure 95 for torque Figure 89 If lock up is not used install turbine assembly on tur bine shaft t Figure 90 Install impeller cover and bearing assembly on turbine hub Drive bearing into position Align holes in im peller with impeller cover and install bolts and lock washers Tighten bolts evenly and securely 21 Figure 91 Install bearing retainer plate Figure 95 Install self locking bearing cap bolts in bearing cap and tighten 52 to 57 ft Ibs torque 70 5 77 3 N m Figure 92 Install bearing plate retainer ring Figure 96 Install pump drive sleeve and pump on converter housing rear cover Figure 93 Install new sealing ring expander spring and oil seal ing ring on
4. governor drive Assembly and disassembly is the same for all Install bolts and tighten 26 to 29 ft lbs torque 35 3 39 3 N m NOTE Adaptor will 18 Figure 70 Install lockwashers and nuts Tighten nuts 64 to 70 ft 155 torque 86 8 94 9 N m If lock up is used refer to Figure 71 through 87 non lock up is used refer to Figures 88 through 94 If Figure 71 Install lock up piston inner sealing ring Figure 74 Install one 1 friction inner disc against lock up piston A 2 i Figure 72 Figure 75 Install lock up piston outer sealing O ring and piston Install one 1 steel outer disc Install friction inner outer lock joint sealing ring disc against steel outer disc m Figure 76 Figure 73 Install lock up backing plate with flat side of plate Install lock up piston in impeller cover against the last friction disc 19 Figure 77 Install backing plate retainer ring with split in ring at lock plate position Figure 78 Install retainer ring lock bolt lock and bolt Tighten bolt to 12 to 16 ft lbs torque 16 3 21 7 N m Bend tangs of bolt lock over head of bolt Figure 79 Install turbine and lock up hub in impeller cover Turn turbine slowly to allow lock up hub to engage in inner lock up discs Do not force this operation When tur bine is in full position in lock up discs turn assembly over and block turbine to prevent it from dropping out of position
5. Pump Adaptor Pump Drive Sleeve Pump Gasket Converter Charging Pump Pump Mounting Stud Nut Pump Mounting Stud Lockwasher Pump Mounting Stud Stud Nut Stud Nut Lockwasher Inner Washer Snap Ring Bearing Washer Snap Rin Oil Baffle Screw Washer Oil Baffle Screw Lockwasher Oil Baffle Screw Oil Baffle Ring Impeller Impeller Hub Impeller Hub Bearing Snap Ring Reaction Member Spacer Roll Pin Reaction Member aren Sings Ring Gear Ring Gear Stud Ring Gear Backing Plate Ring Gear Belleville Washer Ring Gear Stud Nut Impeller Cover Bearing Cap Piston Ring Front Bearing Impeller to Cover g Piston Ring Lock Up Piston O Ring Lock Up Inner Disc Lock UP Inner Disc Backing Plate Snap Ring Snap Ring Lock Plate Screw Lock Plate Lock Plate Screw Turbine and Lock Up Hub Turbine Hub Screw Backing Turbine Hub Screw Lock Up Outer Disc Lock Up Piston Piston Ring Inner Impeller Cover Bearing Retainer Piston Ring Expander Spring Snap Ring cereis erbe Impeller Cover Bearing Cap 5 Impeller Cover Bearing QD A ca ca caca NBR 0OUODBPOOO A 2 0 9 002202 l8922 2 d oo qoM ITEM PRESSURE REGULATING VALVE QTY
6. 122 0 1342 Note Assembly of hub expander installation must be completed within a fifteen minute period from start of screw installation The screws are prepared with a coating which begins to harden after installation in the hub holes If not tightened to proper torque within the fifteen minute period insufficient screw clamping tension will result The special screw is to be used for one installation only If the screw is removed for any reason it must be replaced The compound left in the hub holes must be removed with the proper tap and cleaned with solvent Dry hole thoroughly and use new screw for reinstallation Expander VIEW OF e d RING JOINT 108 5 119 3 N m STANDARD Du Lube holes to be checked prior to assembly Holes niust be of dirt amp burrs pe Torque cover bolts d 52 57 Lbs Ft 70 5 77 3 Must be loose X internal fit bearing No 3 etched on bearing Assemble snap ring with sharp edge out Heat bushing to 200 before assembly of bushing to cover Lock up clutch 2 bronze inner plates 1 steel outer plate Coat with type oil prior to assembly AE Stamped cage bearing only Permatex studs used Expander on rear bearing cap Cork gasket when specified ta be Installed dry Torque output shaft X Nut 250 300 Lbs Ft Ring 339 0 406 7 N m Piston ring and
7. 51 Ball 52 Support to Housing Screw 53 Gear Snap Ring 54 Oil Pump Drive Gear 55 Piston Ring Expander ping 56 Piston Ring 57 Stator Support 58 Distributor Sleeve 59 Housing Inspection Screw and Lockwasher 60 Housing Inspection Cover 61 Dai Plug concu esee 62 Housing Inspection Cover 63 Housing Inspection Screw and Lockwasher 64 Bearing Cone 65 Lock Up Adapto 66 Piston Ring 67 Bearing Cap Shim 68 Bearing Cap Oil Seal 69 Bearing Stud 70 Bearing Cap Stud Lockwasher 71 Bearing Cap Stud Nut 72 Permanent Pump Hole Cover Screw 73 Permanent Pump Hole Cover Screw Lockwasher 74 Permanent Pump Hole 75 Permanent Pump Hole Cover Gasket AR As Required Yama wey e ee e PUE UE E IER PII METER 0 ITEM DESCRIPTION QTY 76 gau 9859989852588 388999925 Cover to Housing Screw Cover to Housing Screw Lockwasl Dowel Pin Pump Drive Shaft Pump Shaft Front Bearing Pump Driven Gear Driven Gear Snap Ring Reaction Member Reaction Member Spacer Impeller Hub Bearing Impeller Hub Impeller to Cover Screw Lockwasher Impeller to Cover Screw Impeller Hub Screw Backing Sing Impeller Hub Screw Rear Bearing Washer Inner Pump Adaptor Ring
8. 61 0 for amp CL 8000 torque PROPER OIL CHECKING amp FILLING PROCEDURE Refer to transmission maintenance manual or lubrication chart Use only specified transmission fluid Fill torque converter and transmission through filler opening until fluid comes up to LOW mark on transmission dipstick NOTE the dipstick is not acces sible oil level check plugs are provided See below Remove LOWER check plug fill until oil runs from LOWER oil hole Replace filler and level plug Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole Install oil level plug or dipstick Recheck with hot oil 180 200 degrees Bring oil level to FULL mark on dipstick or runs freely from UPPER oil level plug FULL OIL LEVEL SPEED SENSOR BUSHING INSTALLATION VIEW S Output Drive Gear Sensor REAR VIEW OF CONVERTER Inspect at assembly Dim W from gear tooth fy ZA I Stake 3 places approx equally spaced After curing of Loctite speed sensor bushing must be secure with 40 s Ft Lb 54 2 N m torque VIEW Pump Drive Gear Sensor Inspect at assembly Dim U from gear tooth Assemble Speed Sensor Bushing in housing to specified
9. 70 86 8 94 9 57 63 77 3 85 4 90 99 122 0 134 2 80 88 108 5 119 3 5625 91 100 123 4 135 6 82 90 111 2 122 0 128 141 173 5 191 2 115 127 156 0 172 2 6250 128 141 173 5 191 2 113 124 153 2 168 1 180 198 244 0 268 4 159 175 215 6 237 3 PRESSURE AND OIL FLOW CHECK SPECIFICATIONS ALL CHECKS MADE WITH HOT OIL 180 200 82 2 93 3 A Clutch Pressure at Transmission Control Cover See Specifications and Service Data B Transmission to Converter Line See External Oil Flow Diagram C Converter Out Pressure See Pressure and Oil Flow Checks D Temperature Gauge Connection See External Oil Flow Diagram E Lubricating Pressure 25 p s i 172 4 kPa Maximum at High Free Idle See External Oil Flow Diagram See Pump Chart Converter Return Line Converter Pump Output TROUBLE SHOOTING GUIDE The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit It is necessary to consider the torque converter charging pump transmission oil cooler and connecting oil lines as complete system when running down the source of trouble since the proper operation of any unit therein depends greatly on the condition and operation of the others By studying the principles of operation together with data in this section it may be possible to correct any malfunction which may occur i the system TROUBLE SHOOTING PROCEDURE BASICALLY CONSISTS OF TWO CLASSIFICATIONS MECHANICAL AND HYDRAULI
10. Distributor with the serial and model number when ordering parts TABLE OF CONTENTS HOW THE UNITS OPERATE serio ae 1 SECTIONAL VIEWS AND PARTS IDENTIFICATION Internal Oil Flow Torque Converter Torque Converter Assembly External Oil Flow Converter and Transmission DISASSEMBLY OF THE TORQUE 8 CLEANING AND 2 12 REASSEMBLY OF THE TORQUE 13 SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL 23 PUMP PRIMING 23 LUBRICATION tnn iin 24 TABLE OF TORQUE LIMITS TROUBLE SHOOTING GUIDE ovs eric 25 RING GEAR INSTALLATION 29 PROPER OIL CHECKING amp FILLING 30 ASSEMBLY INSTRUCTIONS siia onis eun 32 DRIVE PLATE INSTALLATION INSTRUCTIONS eee 34 amp 35 NOTE Metric Dimensions Shown in Brackets The torque converter portion of the power train enacts an important role in delivering engine power to the driving wheels In order to properly maintain and service these units
11. Shift lever into forward 4 or 8 speeds Record pressures Shift lever in reverse and Ist Record pressure All pressure must be equal within 5 p s i 34 5 kPa If clutch pressure varies in any one clutch more than 5 p s i 34 5 kPa repair clutch If a flow meter is available install in line coming out of converter pump See flow diagram for location of pressure on flow checks Check pump volume at 2000 RPM and low engine idle Record readings See pump volume specifications at 2000 RPM Install flow meter in the line coming from transmission to converter Check oil volume at 2000 RPM and at low idle in the following speed selections Record readings Forward Low speed thru High Reverse Low speed Subtract readings in each speed from pump volume reading to get transmission clutch leakage Example Pump Volume at idle 8 gal Pump volume 8 gal Forward Low speed thru High 6 gal Forward Low speed 6 gal Reverse Low speed 6 gal Clutch leakage 2 gal If clutch leakage varies more than 1 gal from one clutch to another repair clutch LEAKAGE IN TRANSMISSION CLUTCHES Leakage in 3000 series must not exceed 4 gal max Leakage in 5000 series must not exceed 4 gal max Leakage in 8000 series must not exceed 6 gal max Leakage in 16000 series must not exceed 7 gal max CONVERTER LUBE FLOW Disconnect CONVERTER DRAIN BACK line at transmission with engine running at 2000 RPM and measure oil into a gallon container Mea
12. expander installation Do not assemble offset gears in any combination except those listed below A wrong combination may mesh but will not run properly P N NO P N NO RATIO TURBINE TEETH OUTPUT TEETH 1323 219417 31 219418 41 VIEW OF 1118 218729 34 218728 38 RING JOINT 1 000 218871 36 218871 36 895 218728 38 218729 34 846 242637 39 242638 33 TAPERED BEARING INFORMATION GENERAL Insure seating of bearings amp related parts by seating bearing cap without using shims CAUTION Install all cap mounting screws when seating bearing cap Adjust to specifications noted right Shaft should be rotated amp housing rapped each time bearing cap is assembled to insure proper alignment of the bearings NOTE Rings adapter adapter piston rings amp lube tube should be assembled after shimming of bearings to prevent damage to the various parts OUTPUT SHAFT BEARINGS Remove bearing cap screws after seating bearing cap as noted left heck gap between cap amp housing with shims used as feeler gage REMOVE sufficient shims to produce a 002 tight condition EXAMPLE Gap is 010 final shim thickness to be 008 TURBINE SHAFT BEARINGS OFFSET amp STRAIGHT THRU DRIVE Remove bearing cap screws after seating bearing cap as noted above Check gap between cap amp housing with shims used as a feeler gage ADD sufficient shims to produce a 002 loose condition EXAMPLE Gap is 01
13. lock the engine mechanically to the output shaft This is accomplished by hydraulic pressure actuating the lock up clutch which in turn locks the impeller cover to the turbine hub During lock up the converter turns at 1 to 1 speed ratio The down stream regulator valve on the converter consists of a valve body and regulator spool The spool is backed up by a spring to hold the valve until converter oil pressure builds up to specified pressure The valve is used to maintain a given converter pressure to insure proper performance under all conditions The control valve assembly on the transmission consists of a valve body with selector valve spools connected to the steering column by exterior linkage detent ball and spring in the selector spool provides four positions one position for each speed range A detent ball and spring in the direction spool provides three positions one each for forward neutral and reverse On certain models this valve also contains a shut off valve spool operated by an air or hydraulic cylinder located on the control cover This valve is connected to the brake system by a hose line When the wheel brakes are applied air or hydraulic fluid enters the valve and overcomes a spring force This forces the spool to shift over and block pressure from entering the directional clutches In this manner a neutral is established without moving the control levers With the engine running and the directional control lever in n
14. or 34000 series power shift transmissions or the HR28000 amp HR32000 series having verter lock up or the C270 series converter having lock up UNLESS IT MEETS THE APPROVED C 3 SPECIFICATIONS deviation from this chart must have written approval from the application department of the Clark Hurth Components Engineering and Marketing Department Normal drain periods and filter change intervals are for average environmental and duty cycle conditions Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause acceler ated deterioration and contamination For extreme conditions judgment must be used to determine the required change intervals 24 TORQUE IN FT LBS BOLTS CAPSCREWS STUDS AND NUTS Grade 8 Identification 6 Radial Dashes 60 Apart on Heod of Bolt Grade 5 Identification 3 Radial Dashes 120 Apart on Head of Bolt LUBRICATED OR PLATED Grade 5 Grade 8 Nominal Fine Thread Course Thread Fine Thread Course Thread Size Torque Lbs Ft N m Torque Lbs Ft N m Torque Lbs Ft N m Torque Lbs Ft N m 2500 9 11 12 2 14 9 8 10 10 8 13 6 11 13 14 9 17 6 9 11 12 2 14 9 13125 16 20 21 7 27 1 12 16 16 3 21 7 28 32 38 0 43 4 26 30 35 3 40 7 3750 26 29 35 3 39 3 23 25 31 2 33 9 37 41 50 2 55 6 33 36 44 7 48 8 4375 41 45 55 6 61 0 37 41 50 2 55 6 58 64 78 6 86 8 52 57 70 5 77 3 5000 64
15. to withstand 300 p s i 2068 4 kPa Disconnect hose between pump and filter at filter end and using suitable fittings connect to pressure port of tester Install hose between filter and tester connecting same to reservoir port of tester DO NOT USE TESTER LOAD VALVE AT ANY TIME DURING TEST When taking flow reading all readings should be taken onthe first left half of flow gauge Whenever the needle shows on the right half of gauge correct by switching to higher scale If a flow meter is not available for checking converter pump output proceed with manual transmission and converter checks If the converter shows leakage within specifications and clutch pressures 180 to 220 p s i 1241 1 1516 8 kPa are all equal within 5 p s i 34 5 kPa refer to paragraph on Low Converter Charging Pump Output PUMPS ARE RATED AT 2000 RPM Refer to Vehicle Manufacture Manual for specific pump output NOMINAL PUMP RATINGS C 5000 C 8000 C 16000 21 21 G P M 40 G P M 31 G P M 31 G P M 50 G P M 40 G P M 65 G P M Pump output listed applies to a new pump in each case A 2096 tolerance below this figure is permissible however if pump output is more than 20 below specification the pump must be replaced or rebuilt 24 TRANSMISSION CLUTCH LEAKAGE Check clutch pressures at low engine idle with oil at operating temperatures 180 200 82 2 93 3 C Engine speed must remain constant during entire leakage check
16. 0 final shim thickness to be 012 NO NO RATIO DRIVE GEAR TEETH DRIVE GEAR TEETH 1 250 226844 32 226845 40 1 057 233658 35 233657 37 946 25 243755 37 25 243756 35 25 946 222035 37 222037 35 800 233715 40 237167 32 ON GEAR OD LOCK UP aye GENERAL ASSEMBLY INSTRUCTIONS 1 Assemble to parts list as to location of charging pump flange size wheel size gear ratios etc All lead in chamfers for oil seals piston rings amp Rings must be smooth amp free from burrs Inspect at assembly Lubricate all piston rings amp Rings at assembly Use Permatex amp Crane Sealer only where specified Apply very light coat of Permatex No 2 to O D of all oil seals prior to assembly After assembly of parts using Permatex or Crane Sealer there must be no free or excess material that could enter the oil circuit Rings marked X have a white identification mark on the O D Denotes high temperature material LOCK UP amp GOV DRIVE LOCK WIRE SEE VIEW R NOTE 946 RATIO 25 PRESSURE ANGLE GEARS IDENTIFIED BY GROOVE GOV DRIVE Apply thin coating of grease between seal lips prior to assembly Torque capscrews amp lockwire together as shown lockwire must not protrude above capscrew head C amp CL8000 Series Converter Drive Plate INSTALLATION INSTRUCTIONS Proper Identification by
17. 3 Remove impeller cover bearing cap bolts Figure 4 Install two bolts in threaded holes in bearing cap Turn bolts evenly and remove bearing cap Figure 5 Remove bearing retainer plate snap ring Figure 6 Remove impeller to impeller cover bolts Figure 7 Using a puller as shown in Figure 7 remove bearing retainer plate impeller cover and turbine from tur bine shaft CAUTION Secure impeller cover with a chain to prevent assembly from dropping Figure 8 Turbine and impeller cover removed Block impeller cover on the outer diameter and drive turbine hub from impeller bearing If lock up is not used omit Figure 9 through 15 and refer to Figure 16 Figure 9 Straighten tangs on bolt lock and remove bolt bolt lock and snap ring lock from lock up cover Figure 10 Remove backing plate retainer ring Figure 11 Remove backing plate Figure 12 Remove inner and outer lock up discs Figure 13 Remove lock up piston iy E Figure 14 Remove lock up piston outer sealing ring and O ring Figure 15 Remove lock up piston inner sealing ring Figure 16 Remove turbine shaft bearing cap Figure 17 Remove lock wire and adaptor bolts from adaptor Install two bolts in threaded holes in adaptor Turn bolts evenly and remove adaptor Figure 18 Lock output gears with a soft bar and remove output flange nut Remove flange washer O ring and flange
18. Bolt Circle Diameter Measure the A dimension Bolt Circle diameter and order Drive Plate Kit listed below DRIVE PLATE AND WELD NUT ASSEMBLY 1 v N macrina RING INTERMEDIATE BACKING RING DRIVE PLATES s INTERMEDIATE DRIVE PLATES 6 A Dimension Bolt Circle Diameter A Dimension Bolt Circle Diameter 15 00 381 000 mm diameter Kit No 802587 10mm 16 00 406 400 mm diameter Kit No 802594 W O Nuts 16 00 406 400 mm diameter Kit No 802558 10mm 16 00 406 400 mm diameter Kit No 802590 7 16 20 16 875 428 625 mm diameter Kit No 802609 7 16 20 17 00 431 800 mm diameter Kit No 802593 10mm 17 00 431 800 mm diameter Kit No 802562 7 16 20 Each kit will include the following parts 5 Intermediate Drive Plates 1 Drive Plate Assembly 1 Backing Plate 14 Drive Plate Mounting Capscrews Instruction Sheet 1 pc Drive Plate Mounting Spacer is included in Kit No 802609 Each kit will include the following parts 6 Intermediate Drive Plates 1 Backing Plate 14 Drive Plate Mounting Capscrews Instruction Sheet NOTE Assembly of flexplates must be completed within a 15 minute period from start of screw installation If the screw is removed for any reason it must be replaced The adhesive left in the tapped holes must be removed with the proper tap and cleaned with solvent Dry the hole thoroughly and use a new screw for reinstallation Position drive plate and
19. C MECHANICAL CHECKS Prior to checking any part of the system from a hydraulic standpoint the following mechanical checks should be made 1 A check should be made to be sure all control lever linkage is properly connected and adjusted at all connecting points 2 Check shift levers and rods for binding or restrictions in travel that would prevent full engagement Shift levers by hand at transmission case if full engagement cannot be obtained difficulty may be in control cover and valve assembly HYDRAULIC CHECKS Before checking on the torque converter transmission and allied hydraulic systems for pressures and rate of oil flow it is essential that the following preliminary checks be made 1 Check oil level in transmission This should be done with oil temperatures of 180 200 F 82 2 93 3 C DO NOT ATTEMPT THESE CHECKS WITH COLD OIL To bring the oil temperature to this specification it is necessary to either work the machine or stall out the converter Where the former means is impractical the latter means should be employed as follows Engage shift levers in forward and high speed and apply brakes Accelerate engine half to three quarter throttle Hold stall until desired converter outlet temperature is reached CAUTION FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER 25 PRESSURE AND OIL FLOW CHECKS Whenever improper performance is evident the following basic pressure and oi
20. Figure 19 Remove rear housing cover bolts Remove rear hous ing Figure 20 Remove output shaft bearing cap Figure 21 Using a split puller as shown remove output shaft and outer taper bearing Figure 22 Remove output gear washer and inner taper bearing from rear housing 10 Remove reaction member from stator support If re action member is tight threaded holes are provided to pull same from stator support Figure 23 Remove turbine shaft and bearing assembly from converter housing Figure 27 Remove impeller and baffle assembly from converter housing Figure 24 Remove three 3 oil baffle retainer bolts and washers from housing Figure 28 Remove pump drive gear retainer ring Remove pump drive gear and oil baffle from impeller hub arem Figure 25 Remove reaction member retainer ring Figure 29 Remove pump driven gear retainer rings 11 Figure 30 Remove pump shaft rear bearing retainer ring and washer Figure 31 Using a soft bar tap pump shaft assemblies from converter housing Figure 32 Remove bolts from stator supports Figure 33 Remove stator support Figure 34 If inner turbine shaft bearing cup is to be replaced remove as shown in Figure 34 CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowl
21. O 45 LBFFT 61 0 C amp CL 8000 249087 2 032 51 62 230594 229769 2 094 53 18 If Backing Ring is to be replaced order Part No 230594 Backing Plate The 802551 Kit Includes 1 249087 24 235050 96 228987 24 229769 1 802552 Remove all burrs from Flywheel Mounting Face and Pilot Bore clean with solvent The engine Flywheel and Housing must conform to standard S A E No 1 S A E J927 tolerance specifications for Pilot Bores Eccentricities and Mounting Face deviations Check engine crankshaft End Play must be the same value before and after the torque converter is mounted to the engine Install three 3 Studs 235050 equally spaced Tighten 33 to 36 Ibf ft 44 8 48 8 N m of torque 3 Install Ring Gear 249087 by tapping lightly in place 29 Ring Gear Stud Belleville Washer Stud Nut Instruction Sheet 4 Install remaining studs Tighten 33 to 36 Ibf ft 144 8 48 8 N m torque a Install Backing Plate 230594 6 Lubricate Stud Threads Belleville Washers and Nuts with S A E 10 oil 7 Install Belleville Washers and Elastic Stop Nuts as shown 3 washers each stud for C amp CL 5000 and HR amp LHR 34000 4 washers each stud for C amp CL 8000 Tighten nuts in a criss cross pattern to 25 34 N m Then tighten nuts in increments of 5 Ibf ft 6 7 N m in a criss cross pattern to 35 Ibf ft 47 5 N m for C amp CL 5000 and HR amp LHR 34000 and 45 Ibf ft
22. Oil Grade 30 API CD SE or CD SF n 9 MIL L 2104C Grade 30 MIL L 2104D Grade 30 a MIL L 2104C Grade 10 b MIL L 2104D Grade 10 Temperature c C2 Grade 10 Range 7 d Grade 10 e Engine Oil Grade 10 or CD SF 0 Quintolubric 822 220 Non Phosphate Ester Fire Temperature a Dexron PTT Range b Dexron II D See Caution Below Temperature a MIL L 46167 Range 74 b MIL L 46167 A Temperature Conoco High Performance Synthetic Motor Oil Range Spec No 6718 PREFERRED OIL VISCOSITY Select highest oil viscosity compati ble with prevailing ambient temperatures and oil application chart Temperature ranges 2 and 3 may be used to lower ambient temperatures when sump preheaters are used Temperature range 4 should be used only in ambient temperature MODULATED SHIFT TRANSMISSIONS 12000 18000 24000 28000 amp 32000 series transmissions with modulated shift use only or temperature range 3 items a 8 b Dexron or I D SEE CAUTION BELOW 3000 4000 5000 6000 8000 16000 amp 34000 series transmissions with modulated shift use only or temperature range 3 item a only Dexron Do NOT use Dexron D SEE CAUTION BELOW CAUTION Dexron not compatible with graphitic clutch plato friction material UNLESS IT MEETS THE APPROVED C 3 SPECIFICATIONS Dexron cannot be used in the 3000 4000 5000 6000 8000 16000
23. ags free of abrasive materials such as metal filings contaminated oil or lapping compound INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date Bearings Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time After inspection dip bear ings in recommended type Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed Oil Seals Gaskets Etc Replacement of spring load oil seals rings metal sealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lip of seal seriously impairs its efficiency Apply a thin coat of Permatex No 2 on the outer diameter of the oil seal to assure an oil tight fit into the retainer When assembling new metal type sealing rings same should be lubricated with coat of chassis grease to stabilize rin
24. ainer washer and ring Figure 39 Install pump driven gear to shaft retainer ring Repeat procedure for all pump shafts and gears Figure 40 Apply a thin coat of No 2 Permatex to outer diameter of oil seal and press into bore of oil baffle Lip of seal must be upward NOTE Before installing oil baffle remove impeller hub bolts and install new impeller to hub O ring 14 A L 2 J Figure 41 Install oil baffle on impeller and hub assembly Use caution as not to damage oil seal Install pump drive gear and retainer ring Figure 42 Install oil baffle ring Lubricate ring with automatic transmission fluid Figure 43 Install new sealing ring expander spring and oil seal ing ring on support Expander spring gap to be 180 from sealing ring hook joint 1 Figure 44 Install impeller and oil baffle assembly over stator support and into converter housing Use caution as not to damage oil baffle O ring Figure 46 Press roll pin in reaction member Press spacer on roll pin Figure 47 Install reaction member on stator support and secure with retainer ring Figure 48 Install oil baffle lockwashers and flat washers on baffle bolts Install bolts and washers in converter housing Tighten evenly and securely 15 Figure 49 Using a soft bar install turbine shaft inner bearing cup e i Figure 50 Install turbi
25. an output flange assembled only on the required end ES CLUTCH PRESSURE CONVERTER PRESSURE ES OIL TO COOLER LUBE AND DRAIN LOCK UP LOCK UP GOV DRIVE GOV DRIVE sit ITEM DESCRIPTION Oil Front Bea 3 1 2 9 Cup 3 Front Bearing Spacer 4 Rear Bearing Cone 5 Rear Bearing 6 Bearing Cap Ring 7 Bearing Cap Stud 8 Bearing Cap Stud Lockwasher 9 Bearing Cap Stud Nut 10 Ia uo MP 11 Flange Washer 13 Flange Nut 14 Flange Ring 15 Oil Seal 16 Bearing Cap 17 Bearing Cap 5 18 Output Shaft 19 Output Shaft Gear 20 Front Bearing Cone 21 Front Bearing Snap Ring 22 Oil Tube 23 Pipe Plug 24 Converter Housing 25 Downstream Pressure Regulating Valve Assembly 26 Pipe Plug 27 Pipe Plug 28 Reducing Bushing 29 Air Breather and Check Valve Assembly 30 Pump Hole Cover Gasket 31 Pump Hole Cover 32 Cover Screw Lockwasher 33 Cover Screw 34 Tube Nut 35 Bearing Cap 36 Lube Tube Ring 37 Tube 38 Lube Tube O Ring 39 Bearing Cap Ring 40 Piston Ring 41 Adaptor to Shaft Screw 42 Bearing Cup 43 Housing Rear Cover 44 Cover to Housing O Ring 45 Turbine Shaft Gear 46 Turbine Shaft 47 Bearing Cone 48 Bearing Cup 49 Piston Ring 50 Pipe Plug
26. bearing plate Expander spring gap to be 180 from sealing ring hook joint Figure 97 Install lockwashers and stud nuts Tighten securely Position new O ring on impeller cover bearing cap Install bearing cap on impeller cover 22 SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the drive line between the engine and the wheels The proper oper ation of either unit depends greatly on the condition and operation of the other therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered completed After the overhauled or repaired transmission has been installed in the machine the oil cooler and con necting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a de gree of judgment must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter elements cleaning out filter cases thoroughly 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow
27. dimension U or W with Loctite 262 and stake 3 three places See Pump Drive and Output Gear Charts for dimensions PUMP DRIVE RATIO DRIVE GEAR DRIVEN GEAR SPEED SENSOR BUSHING RATIO NO OF TEETH OF TEETH DEPTH U PER VIEW T 1 250 32 40 1 060 007 26 9 17 1 057 35 37 1 060 4 007 26 9 17 946 25 37 25 35 25 1 890 4 007 35 3 17 946 37 35 1 390 007 85 3 17 800 40 32 1 390 007 85 3 17 OUTPUT GEAR RATIO TURBINE SHAFT OUTPUT RATIO amp GEAR ASS Y GEAR SPEED SENSOR BUSHING NO OF TEETH NO OF TEETH DEPTH W PER VIEW S 1 823 31 41 1 060 007 26 9 17 1 118 34 38 1 060 007 26 9 17 1 000 36 36 1 390 007 35 3 17 895 38 34 1 390 007 35 3 17 846 39 33 1 390 007 35 3 17 P ASSEMBLY INSTRUCTIONS C 8000 CONVERTER IIMPELLER HUB AND TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS Ring GENERAL ASSEMBLY INSTRUCTIONS 1 Clean hub mounting surface and tapped holes with solvent Dry 2 thoroughly being certain tapped holes dry and clean 2 Install backing ring and special screws to approximately 06 inch 1 5 of seated position With a calibrated torque wrench tighten impeller hub M screws 58 to 64 Ibs ft torque 78 6 86 8 N m and turbine hub screws Piston ring and 90 to 99 Ibs ft torque
28. dle Add oil as necessary to bring oil level to full mark CONVERTER OUT PRESSURE CONTROLS CLUTCH TYPE CLUTCH INNER DISC CLUTCH OUTER DISC TYPE OF OIL CAPACITY CHECK PERIOD NORMAL DRAIN PERIOD SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER Converter outlet oil temp 180 200 182 3 93 3 Transmission in NEUTRAL Operating specifications 55 psi 379 3 kPa minimum pressure at 2000 R P M engine speed AND a maximum of 70 psi 482 6 kPa outlet pressure with engine operating at no load governed speed Forward and Reverse Manual Speed Selection Manual Multiple discs hydraulically actuated spring released automatic wear compensation and no adjustment All clutches oil cooled and lubricated Friction Steel OIL FILTRATION Full flow oil filter safety by pass also strainer screen in sump at bottom of transmission case CLUTCH PRESSURE 180 220 psi 1241 1 1516 8 kPa With parking LUBRICATION See Lube Chart Consult Operator s Manual on applicable machine model for system capacity Torque Converter Transmission and allied hydraulic system must be considered as a whole to determine capacity Check oil level DAILY with engine running at 500 600 RPM and oil at 180 to 200 82 2 93 3 C Maintain oil level to FULL mark Every 500 hours change oil filter element Every 1000 hours drain and refill system as follows Dra
29. eutral position oil pressure is blocked at the control valve and the transmission is in neutral Movement of the forward and reverse spool will direct oil under pressure to either the forward or reverse direction clutch as desired and the opposite one is open to relieve pressure The direction or speed clutch assembly consists of a drum with internal gear teeth and a bore to receive a hydraulically actuated piston A piston is inserted into the bore of the drum The piston is oil tight by the use of sealing rings A friction disc with internal teeth is inserted into the drum and rests against the piston Next a disc with splines at the outer diameter is inserted Discs are alternated until the required total is achieved After inserting the last disc a series of springs and pins are assembled in such a manner that these springs rest on teeth of the piston A heavy back up plate is then inserted and secured by a snap ring A hub with 1 0 and O D splines is inserted into the splines of discs with teeth on the inner diameter and a splined shaft extending through the clutch support This hub is retained by a snap ring The discs and inner shaft are free to increase in speed or rotated in the opposite direction as long as no pressure is present in the direction or speed clutch To engage the clutch as previously stated the control valve is placed in the desired position This allows oil under pressure to flow from the control cover valve through a t
30. gs in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recom mended type Automatic Transmission Fluid before assembly Gears and Shafts If magna flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or splines twisted and that shafts are true Housing Covers etc Inspect housings covers and bearing caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures NOTE If converter housing is replaced see page 31 for speed sensor bushing installation REASSEMBLY OF TORQUE CONVERTER Instructions given below on reassembly of components are given in the sequence that must be followed in rebuilding Figure 35 Install stator support Figure 36 Install support self locking bolts and tighten 80 to 88 ft Ibs torque 108 5 119 3 N m Figure 37 With pump driven gear in position install shaft and bearing assembly through rear of case and into pump driven gear Figure 38 Install pump bearing ret
31. he lubricating oil inlet on the transmission then through a series of tubes to the transmission bearings and clutches The oil then returns to the transmission sump A safety valve is built in the transmission control cover and will open to bypass oil only if an excessive pres sure is built up due to a blocked passage The rear compartment of the converter unit also houses the converter output shaft A flexible hose provides an overflow to the transmission sump The three members of the torque converter are composed of a series of blades The blades are curved in such a manner as to force the oil to circulate from the impeller to the turbine through the reaction member again into the impeller This circulation causes the turbine to turn in the same direction as the impeller Oil enters the inner side of the impeller and exits from the outer side into the outer side of the turbine It then exits from the inner side of the turbine and after passing through the reaction member again enters the inner side of the im peller Converter Stall is achieved whenever the turbine and turbine shaft are stationary and the engine is oper ating at full power or wide open throttle CAUTION Do not maintain Stall for more than 30 seconds at a time Excessive heat will be generated and may cause converter or transmission seal damage In converters equipped with Lock up clutches a hydraulic clutch similar to the transmission clutches is used to
32. impeller hub and drives through gears rotating the hydraulic pumps mounted on the converter housing cover HOW THE UNITS OPERATE With the engine running the converter charging pump draws oil from the transmission sump and directs it through oil filters to the regulating valve located on top of the transmission From the regulating valve it is then directed through the control cover on the transmission to the converter and to the transmission clutches The pressure regulating valve mounted on the top of the transmission remains closed until required pressure is delivered to the transmission for actuating the direction and speed clutches This regulator valve consists of a hardened valve spool operating in a closely fitted bore The valve spool is backed up by a spring to hold the valve spool against its seat until the oil pressure builds up to the specified pressure The valve spool then moves towards the spring until a port is exposed along the side of the bore The oil can then flow through this port into a distrib vtor which directs the oil into the converter inlet port After entering the converter the oil is directed through the stator support to the converter cavity and exits between the turbine shaft and converter support The oil then passes through an oil distributor which directs the oil out of the converter by way of a down stream regulator valve and then to the oil cooler After leaving the cooler the oil is directed through a hose to t
33. in with oil at 150 to 200 65 6 93 3 C NOTE It is recommended that filter elements be changed after 50 and 100 hours of op eration on new and rebuilt or repaired units a Drain transmission and remove sump screen Clean screen thoroughly and replace using new gaskets b Drain oil filters remove and discard filter elements Clean filter shells and install new elements c Refill transmission to LOW mark d Run engine at 500 600 RPM to prime converter and lines e Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil tempera ture is hot 180 200 F 82 2 93 3 C make final oil level check BRING OIL LEVEL TO FULL MARK brake set see note oil temperature 180 200 182 2 93 3 engine at idle 400 to 600 RPM shift thru direction and speed clutches All clutch pressure must be equal within 5 psi 34 5 kPa If clutch pressure varies in any one clutch more than 5 psi 34 5 kPa repair clutch NOTE Never use service brakes while making clutch pressure checks Units having brake actuated declutching in forward and or reverse will not give a true reading ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS RECOMMENDED LUBRICANTS FOR CLARK HURTH COMPONENTS POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS Prevailing Ambient Temperature C 2 Grade 30 f Temperature b Grade 30 Range c Engine
34. it is important to first understand their func tion and how they operate The torque converter and transmission function together and operate through common hydraulic system To obtain maximum serviceability they have been designed and built as separate units It is necessary however to consider both units in the study of their function and operation To supplement the text herein and for reference use therewith the following illustrations are provided Internal Oil Flow Torque Converter Torque Converter Assembly External Oil Flow Converter and Transmission TORQUE CONVERTER ASSEMBLY The torque converter assembly is composed of 1 Torque Converter 2 Output Shaft for driving the trans mission 3 Coupling and Flange to mount the converter charging pump to supply oil under pressure to operate transmission clutches and for converter cooling The torque converter is composed of four members the impeller which is the driving member the turbine which is the driven member the reaction member which is splined on a fixed support and the drive disc which couples the converter to the engine The impeller and drive disc members form the outer shell The turbine runs within the outer shell and is connected to the output shaft The oil is the only connection between the turbine and impeller members The reaction member is splined to the converter support which is fixed and does not ro tate in either direction A gear is splined to the
35. l flow checks should be performed and recorded It is also recommended that these checks be taken periodically as a preventative main tenance measure Doing so will permit possible detection of difficulties in advance of actual breakdown thus permitting scheduling of repair operation Likewise repair of minor difficulties can be made at considerably less cost and down time than when delayed until major and complete breakdowns occur Analyzing the results of these checks by comparison with specifications and with each other will indicate in most cases the basic item or assembly in the system as the source of difficulty Further checking of that assembly will permit isolation of the specific cause of trouble SEE PLUMBING AND CHECK POINT DIAGRAM OIL PRESSURE AT CONVERTER OUT PORT Install hydraulic pressure gauge at PRESSURE connection on Converter Regulator Valve or at CONVERTER OUT pressure tap All models do not have pressure regulating valves Check and record oil pressure at 2000 RPM and at maximum speed engine at full throttle see instructions on Stalling Converter previously listed CONVERTER MINIMUM CONVERTER MAXIMUM CONVERTER MODEL OUT PRESSURE OUT PRESSURE C 5000 i 379 3 kPa 70 p si 482 6 kPa C 8000 879 3 kPa 70 p s i 482 6 kPa C 16000 rrr 54 379 3 kPa 70 p s i 482 6 kPa If a flow meter is available install in line between converter charging pump and oil filters Flow meter must be able
36. ne shaft inner bearing gear and outer bearing on shaft converte Install turbine shaft oil sealing ring Block housing on pilot end and install turbine shaft assembly in converter housing Figure 52 Position output shaft inner bearing gear spacer and gear in converter housing rear cover Figure 53 Press outer bearing on output shaft Turn rear cover over and position output shaft in output gear and spacer Press output shaft into inner bearing Apply a thin coat of Permatex No 2 on the outer diameter of the output shaft oil seal Press oil seal in bearing cap with lip of seal down 16 Figure 55 Install new ring on output shaft bearing cap Install bearing cap on output shaft Figure 56 Install stud nuts and tighten securely This is to insure proper seating of taper bearings Figure 57 Loosen stud nuts Tighten stud nuts evenly finger tight this will prevent bearing cap from moving while select ing shims Check gap between bearing cap and rear cover with shims used as a feeler gauge REMOVE sufficient shims to produce a 002 0 050 mm tight condition EXAMPLE Gap is 010 0 254 mm final shim pack thickness to 008 0 203 mm Figure 58 Install shim pack bearing cap stud lockwashers and stud nuts Tighten nuts to 64 to 70 ft lbs torque 86 8 94 9 N m Figure 59 Install converter housing to rear cover O ring Figure 60 Install rear cover and out
37. put shaft on converter hous ing 3 4 3 Figure 61 Install rear cover bolts and lockwashers Tighten bolts 41 to 45 ft Ibs torque 55 6 61 0 N m 17 Figure 62 Using a soft bar lock converter output gears Install output flange flange O ring washer and nut Figure 63 Tighten flange nut 250 to 300 ft Ibs torque 339 0 406 7 N m Figure 64 If governor drive is used install new oil seal lip of seal up in turbine shaft bearing cap Install turbine shaft outer bearing cup in bearing cap Figure 65 Install bearing cap on turbine shaft Install stud nuts and tighten securely This is to insure proper seating of taper bearings Figure 66 Loosen stud nuts Tighten stud nuts evenly finger tight this will prevent bearing cap from moving while select ing shims Check gap between bearing cap and rear cover with shims used as a feeler gauge ADD sufficient shims to produce a 002 0 050 mm loose condition EXAMPLE Gap is 010 0 254 mm final shim thick ness to be 012 0 304 mm Remove bearing cap Figure 68 Install O rings on lube tube see arrows Using bearing cap as a guide for lube tube flange install lube tube in rear housing Figure 69 With bearing cap shims and new O ring see arrow in position install bearing cap Figure 67 Install adaptor on turbine shaft for lock up lock up and governor drive and
38. rk on dipstick or runs freely from UPPER oil level plug Recheck all drain plugs lines connections etc for leaks and tighten where necessary CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURE 1 Thecause for pump failure must be found and corrected before a replacement pump is installed Check all of the hoses tubes rings adaptors and split flanges Replace any collapsed or damaged hoses damaged split flange rings tube rings and adaptors Start the engine Run the engine at low idle for two minutes watch the clutch pressure gage and listen for cavitation of To bleed off the air from the system loosen the pressure gage line at the pressure regulating valve or loosen the pressure hose at the oil filter or pressure regulating valve Crank the engine over until the air is displaced with oil DO NOT START If bleeding the lines does not correct the problem it may become necessary to prime the pump Disconnect the suction hose or pressure hose whichever is higher and fill the port with transmission oil reconnect the hose and tighten 2 3 After all checks have been made and corrections completed install the pump 4 See filling instructions in paragraph 6 above 5 the pump 6 If the pressure does not come up check the oil level and bleed off air from system as follows 7 THE ENGINE 8 9 Start the engine and check pressure 10 Recheck oil level with hot oil 180 200 F with engine at i
39. rter by pass valve partially open 2 Check for worn by pass ball seat Excessive converter internal leakage See para 3 Remove disassemble and rebuild converter graph on converter lube flow assembly replacing all worn or damaged parts Broken or worn sealing rings in transmission 4 See paragraph on Clutch leakage clutches LOW FLOW THROUGH COOLER WITH HIGH CONVERTER OUT PRESSURE Plugged oil cooler Indicated if transmission 1 Back flush and clean oil cooler lube pressure is low Restricted cooler return line 2 Clean out lines Lube oil ports in transmission plugged Indi 3 Check lube lines for restrictions cated if transmission lube pressure is high OVERHEATING Worn oil sealing rings See paragraph E 1 Remove disassemble and rebuild convert er assembly Worn oil pump 2 Replace Low oil level 3 Fill to proper level Pump suction line taking air 4 Check oil line connections and tighten secur ely NOISY CONVERTER Worn coupling gears 1 Replace Worn oil pump 2 Replace Worn or damaged bearings 3 A complete disassembly will be necessary to determine what bearing is faulty LACK OF POWER Low engine RPM at converter stall 1 Tune engine check governor See Over heating and make same checks 2 Make corrections as explained in Over Heat ing 28 1 C amp CL 8000 TOROUE CONVERTERS FLYWHEEL RING GEAR INSTALLATION PROCEDURE QTY 4 EACH STUD FLYWHEEL 229769 TORQUE T
40. sure oil leakage for 15 seconds and multiply the volume of oil by four to get gallons per minute leakage LEAKAGE IN CONVERTER Leakage in C270 series not to exceed 2 gal max Leakage in C5000 series not to exceed 3 gal max Leakage in C8000 series not to exceed 5 gal max Leakage in C16000 series not to exceed 5 gal max LOW CLUTCH PRESSURE WITH NORMAL CLUTCH LEAKAGE CAUSE REMEDY 1 Low Oil Level 1 Fill to proper level 2 Broken spring in transmission regulator valve 2 Replace spring 3 Clutch pressure regulator valve spool stuck in 3 Clean valve spool and sleeve open position 4 Faulty charging pump 4 See paragraph on charging pump output LOW CLUTCH PRESSURE WITH EXCESSIVE CLUTCH LEAKAGE 1 Broken or worn clutch piston sealing rings 1 Replace sealing rings 2 Clutch drum bleed valve ball stuck in open 2 Clean bleed valve thoroughly position 3 Broken or worn sealing rings on clutch support 3 Replace sealing rings 4 Low converter charging pump output 4 See paragraph on charging pump output 27 LOW CONVERTER CHARGING PUMP OUTPUT CAUSE REMEDY Low oil level 1 Fill to proper level Sump screen plugged 2 Clean screen and sump Air leaks at pump intake hose and connections 3 Tighten all connections or replace hose if or collapsed hose necessary Defective oil pump 4 Replace pump LOW FLOW THROUGH COOLER WITH LOW CONVERTER IN PRESSURE Defective safety by pass valve spring 1 Replace spring Conve
41. ten to specified torque Remove drive plate locating stud Install drive plate attaching screw Snug screw but do not tighten Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed tighten each capscrew to the following torque 7 16 capscrew 58 64 ft Ibs torque 78 86 N m M 10 capscrews 48 55 ft 5 torque 65 75 N m This will require rotating the engine flywheel until the full amount of eight 8 screws have been tightened Measure engine crankshaft end play after converter has been completely installed on engine flywheel This value must be within 001 0 025 mm of the end play recorded in Step No 2 LLLA N 2 777 2 5 8 z Se SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER MEDIATE DRIVE PLATES Plates To Be Installed With Concave Side Toward Engine Flywheel NOTES
42. ube in the transmission case to a chosen clutch Once into the drum oil is directed through a drilled hole into the rear side of the piston bore Pressure of the oil forces the piston and discs over against the heavy back up plate The discs with teeth on the outer diameter clamping against discs with teeth on inner diameter enables the clutch drum and drive shaft to be locked to gether and allows them to turn as a unit There are bleed balls in the clutch drums which allow quick escape for oil when the pressure to the piston is released The transmission gear train consists of six shafts 1 Input Shaft 2 Reverse Shaft 3 Idler Shaft 4 First and Third Shaft 5 Second and Fourth Shaft 6 Output Shaft A screen mounted in a frame is positioned on the bottom of the transmission case to screen out any foreign material This screen is covered by the sump pan This pan is provided with magnets to catch any metallic par ticles Some transmissions may have an axle declutching unit as optional equipment this unit consists of a split output shaft with a sliding splined sleeve to engage or disengage the axle This is accomplished by manually shifting a lever in the operator s compartment which is mechanically connected to the shift fork on the clutch ing unit sliding sleeve This unit of course is only used on the four wheel drive machine On the front drive only or the rear wheel drive only the output shaft is on one piece type and
43. weld nut assembly on Impeller cover with weld nuts toward cover Align intermediate drive plate and backing ring with holes in impeller cover NOTE Two dimples 180 apart in backing ring must be out toward engine flywheel Install capscrews Tighten capscrews 52 57 ft lbs torque 70 4 77 1 N m See page 35 for TORQUE CONVERTER TO ENGINE INSTALLATION PROCEDURE TRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface with solvent Dry thouroughly Check engine flywheel and housing for conformance to standard S A E 1 S A E J 927 and J 1033 tolerance specifications for pilot bore size pilot bore runout and mounting face flatness Measure and record engine crankshaft end play Install two 3 50 88 90 mm long converter to flywheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole Install a 4 00 101 60 mm long drive plate locating stud in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step No 3 Locate converter on flywheel housing aligning drive plate to flywheel and converter to flywheel housing Install converter to flywheel housing screws Tighten screws to specified torque Remove converter to engine guide studs Install remaining screws and tigh
44. will not adequately clean the cooler If neces sary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose DO NOT flushing compounds for cleaning purposes 5 On remote mounted torque converters remove drain plug from torque converter and inspect interior of converter housing gears etc f presence of considerable foreign material is noted it will be necessary that converter be re moved disassembled and cleaned thoroughly It is realized this entails extra labor however such labor is a minor cost compared to cost of difficulties which can result from presence of such foreign material in the system Reassemble all components and use only type oil recommended lubrication section Fill transmission through filler opening until fluid comes up to LOW mark on transmission dipstick NOTE f the dipstick is not accessible oil level check plugs are provided Remove LOWER check plug fill until oil runs from LOWER oil hole Replace filler and level plug Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines Re check level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole Install oil level plug or dipstick Recheck with hot oil 180 200 F 82 2 93 3 C Bring oil level to FULL ma
45. y until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type Cleaners Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bear ings using moisture free compressed air Be careful to direct air stream across bearing to avoid spinning Do not spin bearings when drying Bearings may be rotated slowly by hand to facilitate drying process Housings Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evapora tion of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lintless absorbent wiping r
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