Clutch 3t1344

MOTOR GRADERS 120H (2AN1-UP,3GR1-UP,4MK1-UP,5FM1-UP,6NM1-UP,6YN1-UP,9FN1UP,9YR1-UP), 135H (3YK1-UP,7MN1-UP,8WN1-UP,BDJ1-UP), 12H (2GS1-UP,2LR1-UP,2WR1-UP,4ER1-UP,4XM1-UP,5ZM1-UP,8MN1-UP), 140H (2ZK1-UP,3AS1-UP,3FR1-UP,5HM1-UP,8JM1-UP,8KM1-UP,9TN1-UP,9ZN1UP), 143H (1AL1-UP), 160H (2HS1-UP,2FM1-UP,3GM1-UP,3HR1-UP,6WM1-UP,9EJ1-UP,9JM1-UP), 163H (5AK1-UPMOTOR GRADERS

Problem: There have been reports of unexplained No.7 clutch failures. The No.7 clutch is the low range clutch and is engaged in all lower gears (1F-4F and 1R-3R). The No.7 clutch is unique because it is the only clutch that uses a balance piston. The balance piston is used to keep the clutch from self-engaging due to centrifugal force when the transmission is being used in the higher gears (7th and 8th). Fifteen springs and lube oil pressure in the balance piston cavity are used to exert a force on the clutch piston to keep it from moving when the centrifugal force is high. The lube oil is feed into the balance piston cavity through a supply age orifice (A) in the output shaft. Refer to the illustration.

Solution: There are several things that could cause the No.7 clutch to fail. Listed below are some on the obvious items that would not only apply to No.7 clutch, but to all clutches. 1.Low clutch pressure, caused by control valve problem or clutch piston seal failure. 2.Slow clutch pressure decay when the clutch is disengaged, caused by a blocked decay orifice in the control valve. 3. Clutch piston cocking in its bore. The things unique to the No.7 clutch deal with the balance piston and are sometimes overlooked when investigating the failure. They are the balance piston seal and the lube oil feed orifice. The balance piston seal can cause leakage of the lube oil from the cavity. The feed orifice can become plugged or partially blocked by debris in the oil system. In both cases, the loss of lube oil pressure can allow the No.7 clutch to partially engage causing clutch slippage. When investigating a No.7 clutch failure, special attention should be made to the above two items. The balance piston seal should be inspected for cuts or any damage that would allow oil leakage. The output shaft lube oil age must be inspected for debris. Use an inspection light in order to inspect for debris in the age.

NOTE: DO NOT use air pressure down the age. This can jam the debris tighter into the orifice and could go undetected.

COPYRIGHT 2001 CATERPILLAR ALL RIGHTS RESERVED

Usage: 143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H NA 4XM 163H NA 5AK 163H NA 5AK 120H 5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 120H ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 120H NA 6YN 120H NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H

ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN 135H 8WN 160H NA 9EJ 160H NA 9EJ

Illustration 1

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Illustration 2

View A-A

(1) Spring Test length ... 160 mm (6.3 inch) Test force ... 245 ± 15 N (55 ± 3 lb) Free length after test ... 140 mm (5.5 inch) Outside diameter ... 31.5 mm (1.24 inch)

(2) Cable assembly (3) Shim Outside diameter ... 45.0 mm (1.78 inch) Thickness ... 0.51 mm (0.020 inch)

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(A) Distance from cab floorplate to the bottom edge of the pedal ... 95 ± 6 mm (3.7 ± 0.2 inch) (B) Distance from centerline to centerline of the rod ends ... 447 ± 3 mm (17.6 ± 0.1 inch)

Illustration 3

Cable Assembly

(4) Final installation torque ... 38 ± 7 N·m (28 ± 5 lb ft) (5) Final installation torque ... 8 ± 3 N·m (71 ± 27 lb in)

Usage: 143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H ES 2LR 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H NA 4XM 163H NA 5AK 163H NA 5AK 120H 5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 12H 5ZM 120H ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 160H ES 6WM 120H NA 6YN 135H 7MM 135H 7MM 140H8JM 140H 8JM 140H ES 8KM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN

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Adjustment of the clutch pedal may be necessary after replacement of any of the following items: mechanism for the clutch pedal, clutch control cable and transmission control valve for the clutch pedal. Use the following information for the adjustment of the clutch pedal.

Illustration 1

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

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(6) Rod end

1.

Loosen 9S-1354 Nut (2) and 9S-1354 Nut (3) on 144-5323 Cable As (1) . The cable end is located in 8D-9973 Housing (4) .

2.

Adjust nut (2) in order to show a minimum of two threads on clutch control cable (1) . Tighten nut (3) .

3. 4. 5.

Loosen 6V-8187 Nut (5) that is located on the end of clutch control cable (1) . Screw 5P-7704 Rod End (6) to the end of cable (1) . Adjust 5P-7704 Rod End (6) until the rod end is approximately 4.8 mm (0.19 inch) from the end of the cable (1) . Tighten 6V-8187 Nut (5) .

Illustration 2

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(7) Bolt (8) Locknut (9) Clutch pedal

Illustration 3

Transmission Control Valve

6.

Adjust clutch pedal (9) . Pedal (9) can be adjusted in either of the following two ways.

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i.

Procedure (A) . 

Block the front wheels. Position the machine on stands. Ensure that all the driving wheels will rotate freely.



Loosen locknut (8) and tighten bolt (7) to the bottom of the adjustment.



Start the engine.



Depress pedal (9) . Shift the transmission into First Speed Forward.



Slowly release pedal (9) until the tires start to rotate. Hold pedal (9) in position.



Unscrew the pedal stop bolt (7) so there is a 9.53 mm (0.375 inch) gap between pedal (9) and bolt (7) .



Depress pedal (9) and shift the transmission into Neutral. Engage the parking brake.



Release pedal (9) .



Hold bolt (7) in position and tighten locknut (8) .



Shut off the engine and remove the stands.

i.

Procedure (B) . 

Block the front wheels.






Connect a pressure gauge on the pressure test port (B) of the valve assembly for the transmission.



Start the engine.



Engage the service brakes in order to prevent the machine from moving.



Depress pedal (9) . Shift the transmission into "1st Forward". Slowly release pedal (9) .



Slowly depress the pedal (9) until the pressure drops to zero and maintain the pedal position.



Unscrew the pedal stop bolt (7) so there is a 9.53 mm (0.375 inch) gap between pedal (9) and the bolt (7) .



Fully depress pedal (9) . Shift the transmission into Neutral and engage the parking brake.



Release pedal (9) .






Shut off the engine.


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

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

Before you begin the test, refer to Systems Operation, Testing and Adjusting, "Machine Preparation for Troubleshooting".

Table 1 Required Tools Part Number

Description

1U-5482

Pressure Adapter Group

1

8T-0855

Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))

1

1.

Operate the machine until the transmission oil is at operating temperature of 51 °C (124 °F).

2.

Stop the machine on a hard level surface. Engage the parking brake. Turn off the engine. Place blocks in front of the wheels and place blocks behind the wheels.

Quantit

Illustration 1

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(1) Cover for the transmission control valve

3.

Remove cover (1) from the transmission . Remove the differential drive shaft.

Illustration 2

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Transmission control valve (2) Test port

4.

Remove the cover on test port (2) . Connect 8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) to test port (2) .

Illustration 3

Side view of clutch pedal (3) Clutch pedal

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(4) Pedal stop bolt (5) Locknut

Illustration 4

Side view of clutch control cable assembly. (3) Clutch pedal (6) Clutch control cable (7) Valve spool

5.

Press clutch pedal (3) against pedal stop bolt (4) . Move the transmission control lever to FIRST GEAR FORWARD position and operate at half throttle.

6.

Depress clutch pedal (3) . The transmission should be turning. The pressure at test port (2) should read a minimum of 2125 kPa (310 psi) . Press down clutch pedal (3) . Adjust pedal stop bolt (4) in order to touch clutch pedal (3) when pressure at test port (2) reaches 0.00 kPa (0.00 psi). Tighten locknut (5) .

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7.

If the pressure is correct in Step 6, the modulation is working correctly. If the pressure is not correct in Step 6, follow Step 8.

8.

Disconnect clutch control cable (6) from valve spool (7) . i.

Operate the machine in FIRST GEAR FORWARD at half throttle.

i.

Manually pull out valve spool (7) . The pressure gauge should read 0.00 kPa (0.00 psi).

i.

Push valve spool (7) into the valve body. The spool should move freely. The spool should also be firm because of the spring. The transmission drive shaft should start to turn in the range of 0.00 kPa (0.00 psi) to 834 kPa (120 psi).

i. 9.

The spool may need to be cleaned if the spool does not move freely. If the spool moves freely and modulation occurs in Step 8, clutch control cable (6) may need to be replaced.

10. For more information on the clutch pedal, refer to theSystems Operation, Testing and Adjusting, "Clutch Pedal - Adjust".

Usage: 143H 1AL 143H 1AL 143H 1AL 120H 2AN 120H 2AN 120H 2AN 160H 2F

M 160H 2FM 160H2FM 12H ES 2GS 12H ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 160H ES 2HS 12H ES2LR 12H ES 2LR 12H ES 2LR 12H NA 2WR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 140H ES 3AS 140H NA 3FR 140H NA 3FR 140H NA 3FR 160H NA 3GM 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H NA 3YK 135H NA 3YK 12H 4ER 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H NA4XM 12H NA 4XM 163H NA 5AK 163H NA 5AK 163H NA 5AK 120H 5FM 120H 5FM 120H 5FM

Motor Grader: 120H (S/N: 2AN1-UP; 4MK1-UP; 3GR1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 9FN1-UP; 9YR1-UP) 135H (S/N: 3YK1-UP; 7MM1-UP; 8WN1-UP) 12H (S/N: 2GS1-UP; 4ER1-UP; 5ZM1-UP; 2LR1-UP; 2WR1-UP; 4XM1-UP; 8MN1-UP) 140H (S/N: 2ZK1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3FR1-UP; 3AS1-UP) 143H (S/N: 1AL1-UP) 160H (S/N: 2HS1-UP; 3GM1-UP; 9EJ1-UP; 2FM1-UP; 6WM1-UP; 9JM1-UP) 163H (S/N: 5AK1-UP) Service Magazine SEPD0805, 10 October 2005, "Adjustment Procedure for the Inching Pedal". Disregard this article. Refer to the information below.

Adjustment of the inching pedal may be necessary after replacement of any of the following items: mechanism for the inching pedal, inching cable and transmission control valve for the inching pedal. Use the following information for the adjustment of the inching pedal.

Illustration 1

(1) Inching cable (2) Nut (3) Nut

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(4) Housing (5) Nut (6) Rod end

1.

Loosen 9S-1354 Nut (2) and 9S-1354 Nut (3) on 144-5323 Cable (1). The cable end is located in 8D-9973 Housing (4).

2.

Adjust nut (2) in order to show a minimum of two threads on inching cable (1). Tighten nut (3) .

3. 4. 5.

Loosen 6V-8187 Nut (5) that is located on the end of inching cable (1) . Screw 5P-7704 Rod End (6) to the end of cable (1). Adjust 5P-7704 Rod End (6) until the rod end is approximately 4.8 mm (0.19 inch) from the end of the cable (1) . Tighten 6V-8187 Nut (5) .

Illustration 2

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(7) Bolt (8) Locknut (9) Inching pedal

Illustration 3

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Transmission Control Valve

6.

Adjust inching pedal (9). Pedal (9) can be adjusted in either of the following two ways. i.

Procedure (A) . 

Block the front wheels. Position the machine on stands. Ensure that all the driving wheels will rotate freely.






Start the engine.



Depress pedal (9). Shift the transmission into First Speed Forward.



Slowly release pedal (9) until the tires start to rotate. Hold pedal (9) in position.



Unscrew the pedal stop bolt (7) so there is a 9.53 mm (0.375 inch) gap between pedal (9) and bolt (7) .



Depress pedal (9) and shift the transmission into Neutral. Engage the parking brake.



Release pedal (9) .






Shut off the engine and remove the stands.

i.

Procedure (B) . 

Block the front wheels.






Connect a pressure gauge on the pressure test port (B) of the valve assembly for the transmission.



Start the engine.



Engage the service brakes in order to prevent the machine from moving.



Depress pedal (9). Shift the transmission into "1st Forward". Slowly release pedal (9) .



Slowly depress the pedal (9) until the pressure drops to zero and maintain the pedal position.



Unscrew the pedal stop bolt (7) so there is a 9.53 mm (0.375 inch) gap between pedal (9) and the bolt (7) .



Fully depress pedal (9). Shift the transmission into Neutral and engage the parking brake.



Release pedal (9) .






Shut off the engine.

Usage: 143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 120H 6TM 120H NA 6YN 16H NA 6ZJ 135H 7MM 14H NA 7WJ 140H 8JM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN 135HBDJ 140H XZH 12H XZJ 160H XZK

Illustration 1

The transmission modulator control (pedal) is on the floor of the operator compartment and to the left of the steering console. The transmission modulator pedal disengages the power to the wheels. Depress the transmission modulator pedal when you start the machine and when you stop the machine. Also, depress the transmission modulator pedal when you change the direction of the machine.

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Release the transmission modulator pedal in order to re-engage the power to the wheels. Note: Use the transmission modulator pedal to inch the machine.

Usage: 143H 1AL 160H 2FM 12H ES 2GS 160H ES 2HS 12H ES 2LR 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 12H 5ZM 120H ES 6NM 120H 6TM 160H ES 6WM 135H 7MM 140H 8JM 140H ES 8KM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN

Illustration 1

Schematic of the Circuit of the Shift Lever

Note: Refer to the Electrical System Schematic in the Service Manual of the machine for the correct schematic.

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Problems with the transmission direction and speed control lever will cause the machine to respond incorrectly to the actions of the lever. Some problems with the transmission direction and speed control lever will cause the transmission to remain in the present speed and direction when a problem is detected. Other problems with the transmission direction and speed control lever will cause the transmission to shift to neutral. 1.

View the status. i.

Use the Caterpillar Electronic Technician (ET) to view the status "Group 1 Gear Lever Parameters".

i.

Actuate the transmission shift lever through all speeds in forward and reverse. the positions on the display of the ET.

i.

Operate the machine in all speeds and all directions. All speeds and all directions may not be available.

Expected Result: The failure is NOT present. Results: 

OK - The failure is NOT present. Suspect an intermittent failure. STOP.



2.

NOT OK - The failure is still present. Note the positions that were incorrect on the ET screen. Proceed to Step 2.

Check the harness. i.

Check the harness connectors and the harness from the transmission direction and speed control lever to the power train electronic control module (ECM).

i.

Thoroughly inspect the connectors for the transmission direction and speed control lever and the connectors for the power train ECM.

i.

Visually inspect the harness wiring from the transmission direction and speed control lever to the power train ECM.

i.

Use the ET to view the status "Group 1 Gear Lever Parameters".

i.

Actuate the transmission direction and speed control lever through all speeds in forward and reverse. the positions on the display for the ET.

i.

Operate the machine in all speeds and all directions. All speeds and all directions may not be available.

Expected Result: The harness and harness connectors are correct. The fault is NOT present. Results:

3.



OK - The harness and the harness connectors are correct. The fault is NOT present. Proceed to Step 3.



NOT OK - The harness and/or the harness connectors are NOT correct and the fault is still present. Repair the machine harness and/or the harness connectors. If necessary, replace the machine harness and/or the harness connectors. Ensure that all the seals are properly in place. Also, check that the connectors mate completely. that the repair eliminates the problem. Clear all diagnostic codes. STOP.

Check the voltage. i.

Disconnect the transmission direction and speed control lever from the machine harness.

i. i.

Turn the key start switch to the ON position. Measure the voltage between pin 2 and pin 15 of the 24-pin connector for the transmission direction and speed control lever.

Expected Result: System voltage is present. Results:  

4.

OK - System voltage is present. Proceed to Step 4. NOT OK - System voltage is NOT present. There is a problem with the power supply to the transmission direction and speed control lever. Check the fuse for the transmission direction and speed control lever and the associated harness. STOP.

Check the continuity. i.

Ensure that the key start switch is in the OFF position.

i.

The transmission direction and speed control lever and the power train ECM are disconnected from the machine harness.

i.

Check for continuity from pin 2 to all active pins on the 24-pin connector of the transmission direction and speed control lever.

Expected Result: Continuity is NOT present. Results:  

5.

OK - Continuity is NOT present. Proceed to Step 5. NOT OK - Continuity is present. The problem is in the harness. Repair the harness or replace the harness.

Check the continuity. i.

Check for continuity from pin 15 to all active pins on the 24-pin connector of the transmission direction and speed control lever.

Expected Result: Continuity is NOT present.

Results:  

6.

OK - Continuity is NOT present. Proceed to Step 6. NOT OK - Continuity is present. The problem is in the harness. Repair the harness or replace the harness. STOP.

Check the transmission direction and speed control lever. i. i. i. i.

Reconnect the connectors for the power train ECM. Create a jumper wire that can short from pin 2 to two of the other pins on the connector for the transmission direction and speed control lever. The key start switch should be in the ON position. Use the ET to display "Group 1 Gear Lever Parameters". Conduct the following items and view the parameters on the ET. Refer to Table 1 for the correct connections of the jumper wire to the harness for the transmission direction and speed control lever. Table 1 Check of the Gear Parameters. Jumper Wire Connections. (1)

Ground

Directional

Speed

Indicated Ge

2

11

3

"1"

2

11

4

"2"

2

11

5

"3"

2

11

6

"4"

2

11

7

"5"

2

11

8

"6"

2

11

9

"7"

2

11

10

"8"

2

12

3

"1R"

2

12

4

"2R"

2

12

5

"3R"

(1)

2

12

6

"4R"

2

12

7

"5R"

2

12

8

"6R"

2

12

9

"7R"

2

12

10

"8R"

2

14

10

"N"

All s are on the harness for the shift lever.

iii.

Expected Result: All the gear parameters read the proper gear.

iv.

Results: 

OK - All gear parameters read the proper gear. Replace the transmission direction and speed control lever and correct operation. STOP.



NOT OK - All gear parameters DO NOT read the proper gear. It is unlikely that the power train ECM is faulty. Exit this procedure and perform this CID FMI again. If the cause of the fault is not found, replace the power train ECM. Refer to Testing and Adjusting, "Electronic Control Module (Power Train) - Replace" for more information on replacing the power train ECM. STOP.

Usage: 160H 2FM 12H 4ER 120H 5FM 140H 5HM 120H 6TM 135H 7MM 140H 8J

M 135H 8WN 160H9JM 140H XZH 12H XZJ 160H XZK

Illustration 1

The transmission direction and speed control (lever) is to the right of the operator's seat. Note: You must move the lever from the PARKING BRAKE ENGAGED position before you can move the lever to the NEUTRAL position. Forward (1) - Move the lever to the left and pull back the lever to the desired forward speed setting. The machine will move forward.

1 - First Speed 2 - Second Speed 3 - Third Speed 4 - Fourth Speed 5 - Fifth Speed 6 - Sixth Speed 7 - Seventh Speed 8 - Eighth Speed

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Neutral (2) - Move the lever to the NEUTRAL position when you change direction or when you are preparing to park the machine. A stopped machine on a smooth horizontal surface should not move when the lever is in the NEUTRAL position. Reverse (3) - Move the lever to the right and pull back the lever to the desired speed. The machine will move in reverse.

1 - First Speed 2 - Second Speed 3 - Third Speed 4 - Fourth Speed 5 - Fifth Speed 6 - Sixth Speed

Usage: 160H 2FM 160H 2FM 12H ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H NA 4XM 120H 5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 120H ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 120H NA 6YN 120H NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN 135H8WN 160H NA 9EJ 160H NA 9EJ 160H 9JM 160H 9JM 140H NA 9TN 140H NA 9TN 120H ES9YR

Illustration 1

(1) Torque for 35 bolts ... 30 ± 4 N·m (22 ± 3 lb ft) (2) Torque for pressure switch assembly ... 35 ± 3 N·m (25 ± 2 lb ft) (3) Torque for temperature switch assembly ... 19 ± 3 N·m (14 ± 2 lb ft) (4) Torque for adapter ... 14 ± 4 N·m (10 ± 3 lb ft) (5) Torque for eight nipple assemblies ... 14 ± 4 N·m (10 ± 3 lb ft) (6) Spring Test length ... 12.70 mm (0.500 inch) Test force ... 1.7 ± 0.1 N (0.38 ± 0.02 lb) Free length after test ... 19.0 mm (0.75 inch) Outside diameter ... 9.6 m (0.38 inch)

(A) Position for adapter (4) ... 80 ± 5 degrees


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Illustration 1

(1) Transmission control valve (2) Transmission wiring harness

Transmission control valve (1) provides the proper flows and the proper pressures in order to engage the desired transmission clutches. The transmission control valve is located on the left side of the transmission case. The transmission control valve is constructed of two cast aluminum valve bodies, three cast aluminum manifolds, three steel plates, several aluminum spools, and miscellaneous steel parts.

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Illustration 2

(3) Manual modulation valve (4) Main relief valve

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(5) Priority reducing valve (6) Modulating reducing valves (7) Solenoid valves

The transmission control valve consists of the following components: one main relief valve (4), one priority reducing valve (5), one manual modulation valve (3), wiring harness (2), eight solenoid valves (7) and eight modulating reducing valves (6)

Main Relief Valve

Illustration 3

(4) Main relief valve (8) Spool (9) age to transmission oil cooler

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(10) Orifice (11) Slug (12) Adjustment screw and locknut (13) Spring

The main relief valve is located in the top front quadrant of the inside valve body. Main relief valve (4) provides a restriction in the flow that sets the outlet pressure of the transmission pump. The oil that byes the main relief valve flows to transmission oil cooler line (9) . The main relief valve (4) has a slug (11) that is connected to the outlet flow by orifice (10) that is contained in spool (8). Slug (11) creates a reaction chamber. Oil in the reaction chamber acts against a spring in order to set the pressure. Spring (13) has an external adjustment screw and a locknut (12) that varies the valve pressure setting per turn.

Priority Reducing Valve

Illustration 4

(4) Main relief valve (5) Priority reducing valve (14) Spool

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(15) age (16) Orifice (17) Slug (18) Springs

The priority reducing valve is located at the top rear quadrant of the inside valve body. Priority reducing valve (5) reduces the supply pressure through age (15) to the selector valves and solenoids. The priority reducing valve also provides priority to the selector valves and to the solenoids that are over the fill for the transmission clutch or over the modulation for the transmission clutch. The priority reducing valve (5) receives oil in parallel to main relief valve (4). Slug (17) provides a reaction chamber that is connected to the pump supply flow from the solenoid in age (15) by orifice (16). The oil is contained in spool (14) and balances against the force of springs (18) in order to set the pressure. Note: There is a plug that is located in the bottom of the manifold that is for the transmission control valve. Remove the plug and install a suitable pressure gauge in order to measure the pump supply flow from the solenoid and the priority of the reducing pressure.

Manual Modulation Valve (Inching Valve)

Illustration 5

(3) Manual modulation valve (19) Connection for Push-Pull cable (20) Stop (21) Plunger (22) Piston (23) Springs (24) Spool (25) Slug (26) Adapter (27) Port for temperature sensor

The manual modulation valve is located in the uppermost portion of the outermost valve body.

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Manual modulation valve (3) is connected to the pedal with a push-pull cable (19). The manual modulation valve disengages or the manual modulation valve reduces the power that is transmitted to the drive wheels. This is accomplished by reducing the supply pressure to the directional modulating reducing valves. Modulation valve (3) consists of plunger (21), stop (20), piston (22), spool (24), springs (23), and slug (25). In order to have full pressure at the direction clutches, the transmission modulator control (pedal) must not be activated.

Illustration 6

Location of the transmission modulator control (pedal)

Depressing the pedal reduces the supply pressure to the modulating reducing valve for the direction clutch. The pedal is located in the cab. Fully depressing the pedal reduces supply pressure to 0 kPa (0 psi). Slowly releasing the pedal allows supply pressure to gradually increase following pedal movement to approximately 755 kPa (110 psi). Once the pressure reaches 755 kPa (110 psi), the pressure automatically modulates to a minimum of 2085 kPa (300 psi) after approximately 0.2 seconds. Temperature sensor (27) is mounted into an adapter (26) in the manual modulation valve. Temperature sensor (27) monitors the oil temperature of the drive train.

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Modulation Reducing Valve

Illustration 7

(7) Solenoid

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(28) Selector spool (29) Decay orifice (30) Load piston (31) Modulation orifice (32) Reducing spool (33) Slug (34) Springs

There are eight modulation reducing valves. Four of the modulation reducing valves are located in each valve body. These four provide individual pressure control for the clutch. The modulation reducing valve consists of selector spool (28), load piston (30), reducing spool (32), slug (33), modulation orifice (31), decay orifice (29) and springs (34). Each valve provides a unique pressure for each transmission clutch through different combinations of the springs and the orifices. To pressurize a transmission clutch, solenoid (7) is energized with a 24 volt signal from the electronic control module (ECM). The ECM is activated by the transmission shift lever. This causes selector spool (28) to move toward the center of the valve. This causes load piston (30) and reducing spool (32) to move away from the center of the valve. This will allow oil from the main relief valve to across the reducing valve in order to fill the clutch. When the clutch is full of oil, the oil flows through modulation orifice (31) that is contained in reducing spool (32). This moves load piston (30) toward the selector spool (28), compressing the modulation spring (34) and causing the transmission clutch pressure to gradually rise. In order to disengage the transmission clutch, the solenoid is de-energized. This allows selector spool (28) to move away from the center of the valve. The selector spool connects the load piston cavity in order to drain through decay orifice (29) that is contained in the valve body. This will gradually reduce the clutch pressure.

Solenoid Valves

Illustration 8

(7a) Solenoid (7b) Solenoid (7c) Solenoid

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(7d) Solenoid (7e) Solenoid (7f) Solenoid (7g) Solenoid (7h) Solenoid (35) Speed selector spool (36) Speed range selector spool (37) Direction selector spool

Solenoid valves (7) connect pressurized oil from the priority reducing valve to the corresponding selector spool. The solenoid valves are 24 volt ON/OFF poppet type valves. These poppet type valves are activated. Table 1 Gear

Solenoids

Clutches

8-F

(B), (D), (G)

(1), (8), (5)

7-F

(B), (D), (E)

(1), (8), (4)

6-F

(C), (D), (E)

(2), (8), (4)

5-F

(B), (D), (F)

(1), (8), (6)

4-F

(B), (G), (H)

(1), (5), (7)

3-F

(C), (G), (H)

(2), (5), (7)

2-F

(C), (E), (H)

(2), (4), (7)

1-F

(B), (F), (H)

(1), (6), (7)

N

(D), (G)

(8), (5)

P

(D), (G)

(8), (5)

1-R

(A), (F), (H)

(3), (6), (7)

2-R

(A), (E), (H)

(3), (4), (7)

3-R

(A), (G), (H)

(3), (5), (7)

4-R

(A), (D), (F)

(3), (8), (6)

5-R

(A), (D), (E)

(3), (8), (4)

6-R

(A), (D), (G)

(3), (8), (5)

Speed Range Selector Spools Speed range selector spools (36) trigger the beginning of modulation. Speed range selector spools (36) also trigger the beginning of the decrease of the clutch pressure. The speed range selector spool also prevents the application of two speed range gears at a time. Energizing solenoid (7h) causes speed range selector spool (36) to move toward the center of the valve. This blocks the flow of oil to disengaged solenoid (7d). Also, this drains the supply port of disengaged solenoid (7d) .

Direction Selector Spools The direction selector spools are located in the front center region of the outer valve body. The direction selector spools are part of clutch stations (A), (B), and (C) . Direction selector spools (37) trigger the beginning of the modulation or the beginning of the decrease in clutch pressure. The direction selector spools also prevent the application of two direction clutches at a time. Energizing solenoid (7b) causes direction selector spool (37) to move toward the center of the valve. This blocks the flow of oil to disengaged solenoid (7a) and (7c). Also, this drains the supply port of disengaged solenoid (7a) and (7c) .

Speed Selector Spools The speed selector spools that are located in the front center region of the inner valve body are part of clutch stations (E), (F), and (G) . Speed selector spools (35) trigger the beginning of modulation or the beginning of the decrease in clutch pressure. The speed clutch selector spools also prevent the

application of two speed clutches at a time. Energizing solenoid (7f) causes speed selector spool (35) to move toward the center of the valve. This blocks the flow of oil to disengaged solenoids (7e) and (7g). Also, this drains the supply port of disengaged solenoids (7e) and (7g) .

Manifold Ports for the Transmission Control Valve

Illustration 9

(38) age for clutch 2 (39) Lubrication (40) Elevated drain (41) age from the hydraulic pump (42) age to the oil cooler (43) Drain (44) age for clutch 8 (45) Clutch 7 at station (H) (46) Clutch 5 at station (G) (47) Clutch 6 at station (F) (48) age for clutch 4 (49) age for clutch 3 (50) age for clutch 1 (51) Pilot pressure

Usage: 143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 120H 6TM 120H NA 6YN 135H 7MM 140H 8JM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN 135H BDJ

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Set Up Procedures

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

1. Move the machine to a smooth horizontal location. Move away from working machines and personnel. 2. Lower all implements to the ground. 3. Put the transmission control lever in the Parking Brake ON position. Stop the engine. 4. Put blocks in front of and behind the wheels. 5. Permit only one operator on the machine. Keep all other personnel either away from the machine or in view of the operator. 6. Make sure all hydraulic pressure is released before any fitting, hose or components is loosened, tightened, removed, or adjusted. Always make visual checks first. Check the operation of the machine and then check with instruments.

Introduction

(1) Electronic Control Module.

Motor Graders with the countershaft transmission include an onboard electronic controller referred to as an Electronic Control Module (ECM). The ECM should improve the ability of the mechanic to determine when and where a failure has occurred. Two methods of testing and troubleshooting the transmission system from the ECM are provided. The first (and the recommended) method of checking system status and diagnostics is with the use of the 8T-8697 Electronic Control Analyzer Programmer (ECAP) or an ET. Both the ECAP and the ET can also be used to program the transmission ECM. With the use of a diagnostic tool, a variety of useful information is readily available. Current operating information can be obtained such as: transmission output speed, gear lever position, battery voltage, etc. Also, from the diagnostics screen, transmission diagnostic codes are available to help identify the source of any electrical failure. Transmission diagnostics can also be obtained from the transmission ECM without the use of ECAP or ET. This method will provide the same diagnostic codes available from ECAP and ET. This method will not provide current display status capability available from ECAP or ET.

Using Caterpillar Electronic Technician (ET) To Determine Service Codes

ET Connections

(1) Datalink service connector - at fuse . (2) 7X-1570 Cable. (3) 7X-1700 Communication Adapter (with NEXG4523 Communication Adapter Software installed). (4) 7X-1688 Cable. (5) IBM compatible personal computer with Caterpillar Electronic Technician software installed (see note below).

NOTE: Caterpillar Electronic Technician is a software program that runs on an IBM compatible personal computer. To use Caterpillar Electronic Technician (ET), order ET Single Use Program License software, JERD2124; the information and requirements sheet, JEHP1026; the RS232 connection cable, 7X-1688 and the Data Subscription, JERD2142. The requirements and information sheet lists the hardware required and the features of ET. The service tool ET is not needed to determine or clear service codes, but it makes the tasks easier and faster. ET can also display service code history information. These features make ET a useful troubleshooting tool. ET connects to the datalink service connector which is round and has 9 s. The data link service connector is located next to the key start switch. For more information, see the Electrical System Schematic in the machine Service Manual. To use the ET service tool, choose the MACHINE FUNCTIONS option from the main menu. The next menu is a list of the Electronic Control Modules (ECM) installed on the machine. Choose the menu item "Steer/Brake/Transmission". After determining the service codes with CAT ET, see the topic Troubleshooting Detected Faults that correspond to the service codes.

Using The 8T-8697 Electronic Control Analyzer Programmer (ECAP)

NOTE: The preceding chart has changed from the former issue. The ECAP can be used to: program the transmission ECM, check current machine operating status, check abusive events and check diagnostics codes from the transmission ECM. Prior to connecting the ECAP into the service port on the motor grader, the service equipment must be properly configured. The following steps will configure the ECAP. 1. Install the NEXG4523 Service Program Module (computer chip) into the 7X1700 Communication Adapter as shown on pages two and three of SEHS9264, Using The 7X-1700 Communication Adapter Group. 2. Install the NEXG4521 Machine Functions Service Program Module (two computer chips) into the 8T-8697 Electronic Control Analyzer Programmer (ECAP) as shown in SEHS9343, Using The ECAP NEXG4521 Machine Functions Service Program Module. 3. Connect 7X-1420 Cable between ECAP and 7X-1700 Communication Adapter as shown in SESH9343, Using The ECAP NEXG4521 Machine Functions Service Program Module. NOTE: Newer ECAP units with a Caterpillar part number ending in -A (i.e.. 8T8697-A) will use 7X-1851 Cable instead of 7X-1420 Cable. 4. Install 7X-1570 Cable to 7X-1700 Communications Adapter as shown on page five of SESH9343, Using The ECAP NEXG4521 Machine Functions Service Program Module. At this point ECAP is ready to be connected to the motor grader. NOTE: ECAP receives operating power from the Electronic Control Module (ECM) through the 9-pin CAT Data Link Connector. The following procedure can be used to program the transmission ECM as well as obtain operating status and diagnostics.

(1) Service port. (Remove the cap.)

1. Connect the 7X-1570 Cable to the service port (1) which is the 9-pin, gray plastic, Deutsch® connector located on the front of the seat on the drivers right hand side. 2. Either start the engine or turn the Start/Stop Key Switch to the Run position. 3. At this point the first ECAP screen will appear entitled "Electronic Control Programmer Analyzer". Select "Machine Functions" and press Return in order to direct ECAP to the next screen entitled "Machine ECM Selection" screen.

Electronic Control Analyzer Programmer Screen

4. From the "Machine ECM Selection" screen select "Transmission Control" and press Return to obtain the "Transmission Functions" screen. At this point the ECAP has been directed to communicate with the transmission ECM. See SEHS9343, Using The ECAP NEXG4521 Machine Functions Service Program Module, for further instructions regarding Steps 3 and 4 of this procedure.

Machine ECM Selection Screen

5. Select either Item 1 to read or change parameters, Item 2 for Current Status of the transmission or Item 3 for transmission Diagnostics and press Return.

Transmission Functions Screen

Read/Change Parameters Screen

6. If Item 1 was selected in Step 5, then the "Read/Change Parameters" screen will be displayed. From this screen two choices are available: Item 1 for reading or changing parameters. Item 2 for printing parameters.

Read/Change Parameters Screen

7. If Item 1 was selected in Step 6, then another "Read/Change Parameters" screen will be displayed. From this screen two parameters can be programmed. "The Vehicle ID" is the first option. This input field is provided strictly for customer use and does not have any other function.

The "Transmission Configuration Code" is the second option. This is a critical parameter without which the machine will NOT operate (see Chart 4). The "Total Tattletale" field is not programmable. This field indicates how many times any of the parameters in the list have been changed.

Print All Parameters Screen

8. If Item 2 was selected in Step 6, the "Print All Parameters" screen will be displayed. The transmission parameters will print to the local printer if connected.

Display Status - Screen 1

Display Status - Screen 2

9. If Item 2 was selected in Step 5, then Status Screen # 1 will appear. The other status screen can be obtained by using the up and down arrows or by selecting a screen number and pressing Return. From the status screens all of the status items listed can be observed while the machine is operating.

* Gear Lever - This is a 13 wire input which provides the shift lever position to the ECM. This shows the position of the shift lever. Positions are Neutral, First Forward through Eighth Forward, First Reverse through Sixth Reverse and Park. * Modulator Supply Pressure - This shows the value of the modulation supply pressure switch as read by the control.

On: The directional clutches have pressure. Off: The directional clutches so not have pressure. * Ignition Switch - This is a single wire input that provides a battery voltage signal when turned in the Start position.

Run: Key is in the normal run position. Start: Key is in the crank position (only active when the operator is trying to start the machine). * Transmission Output Speed - This is a single wire frequency input which receives a signal from a magnetic pickup speed sensor on the transmission output. It shows revolutions per minute on the output shaft of the transmission. * Gear - This shows the actual gear that the transmission ECM is engaging. Most of the time it will be the same as selected with the gear lever. * Dual Horsepower Mode - This shows the state of the dual horsepower solenoid (also referred to as VHP). It is engaged in Fourth through Eighth Forward and Fourth through Sixth Reverse or when the all wheel drive system is engaged. This status is only meaningful on motor graders that are equipped with the dual horsepower solenoid.

Normal: Solenoid is Off. High: Solenoid is On. * Transmission Lamp - This is used in conjunction with the diagnostic connector to visually flash light code sequences when diagnosing transmission electrical system faults. On: Transmission lamp is illuminated. Off: Transmission lamp is not illuminated. * Backup Alarm - When the transmission shift lever is Moved to a Reverse speed, the ECM provides power for the backup alarm.

On: The backup alarm is On. Off: The backup alarm is Off.

* Battery Volt - This is a two wire input which provides 24 DCV nominal to drive the electronic circuits within the ECM and all of the external solenoids. It indicates the voltage the control measures between Pins J1-1 and J1-2 at the transmission ECM connector.

Display Diagnostics Screen

Display Diagnostics Screen

10. If Item 3 was selected in Step 5, then "Display Diagnostics" screen will appear. Select either Item 1 for Display/Clear Diagnostics or Item 2 for Display/Clear Events and press Return. 11. If Item 1 was selected, then another screen which is also entitled "Display Diagnostics" will be displayed. Any of the diagnostic codes can be listed in this screen depending on the operating condition of the machine. From this screen the can find: * The number and type of faults which have occurred * When the particular fault first occurred * When the fault last occurred * Whether the fault is currently active

Faults which are not currently active may be cleared. Chart 3 provides a complete list of the Transmission Diagnostic Codes. To clear faults, follow the steps listed: a. Use the arrow up or down to highlight the fault to be cleared. b. Press Return. c. You will be asked to confirm that you really want to clear this fault. Answer Yes or No. Active faults may not be cleared until the problem causing the fault has been corrected.

Display Events Screen

12. If Item 2 was selected in Step 10, then a screen which is entitled "Display Events" will be displayed. Either of the two events listed below could be displayed here: * Coasting in Neutral warning - When the transmission control lever is in neutral with the transmission modulator pedal released with a ground speed greater than 23 km/h (14 mph). * Machine driven with parking brake on - When the transmission control lever is in Park with a ground speed greater than 3 km/h (1.8 mph).

From this screen the can find: * The number and type of events which have occurred * When the particular event first occurred * When the event last occurred

To clear events, follow the steps listed: a. Use the arrow up or down to highlight the event to be cleared.

b. Press Return. c. You will be asked to confirm that you really want to clear this event. Answer Yes or No. 13. To remove the ECAP from use, disconnect 7X-1570 Cable from the service port.

Obtaining Transmission DiagnosticsFrom The Transmission ECM Without The Use Of An ECAP From the transmission ECM the diagnostic codes can be obtained and cleared (if not active) without the use of the ECAP. The following process will entail disconnecting a transmission wiring harness and jumpering specific wires in order to prompt the transmission ECM to display coded messages to the transmission indicator lamp (1) on the EMS .

(1) Transmission indicator lamp.

NOTICE While using this procedure to retrieve transmission diagnostics from the transmission ECM, the machine must be parked with parking brake Applied.

This process is not as easy to use as the ECAP nor is the capability as complete. This capability has been provided for the who does not have ready access to an ECAP. Follow the steps to obtain transmission diagnostics from the ECM.

NOTE: The preceding chart has changed from the former issue.

(2) Diagnostic plug. (3) ECM.

1. The transmission ECM (3) and the diagnostic plug are under the right side of the cab. 2. Locate the transmission indicator lamp (1) located in front of the steering wheel. 3. Place the Start/Stop Key Switch in the Run position with engine off. When the machine Start/Stop Key Switch is turned to the ON position, the machine will display the Transmission Configuration Code as part of normal operation. For example, when the Start/Stop Key of a 140H is turned to ON, a "41" code will be displayed on the EMS transmission indicator lamp (1). The lamp will flash four times in rapid succession followed with a one second pause followed by one additional flash. 4. To enter the Diagnostic Mode of the transmission ECM, uncouple the diagnostic plug (2). At this point the ECM automatically defaults to the Active Diagnostic Mode. In the Active Diagnostic Mode the ECM will flash out the first Active Fault in memory followed by a three second pause and then repeating the original fault. The original fault will continue to be repeated until the diagnostic plug (2) is reconnected. 5. To enter the Active Diagnostic Scroll Mode, jumper sockets 1 and 2 of the diagnostic receptacle of the diagnostic plug (2). The control will display all diagnostics that are presently active on the system. A three second pause separates the codes as they are displayed. Removing the jumper while the control is displaying a diagnostic code will cause the control to repeatedly display that code. Replacing the jumper resumes scrolling. 6. To enter the Logged Diagnostic Scroll Mode, jumper sockets 1 and 3 of the diagnostic receptacle. The ECM will now display any faults which have occurred which are not presently active. A Diagnostic Code of "12" indicates there are no Logged Faults present. Removing the jumper wire while the control is displaying a

Diagnostic Code will cause the control to repeatedly display that code. Replacing the 1 to 3 jumper resumes scrolling. 7. This mode is used to clear Logged Diagnostics from memory. To erase a code, put the control in the Logged Diagnostic Scroll Mode until the desired code is displayed and then remove the jumper. The ECM will continue to display the desired code. Jumper receptacle socket 1 to 4. The transmission indicator lamp (1) will turn off indicating the code has been erased. The lamp will remain off until either the Logged Diagnostic Scroll Mode or the Active Diagnostic Scroll Mode is re-entered. The above process can be repeated until there are no codes stored in memory. An active diagnostic code cannot be erased from memory. 8. Reconnect diagnostic plug (2) to the receptacle when servicing is complete. Transmission indicator lamp (1) will stop flashing.

Programming The Transmission ECM Transmission Configuration Code Without An ECAP

(1) Transmission indicator lamp.

(2) Diagnostic plug. (3) ECM.

1. The transmission ECM (3) and the diagnostic plug are under the right side of the cab. 2. Locate the transmission indicator lamp (1) located in front of the steering wheel. 3. Place the Start/Stop Key Switch in the Run position with engine off. 4. Uncouple the diagnostic plug (2). 5. Determine the right transmission configuration code from Chart 4 for the model of motor grader the control is installed on. (For illustration purposes, assume that the model is a 140H. Therefore the transmission configuration code would be "41". 6. Jumper Sockets 1,2 and 3 on the diagnostic receptacle. Place the transmission control lever in the Forward gear which corresponds to the first digit of the desired transmission configuration code. For this example, place the transmission control lever in Fourth Forward. Wait until the transmission indicator lamp (1) flashes out this digit. Place the transmission control lever in the neutral position. Remove jumpers completely out of the diagnostic receptacle. The first digit is programmed. 7. Jumper Sockets 1, 2 and 4 on the diagnostic receptacle. Place the transmission control lever in the Forward gear which corresponds to the second digit of the desired transmission configuration code. For this example, place the transmission control lever in First Forward. Wait until the transmission indicator lamp (1) flashes out this digit. Place the transmission control lever in the neutral position. Remove jumpers completely out of the diagnostic receptacle. The second digit is programmed. 8. Replace the diagnostic receptacle. Turn the Start/Stop Key Switch to the OFF position. 9. Turn the Start/Stop Key Switch to the ON position. Watch the transmission indicator lamp (1). Make sure that it flashes out the desired transmission configuration code. In our example, you should see a "41" flash code displayed on power up.

Troubleshooting Troubleshooting Without An ECAP Or ECM Diagnostics Operate the machine in each direction and in all speeds. Note the noises that are not normal and find their source. If the operation is not correct, refer to the following problems and procedures.

The following procedure has been designed without the benefit of using diagnostics from the transmission ECM. However, using an ECAP in combination with this troubleshooting guide should improve the efficiency in resolving the problem. Problem: Motor Grader Will Not Key Start/Stop Corrective Procedure: 1. Check the transmission control fuse (10 amp) located in fuse at the base of the steering console. Replace if necessary. 2. Remove the transmission ECM from under the cab and disconnect the 40-pin Deutch® connectors. Measure voltage between Pins J1-1 and J1-2. 3. If the voltage measured in Step 2 is above 20 DCV, the transmission ECM is inoperative. If some voltage is measured and the voltage is less the 20 DCV, the batteries are undercharged. If no voltage was measured in Step 2, proceed to Step 4. 4. Check Pin J1-1 of the 40 pin Deutch® connector to determine the voltage between the pin and frame. If Pin J1-1 has voltage, repair 202 Black ground wire in machine harness. If Pin J1-1 does not have voltage, repair 126 Pink wire in machine harness. Problem: "First Gear Out Of Neutral" Only Working Gear Corrective Procedure: 1. Start engine and operate the machine in order to determine which gears are operable. 2. Stop the machine, engage the parking brake and turn off the engine. 3. Jumper the manual modulation pressure switch in order to determine if this pressure switch is working. The manual modulation pressure switch is located on the Hydraulic Clutch Modulation Control (HCM). Disconnect the 2 pin connector and jumper Pins 1 and 2 of the receptacle.

4. Start the machine and attempt to operate the machine in all gears. If the machine has more than one gear out of neutral then the manual modulation pressure switch has failed. If the first gear out of neutral is still the only gear available, proceed to Step 5. 5. From Step 4, the wiring harness between the manual modulation pressure switch and the transmission ECM is suspect. Remove the transmission ECM from under the cab and disconnect both 40 pin Deutch® connectors. Check continuity between Pins J1-2 and J2-11 of the machine harness. If continuity is obtained while the jumper is in place, the transmission ECM has failed. If continuity is not obtained, the wiring harness between the transmission ECM and the manual modulation pressure switch has failed.

Troubleshooting Faults Detected By The ECM NOTE: The transmission solenoids are identified with letters (A through H) in this publication. The solenoids may also be identified with numbers (1 through 8). Solenoid 1 is Solenoid A, Solenoid 2 is Solenoid B, etc. NOTE: P is used as an abbreviation for Pin. Example: P3 is Pin 3. NOTE: When Harness with a letter (example: Harness F) is used, the Harness F can be identified on the electrical schematic. NOTE: The transmission ECM is seldom the cause of a problem. If the "Troubleshooting With An ECAP" guide directs you to replace the ECM, then double check your steps to be sure that no mistake was made before replacing the ECM.

Detected Faults

Troubleshooting Detected Faults Use the following charts to troubleshoot the faults identified in Chart 5.

Flash Codes: 21-28, CID-FMI: 641-648 F05, Transmission Solenoid Open Circuit

Flash Codes: 31-38, CID-FMI: 641-648 F06, Transmission Solenoid Short To Ground

Flash Codes: 41-48, CID-FMI: 641-648 F03, Transmission Solenoid Short To Battery

Flash Code: 52, CID-FMI: 637 F06, Backup Alarm Short To Ground

Flash Code: 58, CID-FMI: 688 F06, VHP Solenoid Short To Ground

Flash Code: 59, CID-FMI: 688 F03, VHP Solenoid Short To Battery

Flash Code: 61, CID-FMI: 668 F02, Shift Lever Input Invalid

Flash Code: 62, CID-FMI: 668 F03, Shift Lever Open Circuit/Short To +Battery

Flash Code: 65, CID-FMI: 701 F02, Transmission Output Speed Signal Incorrect

Flash Code: 68, CID-FMI: 168 F01, System (+Battery) Voltage Below Normal

Flash Code: 71, CID-FMI: 520 F02, Invalid Transmission Configuration Code; Flash Code:

72, CID-FMI: 268 F02, Check Programmable Parameters

Flash Code: 73, CID-FMI: 764 F05, Transmission Indicator Lamp Open Circuit

Flash Code: 74, CID-FMI: 764 F06, Transmission Indicator Lamp Short To Ground

Flash Code: 75, CID-FMI: 764 F03, Transmission Indicator Lamp Short To Battery

Flash Code: 76, CID-FMI: 177 F03, Transmission Oil Temperature Sensor short to Battery or Open Circuit

Flash Code: 77, CID-FMI: 177 F04, Transmission Oil Temperature Sensor short to Ground

Flash Code: 81, CID-FMI: 868 F05, Auto/Manual Lamp Open Circuit

Flash Code: 82, CID-FMI: 868 F06, Auto/Manual Lamp Short to Ground

Flash Code: 83, CID-FMI: 868 F03, Auto/Manual Lamp Short to Battery

Sensor Signal Voltage Test

Schematic

Usage: 120H 124 12H 125 140H 126 143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H 5FM 140H 5HM 120H 6TM 120H NA 6YN 135H 7MM 140H 8JM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN 120H ALZ 135H AMX 12H AMZ 140H APM 143H APN 163H ARL 160H ASD 135H BDJ 120HCAF 135H CBC 12H CBK 140H CCA 160H C

140H XZH 12H XZJ 160H XZK



Before you begin the test, refer to Systems Operation, Testing and Adjusting, "Machine Preparation for Troubleshooting".

Table 1 Required Tools Part Number

Description

Quantity

1U-5481

Pressure Gauge Group

1

1U-5482


1

Table 2 Transmission Lubrication Pressure (Minimum) Neutral LOW Idle

HIGH Idle

First Gear Forward

28 kPa (4 psi)

7 kPa (1 psi)

345 kPa (50 psi)

207 kPa (30 psi) Table 3

Transmission Lubrication Pressure Differential Lock in the ON Position Neutral

First Gear Forward

LOW Idle HIGH Idle Transmission Lubrication Pressure Differential Lock in the OFF Position Neutral

First Gear Forward

LOW Idle HIGH Idle 1.

Operate the machine until the transmission oil is at operating temperature of 51 °C (124 °F).

2.

Stop the machine on a hard level surface. Engage the parking brake. Turn the engine OFF.

Illustration 1

Rear of the machine (1) Fitting (Test)

3.

Remove the plug from the transmission case. Install 6V-3965 Fitting (Test) (1) into the port. Attach the 8T-0846 Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) to fitting (1) . Remove the drive shaft.

4.

Start the engine. Turn the differential lock to the ON position. Operate the machine in the NEUTRAL position at low idle. The pressure on the gauge should be a minimum of 28 kPa (4 psi). Record the gauge reading in Table 4.

5.

Operate the machine in the NEUTRAL position at high idle. The pressure on the gauge should be a minimum of 340 kPa (50 psi). Record the gauge reading in Table 4.

6.

Operate the machine in FIRST GEAR FORWARD at low idle. The gauge pressure should be a minimum of 7 kPa (1 psi). Record the gauge reading in Table 4.

7.

Operate the machine in FIRST GEAR FORWARD at high idle. The gauge pressure should be a minimum 207 kPa (30 psi). Record the gauge reading in Table 4.

8.

Repeat Step 4 through Step 7 with the differential lock in the OFF position. Pressures from the transmission lubrication that vary with the differential lock in the ON position indicate leakage in the differential lock system.

9.

Stop the machine. Turn the engine OFFand install the differential drive shaft. Remove the test equipment.

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Usage: 143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 120H 6TM 120H NA 6YN 135H 7MM 140H 8JM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN 135H BDJ 140H XZH 12H XZJ 160H XZK


Personal injury can result from spring force released when removing cap screws. Internal spring force will be released when cylinder assembly cap screws are removed causing injury. Always restrain cover as cap screws are loosened. Follow the established procedure in the Service Manual to service these parts.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1.

Stop the machine. Engage the parking brake and turn off the engine.

Illustration 1

(1) Transmission control valve (2) Guard

2.

Remove guard (2) from transmission control valve (1) . This will provide access to the control.

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Illustration 2

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Pressure Tap Port (3) Caps

3.

Put blocks in front of the wheels and behind the wheels of the machine. Remove the differential drive shaft.

4.

Remove caps (3) and install 6000 kPa (870 psi) pressure gauges on pressure tap (D) and pressure tap (G) .

5.

Operate the engine at low idle either in the PARK position or NEUTRAL position. Record the gauge pressures. Pressure tap (D) is clutch 8 and pressure tap (G) is clutch 5. Remove the pressure gauges and replace caps (3) .

6.

Remove caps (3) and install 6000 kPa (870 psi) pressure gauges on the pressure tap (B) , pressure tap (F) and pressure tap (H) .

7.

Operate the engine at low idle in FIRST GEAR FORWARD. Record the gauge pressures. Pressure tap (B) is clutch 1. Pressure tap (F) is clutch 6 and pressure tap (H) is clutch 7. Remove the pressure gauges and replace caps (3) .

8.

Remove caps (3) and install 6000 kPa (870 psi) pressure gauges on pressure tap (C) and pressure tap (E) .

9.

Operate the engine at low idle in SECOND GEAR FORWARD. Record the gauge pressure. Pressure tap (C) is clutch 2 and pressure tap (E) is clutch 4. Remove the pressure gauges and replace caps (3) .

10. Remove cap (3) and install a 6000 kPa (870 psi) pressure gauge on the pressure tap (A) . 11. Operate the engine at low idle in the FIRST GEAR REVERSE position. Record the gauge pressure. Pressure tap (A) is clutch 3. Remove the pressure gauges and replace cap (3) . 12. Refer to Table 2 for the correct pressures. If an adjustment is needed, refer to Systems Operation, Testing and Adjusting, "Initial Pressures - Test and Adjust". Table 1 Test port A-3

B-1

Minimum Pressure

(1)

Maximum Pressure

2145 kPa (311 psi)

2365 kPa (343 psi)

2080 kPa (302 psi)

2275 kPa (330 psi)

(1)

C-2

D-8

E-4

F-6

G-5

H-7 (1)

2255 kPa (327 psi)

2445 kPa (355 psi)

2570 kPa (373 psi)

2765 kPa (401 psi)

1855 kPa (269 psi)

2075 kPa (301 psi)

2580 kPa (374 psi)

2760 kPa (400 psi)

2710 kPa (393 psi)

2875 kPa (417 psi)

2525 kPa (366 psi)

2815 kPa (408 psi)

All pressures are taken at low idle and at 51° C (123° F).

Table 2 Test port

Minimum Pressure

Maximum Pressure

A-3 B-1 C-2 D-8 E-4 F-6 G-5 H-7 13. Stop the engine. Install the differential drive shaft and engage the parking brake. Replace all the covers and the guards.

Usage: 143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 120H 6TM 120H NA 6YN 135H 7MM 140H 8JM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN 135H BDJ 140H XZH 12H XZJ 160H XZK

Table 1 Tools Needed Qty

Part Number

Description

1

139-7050

Cover Plate

1

1U-5482


1

1U-5481


1

8T-0856

Pressure Gauge (0 to 6,000 kPa (0 to 870 psi)) Table 2 Initial Pressures

Test Port A-3

B-1

C-2

D-8

Pressure

(1)

380 ± 20 kPa (55 ± 3 psi)

375 ± 20 kPa (54 ± 3 psi)

405 ± 20 kPa (59 ± 3 psi)

335 ± 20 kPa (49 ± 3 psi)

E-4

380 ± 20 kPa (55 ± 3 psi)

F-6

360 ± 20 kPa (52 ± 3 psi)

G-5

385 ± 20 kPa (56 ± 3 psi)

H-7 (1)

340 ± 15 kPa (49 ± 2 psi)

All pressures are taken at 2000 RPM and 51° C (123° F).

Table 3 Initial Pressures Test Port

Pressure

A-3 B-1 C-2 D-8 E-4 F-6 G-5 H-7 Table 4 Test Port A-3

Change in pressure for one 5J1036 Shim

88 kPa (12.8 psi)

Change in pressure for one 4M 1751 Spacer

44 kPa (6.4 psi)

B-1

C-2

D-8

E-4

F-6

G-5

H-7 1.

88 kPa (12.8 psi)

44 kPa (6.4 psi)

94 kPa (13.6 psi)

47 kPa (6.8 psi)

111 kPa (16 psi)

55 kPa (8.0 psi)

77 kPa (11.2 psi)

39 kPa (5.6 psi)

111 kPa (16 psi)

55 kPa (8.0 psi)

116 kPa (16.9 psi)

58 kPa (8.4 psi)

61 kPa (8.8 psi)

30 kPa (4.4 psi)

Stop the machine. Engage the parking brake. Stop the engine.

Illustration 1

(1) Transmission control valve (2) Guard

2.

Remove guard (2) from transmission control valve (1) in order to provide access to the control.

3.

Put blocks in front of the wheels and behind the wheels of the machine. Remove the differential drive shaft.

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Illustration 2

Transmission Control Valve (3) Wiring harness (4) Bolts

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(5) Cover (6) Bolt (7) Caps

4.

Remove fourteen mounting bolts (4) that are used to retain cover (5). The top three bolts can not be removed without removing the entire valve. These bolts should just be loosened. Remove bolt (7) from the transmission control valve.

5.

Slide the 139-7050 Cover Plate under cover (5). The U-shaped slots should be facing upward so that the bolt holes line up with the holes in the plate.

6.

Tighten bolts (4) and bolt (6). Refer to Specifications, "Transmission Control Valve" for the correct torque.

Illustration 3

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(8) 4M-1751 Spacer and 5J-1036 Shim (9) Adjuster assembly (10) Manifold (11) Locknut (12) Adjustment screw

7.

Remove caps (7). Install the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) on taps (D) and (G) .

8.

Operate the engine at high idle in NEUTRAL. Record the pressures. Pressure tap (D) is clutch 8 and pressure tap (G) is clutch 5. Remove the pressure gauges and replace the caps (7) .

9.

Remove caps (7) and install the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) on pressure tap (B), pressure tap (F) and pressure tap (H) .

10. Operate the engine at high idle in the FIRST GEAR FORWARD position. Record the gauge pressures. Pressure tap (B) is clutch 1. Pressure tap (F) is clutch 6 and pressure tap (H) is clutch 7. Remove the pressure gauges and replace caps (7) . 11. Remove caps (7) and install the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) on pressure tap (C) and pressure tap (E) . 12. Operate the engine at high idle in the SECOND GEAR FORWARD position. Record the gauge pressures. Pressure tap (C) is clutch 2 and pressure tap (E) is clutch 4. Remove the pressure gauges and replace caps (7) . 13. Remove caps (7) and install a 8T-0856 Pressure Gauge (0 to 6,000 kPa (0 to 870 psi)) pressure gauge on pressure tap (A) . 14. Operate the engine at high idle in the FIRST GEAR REVERSE position. Record the gauge pressures. Pressure tap (A) is clutch 3. Remove the pressure gauges and replace caps (7) . 15. Refer to Table 2 for the correct pressures. If an adjustment is needed, follow Step 16 and Step 17. 16. If the pressures do not agree with the pressures that are listed in Table 2, use the following procedure to adjust the pressures. i.

Loosen locknut (11) on adjuster assembly (9) .

i.

While you monitor the pressure, adjust the pressure by turning adjustment screw (10). To lower the pressure, turn the adjustment screw clockwise. One turn of the adjustment screw will change the pressure approximately 132 kPa (19 psi).

i.

Tighten locknut (11). Refer to Specifications, "Selector and Pressure Control Valve" for the correct torque. For all clutches except clutch (D) and clutch (G), shift the transmission to the NEUTRAL position for a minimum of 15 seconds. Then, shift the transmission back to the gear that is specified in Step 7 through Step 15. For clutch (D) and clutch (G), shift the transmission to the FIRST GEAR FORWARD for a minimum of 15 seconds and then shift the transmission back to

NEUTRAL. Make sure that the pressures agree with the pressures that are listed in Table 2. i.

If the pressure cannot be adjusted to the acceptable limits with adjustment screw (10), stop the engine and remove manifold (12). This will allow you to access the selector spool. Remove the selector spool. Add shims and spacers or remove shims and spacers, as required.

i.

Install the manifold. Adjust the initial pressure according to the procedure that is listed in Steps 16.a through 16.c.

17. Continue the procedure until all the stations (pressure taps) are checked and adjusted. 18. Stop the engine. Remove the 139-7050 Cover Plate . 19. Use new 9P-9150 Washers and install the transmission control valve on the transmission. Tighten bolts (4). Refer to Specifications, "Transmission Control Valve" for the correct torque. 20. To the clutch pressures, refer to System Operation, Testing and Adjusting, "Transmission Pressures - Test". 21. Install the guards and the differential drive shaft.

Note: This procedure should be followed whenever a transmission control valve is repaired by replacing any of the springs or any of the spools that are contained within the individual clutch stations. Note: If the transmission clutch pressure is out of the tolerance range, the most likely cause of the failure will be a failed modulation spring, debris in the control valve or a seal failure within the transmission.

Usage: 143H 1AL 143H 1AL 160H 2FM 160H 2FM 12H ES 2GS 12H ES 2GS 160H ES 2HS 160H ES2HS 12H ES 2LR 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES3AS 140H ES 3AS 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H NA 3YK 12H 4ER 12H4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H NA 4XM 163H NA 5AK 163H NA 5AK 120H5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 12H 5ZM 120H ES 6NM 120H ES 6NM 120H6TM 120H 6TM 160H ES 6WM 160H ES 6WM 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H ES 8KM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN 135H 8WN 160H NA 9EJ



Before you begin the test, refer to Troubleshooting, "Machine Preparation for Troubleshooting". Table 1 Required Tools Part Number

Description

Quantity

1U-5481


1

1U-5482


1

Table 2 Transmission Lubrication Pressure

Neutral LOW Idle

HIGH Idle

First Gear Forward

80 ± 30 kPa (12 ± 4 psi)

Minimum 7 kPa (1 psi)

558 ± 55 kPa (80 ± 8 psi)

241 ± 27 kPa (35 ± 4 psi) Table 3

Transmission Lubrication Pressure Differential Lock in the ON Position Neutral

First Gear Forward

LOW Idle HIGH Idle Transmission Lubrication Pressure Differential Lock in the OFF Position Neutral

First Gear Forward

LOW Idle HIGH Idle 1.

Operate the machine until the transmission oil is at operating temperature of 52° ± 3°C (125° ± 5°F).

2.

Stop the machine on a hard level surface. Engage the parking brake. Turn the engine OFF.

Illustration 1

Rear of the transmission (1) Test port

3.

Remove the plugin test port (1) from the transmission case. Install 6V-3965 Fitting (Quick Disconnect) into test port (1). Attach the 8T-0846 Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) to fitting (1). Remove the differential drive shaft.

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4.

Start the engine. Turn the differential lock to the ON position. Operate the machine in the NEUTRAL position at low idle. The pressure on the gauge should be a minimum of 50 kPa (7 psi). Record the gauge reading in Table 3.

5.

Operate the machine in the NEUTRAL position at high idle. The pressure on the gauge should be a minimum of 500 kPa (72 psi). Record the gauge reading in Table 3.

6.

Operate the machine in FIRST GEAR FORWARD at low idle. The gauge pressure should be a minimum of 7 kPa (1 psi). Record the gauge reading in Table 3.

7.

Operate the machine in FIRST GEAR FORWARD at high idle. The gauge pressure should be a minimum 215 kPa (31 psi). Record the gauge reading in Table 3.

8.

Repeat Step 4 through Step 7 with the differential lock in the OFF position. Transmission oil pressures that vary with the differential lock in the ON position indicate leakage in the differential lock system.

9.

Stop the machine. Turn the engine OFF and install the differential drive shaft. Remove the test equipment. Install 5P-4483 Plug back into test port (1) with a torque of 35 ± 3 N·m (26 ± 2 lb ft).

Usage: 12H ES 2GS 12H ES 2GS 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 12H 4ER 12H 4ER 12H NA 4XM 12H NA 4XM 140H 5HM 140H5HM 12H 5ZM 140H 8JM 140H 8JM 140H ES 8KM 12H NA 8MN 12H NA 8MN 140H NA 9TN 140H NA 9TN 140H NA 9ZN 140H NA 9ZN

Illustration 1

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(1) 6Y-2300 Input Shaft Group (2) 6Y-2301 Transmission Clutch (Forward) (3) 6Y-2302 Transmission Clutch (Reverse and Second) (4) 6Y-2303 Transmission Clutch (First Gear and Third Gear) (5) 8E-9316 Transmission Clutch (High Gear and Low Gear)

Illustration 2

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Section A-A

6Y-2300 Input Shaft Group

Illustration 3

(A) ... 1.02 ± 0.99 mm (.040 ± .039 inch) (B) ... 5.75 ± 0.25 mm (.226 ± .010 inch)

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6Y-2301 Transmission Clutch (Forward)

Illustration 4

(1) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch)

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Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number one clutch pack (Forward Low Gear) ... 3.03 ± .5 mm (0.1193 ± 0.020 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 108-5751 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Install 108-5751 Friction Disc into the clutch pack so that the grooved pattern faces toward the center of the clutch pack. One of the friction discs is located at the front of the clutch pack and one of the friction discs is located at the rear of the clutch pack. Minimum allowable thickness for reusability ... 3.67 mm (.144 inch) Thickness of one new 6I-8911 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 9U-9995 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (2) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number two clutch pack (Forward High Gear) ... 1.65 ± .64 mm (0.065 ± 0.025 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(3) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch) (4) 9U-8815 Spring Test length ... 41.03 mm (1.615 inch) Test force ... 459.6 ± 36.8 N (103.27 ± 8.26 lb) Free length after test ... 150.6 mm (5.93 inch) Outside diameter ... 106.0 mm (4.17 inch)

(5) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch)

Illustration 5

Detail A

(B) Install 5H-8985 Spring Pin (6) in 6Y-1119 Seal Carrier (7) with 6.5 mm (.26 inch) maximum protruding out of the carrier.

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6Y-2302 Transmission Clutch (Reverse and Second)

Illustration 6

(1) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch)

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Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number three clutch pack (Reverse Gear) ... 1.65 ± .64 mm (0.065 ± 0.025 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (1.570 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (2) Thickness of four new friction discs and of three new plates ... 25.00 ± 0.56 mm (.984 ± .020 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of four new friction discs and three new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number four clutch pack (Second Gear) ... 1.15 ± .53 mm (0.045 ± 0.021 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (3) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch) (4) 9U-8815 Spring Test length ... 41.03 mm (1.615 inch) Test force ... 459.6 ± 36.8 N (103.27 ± 8.26 lb) Free length after test ... 150.6 mm (5.93 inch)

Outside diameter ... 106.0 mm (4.17 inch)

(5) 102-5881 Wave Spring Test length ... 38.20 mm (1.503 inch) Test force ... 2090 ± 222 N (470 ± 50 lb) Free length after test ... 50.0 mm (1.97 inch) Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)

Illustration 7

Detail A

(C) Install 5H-8985 Spring Pin (8) in 6Y-1119 Seal Carrier (7) with 6.5 mm (.26 inch) maximum protruding out of the carrier.

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Illustration 8

Detail B

(D) Installation depth for 6Y-1895 Sleeve Bearing (6) in 6Y-3854 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch) Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch) Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

6Y-2303 Transmission Clutch (First Gear and Third Gear)

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Illustration 9

(1) Thickness of six new friction discs and of five new plates ... 39.00 ± 0.88 mm (1.535 ± .035 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of six new friction discs and five new plates. This dimension does not include the running clearance of the clutch pack.

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Running clearance for number six clutch pack (First Gear) ... 1.91 ± .62 mm (0.075 ± 0.024 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (2) Thickness of four new friction discs and of three new plates ... 25.00 ± 0.56 mm (.984 ± .022 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of four new friction discs and three new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number five clutch pack (Third Gear) ... 1.15 ± .53 mm (0.045 ± 0.021 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (4) Torque for two bolts ... 55 ± 10 N·m (41 ± 7 lb ft) (7) 102-5881 Wave Spring Test length ... 38.2 mm (1.50 inch) Test force ... 2090 ± 222 N (470 ± 50 lb) Free length after test ... 50.0 mm (1.97 inch) Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)

Illustration 10

Detail A

(D) Install 5H-8985 Spring Pin (6) in 6Y-2425 Seal Carrier (5) with 6.5 mm (.26 inch) maximum protruding out of the carrier.

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Illustration 11

Detail B

(E) Installation depth for 6Y-2419 Sleeve Bearing (3) in 6Y-3857 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch) Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch) Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

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Illustration 12

Detail C

(F) Installation depth for 6Y-1895 Sleeve Bearing (8) in 6Y-3856 Gear Assembly (10) ... 0.5 ± 0.5 mm (.02 ± .02 inch) Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch) Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

8E-9316 Transmission Clutch (High Gear and Low Gear)

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Illustration 13

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(1) Thickness of seven new friction discs and of eight new plates ... 52.56 ± 1.34 mm (2.069 ± .053 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of seven new friction discs and of eight new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number seven clutch pack (Low Gear) ... 4.27 ± .52 mm (0.168 ± 0.021 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6Y-7981 Friction Disc ... 4.32 ± 0.10 mm (.170 ± .004 inch) Minimum allowable thickness for reusability ... 3.65 mm (.144 inch) Thickness of one new 3P-0337 Plate ... 2.79 ± 0.08 mm (.109 ± .003 inch) (2) Thickness of six new friction discs and of five new plates ... 39.00 ± 0.88 mm (1.530 ± .035 inch) Note: The measurement must be made when the friction discs and the plates are compressed. Note: This dimension is only the thickness of six new friction discs and five new plates. This dimension does not include the running clearance of the clutch pack. Running clearance for number eight clutch pack (High Gear) ... 1.91 ± .62 mm (0.075 ± 0.024 inch) Note: Refer to the procedure: Procedure to Measure Running Clearance Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch) Minimum allowable thickness for reusability ... 3.33 mm (.131 inch) Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch) (4) 8M-4295 Spring Test length ... 26.9 mm (1.06 inch)

Test force ... 74 ± 6 N (16 ± 1 lb) Free length after test ... 44.0 mm (1.75 inch) Outside diameter ... 15.2 mm (.60 inch)

(5) 102-5881 Wave Spring Test length ... 38.2 mm (1.50 inch) Test force ... 2090 ± 222 N (470 ± 50 lb) Free length after test ... 50.0 mm (1.97 inch) Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)

(7) Torque for two bolts ... 55 ± 10 N·m (40 ± 7 lb ft)

Illustration 14

Detail A

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(D) Install 5H-8985 Spring Pin (8) in 6Y-2425 Seal Carrier (6) with 6.5 mm (.26 inch) maximum protruding out of the carrier.

Illustration 15

View (B)

(E) Installation depth for 9W-6467 Sleeve Bearings (3) in 8E-1158 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch) Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch) Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

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Illustration 16

Detail C

(F) (G) Installation depth for 9W-6467 Sleeve Bearings (10) in 8E-1159 Gear Assembly (11) ... 0.5 ± 0.5 mm (.02 ± .02 inch) Inside diameter of bearing after assembly ... 69.925 ± 0.039 (2.7529 ± .0015 inch) Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

Procedure to Measure Running Clearance

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Illustration 17

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Typical Example

Use this procedure in order to check for proper clutch assembly. Note: Do not use a puller to remove rotor (7) from the clutch assembly. Remove the following components from the clutch group: bearing (1), disc (2), gear assembly (3), ring (4), gear assembly (5), disc (6), rotor (7), race and bearing (8) and carrier (9).

Illustration 18

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1.

2. 3.

Position the assembled clutch group with the shaft in the vertical position. Position the hub assembly of the clutch that is being measured so that the hub assembly faces upward. Make sure that hub assembly (10) moves freely. Position the tip of a dial indicator on the side of the clutch pack of the transmission at location (B). Zero the indicator.

Personal injury can result from applying air pressure without the lock ring securely in place. Make sure the lock ring (11) is securely in place before applying air pressure to the clutch pack.

4.

To check the running clearance for the clutch packs, apply approximately 140 kPa (20 psi) air pressure to age (14) for clutch pack (12) .

5.

Piston (13) and the clutch pack (12) should move up. Determine the distance that the piston and the clutch pack has moved from the dial indicator. This is the running clearance for the clutch pack.

Note: Use this same procedure in order to determine the running clearances for the clutch pack for the existing clutch assemblies.


Components

Illustration 1

The end view of the transmission for the shaft location (1) Forward shaft

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(2) Input shaft (3) Shaft assembly (4) Shaft assembly (5) Shaft assembly

Illustration 2

(1) Forward shaft (2) Input shaft (3) Shaft assembly (4) Shaft assembly (5) High/Low shaft (6) Gear (7) Gear (8) Cover (9) Gear (10) Gear (11) No. 2 clutch (12) Gear (13) Gear (14) No. 3 clutch (15) Gear (16) No. 5 clutch (17) Gear (18) Gear (19) No. 7 clutch (20) Output yoke (21) Parking brake

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(22) Drain (23) Transmission case (24) No. 8 clutch (25) Hub (26) Gear (27) Gear (28) No. 6 clutch (29) Gear (30) Gear (31) High/Low shaft (32) No. 4 clutch (33) Drain (34) No. 1 clutch (35) Gear

First Forward Gear with Engaged Clutches (No. 1, No. 6 and No. 7)

Illustration 3

(1) Forward shaft (2) Input shaft (3) Shaft assembly (4) Shaft assembly (5) High/Low shaft (6) Gear (9) Gear (12) Gear (17) Gear (18) Gear (19) No. 7 clutch (20) Output yoke (28) No. 6 clutch (30) Gear (31) High/Low shaft (34) No. 1 clutch (35) Gear

When forward No. 1 clutch (34) is engaged, power is transmitted from gear (6) on input shaft (2) to gear (35) on forward shaft (1) . Gear (35) transfers power to forward shaft (1) . Gear (9) on the forward shaft (1) drives gear (12) on the shaft assembly (3) . Shaft assembly (3) transfers power to gear (31) . Gear (31) drives gear (30) on shaft assembly (30) .

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When No. 6 clutch (28) is engaged, power transfers from gear (30) to shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, the power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Second Forward Gear with Engaged Clutches (No. 2, No. 4 and No. 7) When No. 2 clutch (11) is engaged, the power is transmitted from gear (7) on input shaft (2) to gear (10) on forward shaft (1) . Gear (10) transfers power to forward shaft (1) . Gear (9) on forward shaft (1) drives gear (12) on shaft assembly (3) . When the second gear for No. 4 clutch (32) is engaged, power is transferred from shaft assembly (3) to gear (33) . Gear (33) drives gear (27) on shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Third Gear Forward with Engaged Clutches (No. 2, No. 5 and No. 7) When forward No. 2 clutch (9) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (10) on forward shaft (1) . Gear (10) transfers power to forward shaft (1) . Gear (9) on forward shaft (1) drives gear (12) on shaft assembly (3) . Gear (32) on shaft assembly (3) drives gear (15) on shaft assembly (4) . When the third gear for No. 5 clutch (16) is engaged, power is transferred from gear (15) to shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Fourth Gear Forward with Engaged Clutches (No. 1, No. 5, and No. 7) When forward No. 1 clutch (34) is engaged, power is transmitted from gear (6) on input shaft (2) to gear (35) on forward shaft (1) . Gear (35) transfers power to forward shaft (1) . Gear (9) on forward shaft (1) drives gear (12) on shaft assembly (3) . The gear (12) on shaft assembly (3) drives gear (15) on shaft assembly (4) . When the third gear for No. 5 clutch (16) is engaged, power is transferred from gear (15) to shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) .

When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Fifth Gear Forward with Engaged Clutches (No. 1, No. 6, and No. 8) When forward No. 1 clutch (34) is engaged, power is transmitted from gear (6) on input shaft (2) to gear (35) on forward shaft (1) . Gear (35) transfers power to forward shaft (1) . Gear (9) on forward shaft (1) drives gear (12) on shaft assembly (3) . Gear (31) on shaft assembly (3) drives gear (30) on shaft assembly (4) . When No. 6 clutch (28) is engaged, power is transferred from gear (30) to shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

Sixth Gear Forward with Engaged Clutches (No. 2, No. 4, and No. 8) When forward No. 2 clutch (9) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (10) on forward shaft (1) . Gear (10) transfers power to forward shaft (1) . Gear (9) on forward (1) drives gear (12) on shaft assembly (3) . When the second gear for No. 4 clutch (32) is engaged, power is transferred from shaft assembly (3) to gear (33) . Gear (33) drives gear (27) on shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

Seventh Gear Forward with Engaged Clutches (No. 1, No. 4, and No. 8) When forward No. 1 clutch (34) is engaged, power is transmitted from gear (6) on input shaft (2) to gear (35) on forward shaft (1) . Gear (35) transfers power to forward shaft (1) . Gear (9) on forward shaft (1) drives gear (12) on shaft assembly (3) . When the second gear for No. 4 clutch (32) is engaged, power is transferred from shaft assembly (3) to gear (33) . Gear (33) drives gear (27) on shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26 ) on high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

Eighth Forward Gear with Engaged Clutches (No. 1, No. 5, and No. 8) When forward No. 1 clutch (34) is engaged, power is transmitted from gear (6) on input shaft (2) to gear (35) on forward shaft (1) . Gear (35) transfers power to forward shaft (1) . Gear (9) on the forward shaft (1) drives gear (12) on shaft assembly (3) . Gear (12) on shaft assembly (3) drives gear (15) on shaft assembly (4) . When No. 5 clutch (16) is engaged, power is transferred from gear (15) to shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on the high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

First Reverse Gear with Engaged Clutches (No. 3, No. 6, and No. 7)

Illustration 4

(1) Forward shaft (2) Input shaft (3) Shaft assembly (4) Shaft assembly (5) High/Low shaft (7) Gear (13) Gear (14) No. 3 clutch (17) Gear (18) Gear (19) No. 7 clutch (20) Output yoke (28) No. 6 clutch (30) Gear (31) High/Low shaft

When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (31) transfers power to shaft assembly (3) . Gear (31) on the shaft assembly (3) drives gear (30) on shaft assembly (4) . When No. 6 clutch (28) is engaged, power is transferred from gear (30) to shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

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Second Reverse Gear with Engaged Clutches (No. 3, No. 4, and No. 7) When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (13) transfers power to the shaft assembly (3) . When the second gear for No. 4 clutch (32) is engaged, power is transferred from shaft assembly (3) to gear (33) . Gear (33) drives gear (27) on shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Third Reverse Gear with Engaged Clutches (No. 3, No. 5, and No. 7) When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (13) transfers power to shaft assembly (3) . Gear (12) on shaft assembly (3) drives gear (15) on shaft assembly (4) . When No. 6 clutch (28) is engaged, power is transferred from gear (30) to shaft assembly (4) . Gear (17) on shaft assembly (4) transfers power to gear (18) on high/low shaft (5) . When the low gear for No. 7 clutch (19) is engaged, power is transferred from gear (18) to high/low shaft (5) and to output yoke (20) .

Fourth Reverse Gear with Engaged Clutches (No. 3, No. 6, and No. 8) When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (13) transfers power to shaft assembly (3) . Gear (31) on shaft assembly (3) drives gear (30) on shaft assembly (4) . When No. 6 clutch (28) is engaged, power is transferred from gear (30) to shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on high/low shaft (5) . When the high/low gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

Fifth Reverse Gear with Engaged Clutches (No. 3, No. 4, and No. 8) When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (13) transfers power to shaft assembly (3) . When the second gear for No. 4 clutch (32) is engaged, power is transferred from shaft assembly (3) to gear (33) . Gear (33) drives gear (27) on shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20) .

Sixth Reverse Gear with Engaged Clutches (No. 3, No. 5, and No. 8) When reverse No. 3 clutch (14) is engaged, power is transmitted from gear (7) on input shaft (2) to gear (13) on shaft assembly (3) . Gear (13) transfers power to shaft assembly (3) . Gear (12) on shaft assembly (3) drives gear (15) on shaft assembly (4) . When No. 5 clutch (16) is engaged, power is transferred from gear (15) to shaft assembly (4) . Gear (29) on shaft assembly (4) transfers power to gear (26) on high/low shaft (5) . When the high gear for No. 8 clutch (24) is engaged, power is transferred from gear (26) to high/low shaft (5) and to output yoke (20)

Usage: 143H 1AL 160H 2FM 12H ES 2GS 160H ES 2HS 12H ES 2LR 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H NA 4XM 163H NA 5AK 120H5FM 140H 5HM 12H 5ZM 120H ES 6NM 120H 6TM 160H ES 6WM 135H 7MM 140H 8JM 140H ES 8KM 12H NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H NA 9TN 120H ES 9YR 140H NA 9ZN

Table 1 Required Tools

Part Number

Description

Quantity

8T-5096

Dial Indicator Gp

1

Use this procedure in order to check for proper clutch assembly. Refer to Specifications, "Power Train" for running clearances for the clutch packs.

Illustration 1

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(1) Bearing (2) Disc (3) Gear assembly (4) Washer (5) Gear assembly (6) Disc (7) Rotor (8) Bearing (9) Carrier

1.

Remove the following components from the clutch group: 

Bearing (1)



Disc (2)



Gear assembly (3)



Washer (4)



Disc (5)



Gear assembly (6)



Rotor (7)



Bearing (8)



Carrier (9)

Note: Do not use a puller to remove rotor (7) from the clutch assembly.

Illustration 2

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(10) Hub assembly (11) Ring (12) Clutch pack (13) Piston (14) age

2.

3. 4.

Position the assembled clutch group with the shaft in the vertical position. Position the hub assembly of the clutch that is being measured so that the hub assembly faces upward. Make sure that piston (13) moves freely. Position the tip of a dial indicator on the flat of piston (13) at location (B). Zero the indicator.

Note: Ensure that the tip of the indicator is parallel with the centerline of the shaft assembly.

Personal injury can result from applying air pressure without the lock ring securely in place. Make sure the lock ring (11) is securely in place before applying air pressure to the clutch pack.

5.

To check the running clearance for the clutch packs, apply approximately 140 kPa (20 psi) air pressure to age (14) for clutch pack (12) .

6.

Piston (13) and clutch pack (12) should move up. Determine the amount of piston movement from the reading on the dial indicator. This is the running clearance for the clutch pack.

Repeat Step 1 through Step 6 in order to determine the running clearances for the remaining clutch packs.

Usage: 12H 125 140H 126 160H 2FM 12H ES 2GS 160H ES 2HS 12H ES 2LR 12H NA 2WR 140H NA2ZK 140H ES 3AS 160H NA 3GM 12H 4ER 12H NA 4XM 140H 5HM 12H 5ZM 160H ES 6WM 140H 8JM 140H ES 8KM 12H

NA 8MN 160H NA 9EJ 160H 9JM 140H NA 9TN 140H NA 9ZN 12H AMZ 140H APM 160H ASD 12H CBK 140H CCA 160H C 120K JAP 160K JBP 12K JJA 140K JPA 140K SZL 160K SZM 120K SZN 12K SZP 120K 2 SZS 140K 2 SZW 140H XZH 12HXZJ 160H XZK

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

1

B

154-6181

Forcing Screw

2

C

6V-5221

Bolt

1

D

4C-8156

Fixture

1

E

6V-3918

Bolt

1

F

4C-8157

Fixture

2

G

1U-6405

Three Jaw Puller

1

H

1U-6341

Threaded Rod

1

J

5P-7970

Nut

1

K

9U-7479

Compressing Tube

1

L

5B-0637

High Idle Nut

1

5F-7353

Washer

1

1B-4207

Full Nut

2

5F-7369

Puller Leg

2

3H-0465

Push-Puller Plate

2

5F-7366

Screw

1

5P-4808

Cap

2

1U-9895

Crossblock

1

Block

2

1B-4206

Nut

4

8B-7552

Bolt

2

9S-9151 M

N

1U-6343

Threaded Rod

1

P

6V-8149

Nut

1

Q

2P-8312

Pliers

1

1P-2326

Screw

1

1P-2325

Head

1

3H-0462

Bolt and Nut

4

8H-0709

Strap

4

5F-7373

Jaw

3

Eyebolt

1

R

S

3E-3882

Start By: 1.

Remove the transmission control valve. Refer to Disassembly and Assembly, "Transmission Control Valve - Remove".

2.

Remove the parking brake. Refer to Disassembly and Assembly, "Parking Brake Remove".

3.

Remove the transmission speed sensor.

4.

Remove the transmission oil pump. Refer to Disassembly and Assembly, "Gear Pump (Transmission Charging and Scavenge) - Remove".

5.

Remove the transmission magnetic screen base. Refer to Disassembly and Assembly, "Magnetic Screen - Remove and Install".

Illustration 1

1. 2. 3.

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Place transmission (1) level on the floor. Remove 12 bolts (2), four covers, and the O-ring seals from transmission case assembly (3) . Remove 41 bolts (4) from the transmission case assembly (3) .

Illustration 2

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Note: Identify the location of seal carrier (5) in the transmission case assembly (3) for assembly purposes. 4. 5. 6.

Remove two bolts (6) from seal carrier (5) . Install Tooling (A) (not shown) in seal carrier (5). Remove seal carrier (5) and the three ring seals from the transmission case assembly bore (7) . Repeat Step 4 through Step 5 on the three remaining seal carriers (5) .

Illustration 3

7.

Remove seal rings (9) from seal carrier (5) .

8.

Remove three or four seals (8) from seal carrier (5) .

9.

Remove spring pin (10) from seal carrier (5) .

10. Repeat Step 7 and Step 9 for the remaining three seal carriers (5) .

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Illustration 4

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11. Install Tooling (B) in the transmission case assembly (3). Tighten Tooling (B) evenly to separate transmission case assembly (3) from transmission cover assembly (11) . 12. Attach Tooling (A) to transmission case assembly (3). Position a lifting device to Tooling (A). Secure the lifting device to a hoist. Slowly raise the transmission case assembly (3) from the transmission cover assembly (11). Be careful not to bind the transmission case assembly (3) during separation.

Illustration 5

13. Remove three bolts (12) from tube assembly (13). Remove tube assembly (13) from the transmission cover assembly (11) . 14. Remove the O-ring seal from tube assembly (13) .

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Illustration 6

Note: First/Third shaft assembly (14) and High/Low shaft assembly (15) must be removed together. 15. Install Tooling (D) on First/Third shaft assembly (14) and High/Low shaft assembly (15). Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly (14) and High/Low shaft assembly (15), as shown. First/Third shaft assembly (14) and High/Low shaft assembly (15) must be removed together. 16. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly (14) and High/Low shaft assembly (15) from the transmission cover assembly (11). The weight of the two shaft assemblies is 177 kg (390 lb).

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Illustration 7

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17. Place First/Third shaft assembly (14) and High/Low shaft assembly (15) on Tooling (F) or on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (14) and High/Low shaft assembly (15). The weight of each shaft assembly is 89 kg (195 lb).

Illustration 8

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Illustration 9

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Note: Place High/Low shaft (15) in a modified work bench or on blocks. Modify a substantial workbench by cutting a 116.0 ± 2.0 mm (4.60 ± 0.08 inch) clearance hole in the top of the bench.

Illustration 10

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Illustration 11

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Note: Do not attach Tooling (G) to rotor (17). If pressure is applied to rotor (17) with Tooling (G), rotor (17) will brake. Attach the Tooling (G) to gear assembly (18) . 18. With High/Low shaft assembly (15) on the modified work bench or on blocks, use Tooling (G) in order to remove race and bearing (16), rotor (17), gear assembly (18), and two sleeve bearings (not shown) from High/Low shaft assembly (15). Press fit Bearing (16) and rotor (17) on High/Low shaft assembly (15) . 19. Remove bearing (16), rotor (17), thrust disc (19), and gear assembly (18) from High/Low shaft assembly (15). Attach Tooling (G) to gear assembly (18). Do not attach Tooling (G) to rotor (17) .

Illustration 12

20. Remove thrust disc (20) and the washer from High/Low shaft assembly (15) .

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Illustration 13

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21. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly (21). Tighten Tool (J) on Tooling (H) (not shown) in order to compress clutch assembly (21). Remove two half rings (22) and two lock rings (23) from the High/Low shaft assembly (15) . 22. Carefully loosen Tool (J) on Tooling (H) in order to relieve pressure from clutch assembly (21). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (15) and clutch assembly (21). The clutch assembly (21) is made up of five clutch plates, six friction discs, and the hub assembly. Identify the position of the clutch assembly (21) for assembly purposes.

Illustration 14

23. Remove wave spring (25) from High/Low shaft assembly (15) .

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24. Remove piston (24) from High/Low shaft assembly (15) .

Illustration 15

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25. Remove seal extension ring (27) and seal ring (26) from piston (22) .

Illustration 16

26. Position High/Low shaft assembly (15), as shown. Place High/Low shaft (15) in the modified work bench, or on blocks. The weight of High/Low shaft assembly (15) is 50 kg (110 lb). 27. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (15) and inner bearing (28). Remove inner bearing (28) from High/Low shaft assembly (15).

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Remove two thrust discs (29), two bearing sleeves, and gear assembly (30) from High/Low shaft assembly (15) .

Illustration 17

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28. Remove thrust disc (31) and the washer from High/Low shaft assembly (15) .

Illustration 18

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Note: Tooling (K) is the old style tool that is now modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N) . 29. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly (32). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (32). Remove two half rings (33) and two lock rings (34) from the High/Low shaft assembly (15) . 30. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch assembly (32). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (15) and clutch assembly (32). The clutch assembly (32) is made up of eight clutch plates, seven friction discs, and the hub assembly. Identify the position of the clutch assembly (32) for assembly purposes.

Illustration 19

Note: Tooling (K) is the old style tool that must be modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N) . 31. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and balance piston (35). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (35) . 32. Use Tooling (Q) in order to remove retaining ring (36) from High/Low shaft assembly (15) . 33. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston (35). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft assembly (15) and balance piston (35) .

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Illustration 20

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34. Remove balance piston (35) and seal extension ring (37) from High/Low shaft assembly (15) . 35. Remove 15 springs (38) from piston (39) . 36. Remove piston (39), the seal extension ring (not shown), and a ring seal (not shown) from High/Low shaft assembly (15) .

Illustration 21

37. Remove seal ring (40) and seal extension ring (41) from piston (39) .

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Illustration 22

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38. Place First/Third shaft assembly (14) on the modified work bench or on blocks. Use Tooling (F) in order to remove race and bearing (42), thrust disc (not shown), and gear assembly (43) from First/Third shaft assembly (14) .

Illustration 23

39. Remove thrust disc (44) and gear assembly (45) from First/Third shaft assembly (14) .

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Illustration 24

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40. Remove sleeve bearing (not shown), thrust disc (46) and washer (47) from First/Third shaft assembly (14) .

Illustration 25

41. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (14) and clutch assembly (48). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (48). Remove two half rings (49) and two lock rings (50) from First/Third shaft assembly (14) . 42. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (48). Remove Tooling (K) and Tooling (H) from First/Third shaft

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assembly (14) and clutch assembly (48). As you remove clutch assembly (48) from First/Third shaft assembly (14), identify the positions of the five clutch plates, the six friction disc, and the hub assembly for assembly purposes.

Illustration 26

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43. Remove wave spring (51) from First/Third shaft assembly (14) . 44. Remove piston (52) from First/Third shaft assembly (14) .

Illustration 27


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Illustration 28

46. Position First/Third shaft assembly (14), as shown. Place First/Third shaft assembly (14) in the modified work bench, or on blocks. The weight of First/Third shaft assembly (14) is 55 kg (120 lb). 47. Remove the seal ring (not shown) from First/Third shaft assembly (14) . 48. Use Tooling (R) in order to remove inner bearing (55), thrust disc (not shown), gear (56), and thrust disc (not shown). 49. Remove gear assembly (57), the bearing sleeve (not shown), the thrust disc, and the washer (not shown) from First/Third shaft assembly (14) .

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Illustration 29

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50. Install Tooling (K) and Tooling (H) on First/Third shaft assembly (14) and clutch assembly (58). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (58). Remove two half rings (59) and two lock rings (60) from the First/Third shaft assembly (14) . 51. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (58). Remove Tooling (H) and Tooling (K) from First/Third shaft assembly (14) and clutch assembly (58). As you remove clutch assembly (58) from First/Third shaft assembly (14), identify the position of the three clutch plates, four friction disc, and the hub assembly for assembly purposes.

Illustration 30

52. Remove wave spring (61) from First/Third shaft assembly (14) . 53. Remove piston (62) from First/Third shaft assembly (14) .

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Illustration 31

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Illustration 32

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Illustration 33

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55. Use Tooling (R) in order to remove inner bearing (66) and gear (67) from input shaft assembly (65). This is necessary at this time in order to remove the remaining two shaft assemblies.

Illustration 34

56. Install Tooling (S) and remove Reverse/Second shaft assembly (68) from the transmission cover assembly (11). The weight of Reverse/Second shaft assembly (68) is 64 kg (140 lb).

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Illustration 35

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57. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks. 58. Use Tooling (R) in order to remove race and bearing (69), spacer (70), and gear (71) from Reverse/Second shaft assembly (68) .

Illustration 36

59. Remove spacer (72) and thrust disc (not shown) from Reverse/Second shaft assembly (68) . 60. Remove gear assembly (73), the sleeve bearing (not shown), the thrust disc (not shown), and the washer (not shown) from Reverse/Second shaft assembly (68) .

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Illustration 37

61. Install Tooling (K) and Tooling (H) on Reverse/Second shaft assembly (68) and clutch assembly (74). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (74). Remove two half rings (75) and two lock rings (76) from Reverse/Second shaft assembly (68) . 62. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (74). Remove Tooling (H) and Tooling (K) from Reverse/Second shaft assembly (68) and clutch assembly (74). As you remove clutch assembly (74) from Reverse/Second shaft assembly (68), identify the positions of the three clutch plates, four friction disc and the hub assembly for assembly purposes.

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Illustration 38

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63. Remove wave spring (77) from Reverse/Second shaft assembly (68) . 64. Remove piston (78) from Reverse/Second shaft assembly (68) .

Illustration 39

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65. Remove seal ring (80) and seal extension ring (79) from piston (78) .

Illustration 40

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66. Position Reverse/Second shaft assembly (68), as shown. The weight of Reverse/Second shaft assembly (68) is 41 kg (90 lb). 67. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks. 68. Install Tooling (L) and Tooling (M) on gear assembly (82) and Reverse/Second shaft assembly (68) . 69. Remove inner bearing (81), the thrust race (not shown), the two thrust discs (not shown), and gear assembly (82) from Reverse/Second shaft assembly (68) .

Illustration 41

70. Remove roller bearing (83) from Reverse/Second shaft assembly (68) . 71. Remove thrust disc and washer (84) from Reverse/Second shaft assembly (68) .

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Illustration 42

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72. Use a second person in order to compress clutch assembly (85) . 73. Remove two half rings (86) from Reverse/Second shaft assembly (68). Release the pressure from clutch assembly (85) slowly, until the spring (89) underneath clutch assembly (85) is extended and relaxed.

Illustration 43

74. Remove hub assembly (87) from Reverse/Second shaft assembly (68) . 75. Remove spring (89) from Reverse/Second shaft assembly (68) . 76. As you remove clutch plates (88) and friction discs (90), identify the locations of clutch plates (88) and friction discs (90) for installation purposes. Remove six clutch plates (88) and seven friction disc (90) from Reverse/Second shaft assembly (68) .

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Illustration 44

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77. Remove valve assembly (91) from Reverse/Second shaft assembly (68) . 78. Remove piston (92) from Reverse/Second shaft assembly (68) .

Illustration 45

79. Remove seal ring (93) and (94) from piston (92) . 80. Remove the cup plug (not shown) from Reverse/Second shaft assembly (68) .

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Illustration 46

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81. Install Tooling (S) in Forward shaft assembly (95). Remove Forward shaft assembly (95) from the transmission cover assembly (11). The weight of Forward shaft assembly (95) is 64 kg (140 lb).

Illustration 47

82. Place Forward shaft assembly (95) on the modified work bench, or on blocks. Install Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly (97) . 83. Remove race and bearing (96), two thrust disc (not shown), and gear assembly (97) from Forward shaft assembly (95) .

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Illustration 48

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84. Remove roller bearing (98) from Forward shaft assembly (95) . 85. Remove the thrust disc and washer (99) from Forward shaft assembly (95) .

Illustration 49

86. Use a second person in order to compress clutch assembly (100) . 87. Remove two half rings (101) from Forward shaft assembly (95). Release the pressure from clutch assembly (100) slowly, until the spring (104) underneath clutch assembly (100) is extended and relaxed.

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Illustration 50

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88. Remove hub assembly (102) from Forward shaft assembly (95) . 89. Remove spring (104) from Forward shaft assembly (95) . 90. Remove six clutch plates (105) and seven friction disc (103) from Forward shaft assembly (95). Identify the positions of the clutch plates (105) and friction discs (103) for assembly purposes.

Illustration 51

91. Remove valve assembly (106) from Forward shaft assembly (55) . 92. Remove piston (107) from Forward shaft assembly (95) .

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Illustration 52

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93. Remove two seal rings (108) from piston (107) .

Illustration 53

94. Position Forward shaft assembly (95), as shown. The weight of Forward shaft assembly (95) is 43 kg (95 lb). Place Forward shaft assembly (95) in the modified work bench or on blocks. 95. Install Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly (110) .

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96. Remove inner bearing (109), the thrust race (not shown), the two thrust disc (not shown), and gear assembly (110) from Forward shaft assembly (95) .

Illustration 54

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97. Remove roller bearing (111) from Forward shaft assembly (95) . 98. Remove the thrust disc and washer (112) from Forward shaft assembly (95) .

Illustration 55

99. Use a second person in order to compress clutch assembly (113) . 100. Remove two half rings (114) from Forward shaft assembly (95) .

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101. Release the pressure from clutch assembly (113) slowly, until the spring (116) underneath clutch assembly (113) is extended and relaxed.

Illustration 56

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102. Remove hub assembly (115) from Forward shaft assembly (95) . 103. Remove spring (116) from Forward shaft assembly (95) . 104. Remove six clutch plates (117) and seven friction discs (118) from Forward shaft assembly (95). Identify the positions of the clutch plates (117) and friction disc (118) for assembly purposes.

Illustration 57

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105. Remove valve assembly (119) from Forward shaft assembly (95) . 106. Remove piston (120) from Forward shaft assembly (95) .

Illustration 58

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107. Remove two seal rings (121) from piston (120) . 108. Remove the cup plug (not shown) from Forward shaft assembly (95) .

Illustration 59

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109. Install Tooling (S) in Input shaft assembly (65). Remove Input shaft assembly (65) from the transmission cover assembly (11). The weight of Input shaft assembly (65) is 23 kg (50 lb).

Illustration 60

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110. Remove two seal rings (122) from Input shaft assembly (65) . 111. Remove inner bearing (123) and gear (124) from Input shaft assembly (65) . 112. Remove the cup plug (not shown) from input shaft assembly (65) .

Illustration 61

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113. Remove four bolts (125) from gear assembly (126). Rotate gear assembly (126) in order to locate the two bolts (not shown). 114. Remove gear assembly (126) from the transmission cover assembly (11) .

Illustration 62

115. Position gear assembly (126), as shown. Use Tooling (Q) to remove snap ring (129) from gear assembly (126) . 116. Position gear assembly (126) to the opposite side. In order to drive ball bearing (127) off gear assembly (126), push a small driver through three small holes (not shown). 117. Remove ball bearing (127) from bearing retainer (128) .

Note: This is a slip fit.

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Illustration 63

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118. Remove five bearing outer races (130) from the transmission cover assembly (11) . 119. Repeat Step 118 for transmission case assembly (3) .

Usage: 160H 2FM 12H ES 2GS 160H ES 2HS 12H ES 2LR 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H NA 3GM 12H 4ER 12H NA 4XM 140H 5HM 12H 5ZM 160H ES 6WM 140H 8JM 140H ES8KM 12H NA 8MN 160H NA 9EJ 160H 9JM 140H NA 9TN 140H NA 9ZN 12H XZJ 160H XZK

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

4C-8161

Bracket

1

A

4C-8162

Bracket

1

B

5P-9736

Links

2

Start By:

1.

Remove the radiator. Refer to Engine Supplement, " 12H, 140H and 160H Motor Graders" for the correct procedure.

2.

Remove the batteries and battery boxes. Refer to Engine Supplement, " 12H, 140H and 160H Motor Graders" for the correct procedure.

3.

Remove the fuel tank. Refer to Machine Systems, " 12H, 140H and 160H Motor Graders" for the correct procedure.

4.

Remove the differential drive shaft. Refer to Disassembly and Assembly, "Drive Shaft - Remove and Install" for the correct procedure.

Hot oil and components can cause personal injury. Do not allow hot oil or components to skin.

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. 1.

Drain the transmission fluid in a suitable container for storage or disposal. The capacity of the power train system is 47 L (50 qt).

Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal components.

Illustration 1

2.

Disconnect three wire terminals (2) from alternator (3) .

3.

Loosen bolts (4) that hold the alternator. Loosen V-belts (1) .

Illustration 2

4. 5.

Remove bolt (6) and the washer from the hose clip. Attach a lifting device to the fan and alternator assembly. Secure the lifting device to a hoist. Remove four mounting bolts (5) and the washers that hold the fan assembly to the machine frame. Remove the fan assembly from the machine. The weight of the fan assembly is 100 kg (220 lb).

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

Illustration 3

6.

Relieve air pressure from air tank (7) .

7.

Put identification marks on four hoses (8) for installation purposes. Disconnect four hoses (8) from air tank (7) .

8.

Remove four bolts (9), the washers and shims from two mounting plates (10). Remove air tank (7) from the machine frame. The weight of air tank (7) is 17 kg (37 lb).

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Illustration 4

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View from upper right side of transmission

9.

Remove four bolts (11), the washers, and flange (12) in order to disconnect filter hose assembly (13) .

Illustration 5

10. Remove four bolts (15), the washers, and flange (14) in order to disconnect two hose assemblies (16) . 11. Disconnect two wire harness terminals (17) from the transmission control valve.

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Illustration 6

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12. Remove bolt (22) and the clip from transmission hose assembly (18) . 13. Disconnect the fittings of hose assembly (20) from filter base (19) . 14. Remove two bolts (21) and the washers that hold filter base (19) to the machine frame. Move filter base (19) out of the way.

Illustration 7

15. Put identification marks on two hose assemblies (23) for installation purposes. Disconnect the fittings of the hoses from the transmission.

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Illustration 8

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16. Disconnect shift control cable (24) from the transmission hydraulic control valve.

Illustration 9

17. Remove four bolts (26), the washers, and the flange in order to disconnect hose assembly (25) from the transmission.

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18. Disconnect the fittings on hose assembly (27) from the transmission. 19. Loosen clamp (29) and disconnect hose assembly (28) from hose connector (30) . 20. Loosen clamp (32) and disconnect hose (31) from the differential.

Illustration 10

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21. Install Tooling (A) to both sides of flywheel housing (33). Adjust both screws (34) in order to the machine frame. This tooling will the engine after the rear motor mounts are removed.

Illustration 11

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22. Install Tooling (B) and a suitable hoist to the transmission. 23. Remove 12 bolts (35) from the transmission flange. 24. Remove two bolts (36), the washers, and mounting flange assemblies (37) from the machine frame and motor mounts.

Note: Mark the location of the flange assembly (37) components for installation purposes. Note: The transmission must be moved straight back approximately 50.8 mm (2.00 inch) in order to clear the torsion coupling with the splined shaft. The transmission can be lifted after the clearance is attained. 25. Carefully remove the transmission from the machine frame and the flywheel housing. Check for clearance of wire harnesses and hose assemblies when you remove the transmission. The weight of the transmission is 817 kg (1800 lb). 26. Remove the fan drive pulley from the transmission.

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