Jbt Manual.pdf

Halvorsen Halvorsen 25 000 lb. Loader for Aircraft

627-9734-0NN

Halvorsen Halvorsen Ground Support GROUND SUPPORT AROUND THE WORLD

For assistance or questions with set-up, warranty or parts, please contact your closest JBT Sales and Service Center.

Location

Orlando Headquarters John Bean Technologies Corp. 7300 Presidents Drive Orlando, Florida 32809 USA

Warranty and Service

Part Sales

Telephones +1.407.850.4207 worldwide 1.800.327.1686 within USA +1.407.850.4221 Fax

Telephones +1.407.850.4208 worldwide 1.800.821.3019 within USA +1.407.850.4221 Fax

[email protected]

[email protected]

+34.91.877.5880 Telephone +34.91.877.5881 Fax

+34.91.877.5883 Telephone +34.91.877.5884 Fax

[email protected]

[email protected]

+44.208.587.0666 Telephone +44.208.587.0660 Fax

+44.208.831.2200 Telephone +44.208.587.0660 Fax

[email protected]

[email protected]

+65.6542.9255 Telephone +65.6542.7493 Fax

+65.6542.9255 Telephone +65.6542.7493 Fax

[email protected]

[email protected]

Madrid John Bean Technologies AeroTech S.L. Autovía A-2, km 34,4 28805 Alcalá de Henares, Madrid, Spain

London John Bean Technologies Ltd. Arnold Hawker House Central Way Feltham, England Middlesex, United Kingdom TW14 0XQ

Singapore John Bean Technologies Singapore Pte. Ltd. 6 Loyang Lane #03-00 Young Heng Industrial Building Singapore 508920

JBTAeroTech.com Comments or suggestions regarding our manuals? At JBT Technical Publications we are always improving our technical documentation. If you have any comments or suggestions, please contact us.

www.JBTAeroTechDirect.com

Technical Publications John Bean Technologies 7300 Presidents Drive Orlando, Florida 32809 USA

+1.407.851.3377 Telephone +1.407.850.4221 Fax [email protected]

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Halvorsen INTRODUCTION

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS. MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO MAINTENANCE SCHEDULES AND MANUFACTURERS’ RECOMMENDATIONS. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE CONTACT YOUR LOCAL JBT SERVICE CENTER BEFORE PROCEEDING. 1.

PURPOSE This technical manual presents operation, maintenance, service and parts procurement information for the Halvorsen, 25 000 lb. Loader for Aircraft, manufactured by JBT.

2.

SCOPE This manual describes the procedures for safe operation, maintenance and repair of the Halvorsen loader, and ordering of spare parts. This manual does not provide procedures or guidelines specific to the operation of the vehicle on airports or the handling of aircraft. It requires that operators be aware of all applicable rules and regulations for operating the vehicle in traffic, on the airport and with aircraft, and that the operator has been properly trained in the operation of the vehicle. Maintenance and repairs must only be performed by technicians skilled and experienced on heavy industrial vehicles.

3.

TERMS Throughout this manual, the Halvorsen will be referred to as the “vehicle” or “unit.” The terms “right” and “left” in the descriptive paragraphs refer to the operator’s right and left from a normal operating position. For additional terms and acronyms used in this manual refer to Chapter 1, Section 1, “Description”. NOTE:

4.

MAINTENANCE IS DEFINED AS, BUT NOT LIMITED TO, INSPECTIONS, CHECKS, ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, REMOVAL, REPLACEMENT OF COMPONENTS, MODIFICATIONS OR ANY OTHER WORK, REQUIRED FOR THE VEHICLE TO OPERATE.

IMPORTANT SAFETY NOTICE This manual contains instructions, warnings and cautions based on normal operation and maintenance practices. In addition to the instructions in this manual, operators and maintenance personnel should follow all locally applicable guidelines and regulations, and maintain the vehicle in optimum condition and avoid hazardous situations. A safety conscious operator and a well cared for vehicle make a safe and efficient combination. Your vehicle may operate slightly different depending on specifications and optional features.

iii

Halvorsen 5.

VEHICLE MODIFICATIONS OR TAMPERING Modifications, including changing of settings, replacement of parts with no OEM parts and addition of components or features may affect the safety and operational ability of the vehicle. Do not make modifications without prior written approval from JBT, Orlando, Florida, USA. Tampering with emission control devices by means of removing, bypassing, defeating, damaging or in any way rendering ineffective any vehicle emission control device or element, including diesel exhaust fluid (DEF) to be used or installed on the vehicle is prohibited and will void all warranties and subject to federal, state and local laws and fines.

6.

TECHNICAL ADVISORIES JBT may issue technical advisories during the life span of the vehicle. These technical advisories are intended to improve the reliability of the vehicle or address any safety related issues that may arise. Unless the technical advisory instructs otherwise, please insert it immediately after the list of warnings and cautions located in the front of this manual. To receive these important technical advisories, it is required that you inform JBT in the event the contact information of the person responsible for this equipment has changed, the vehicle has moved to a different location, or the vehicle has transferred ownership. Required Information: Equipment type Serial number(s) Vehicle’s operating location address Technical Advisory mailing information (No P.O. boxes please) Contact personnel (GSE Manager, Safety Manager) Telephone number(s) E-mail address(es) Please send this information to: Technical Publications Dept. JBT, Ground Support Equipment 7300 Presidents Drive Orlando, Florida 32809 USA [email protected]

7.

CE COMPLIANCE This vehicle meets or exceeds the following CE requirements: •

iv

Machinery Directive - Annex IV . . . . . . . . . . . . . . . . . . . . . .

2006/42/EC

Halvorsen

EC Declaration of Conformity This document declares that the machinery fulfills the relevant provisions of 2006/42/EC. EC Type Examination Certificate Number “(Pending)” Certificate issued by SMP Svensk Maskinprovning AB THE SWEDISH MACHINERY TESTING INSTITUTE PO Box 7035, SE-750 07 Uppsala, Sweden NB No.: 0404

This Machine also fulfills the applicable requirements of the following EC Directives: 2006/95/EC, Low Voltage Directive 2004/108/EC, EMC-directive

Standards taken into consideration: Inspection is based on: EN 1915-1:2013 and EN 12312-9:2013.

Place of Manufacture John Bean Technologies Corporation JBT AeroTech 7300 Presidents Drive Orlando, Florida 32809 United States of America Phone +1.407.851.3377 Fax +1.407.850.2839

Technical Documentation Contact JBT AeroTech CO: Engineering Manager Autovía A-2, km 34,4 28805 Alcalá de Henares Madrid, Spain Phone +34.91.877.5880 Fax +34.91.877.5881

Type of Equipment: Model: Halvorsen Serial No.: Spec No.:

Signature: ________________________ Name Title JBT AeroTech

NOTE:

25 000 lb. Loader for Aircraft

CERTIFICATES ARE ISSUED FOR EACH VEHICLE BASED ON INDIVIDUAL CUSTOMER SPECIFICATION.

Halvorsen DoC

Date:

2015-05-01

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Halvorsen 8.

VEHICLE IDENTIFICATION PLATE The vehicle identification plate contains specific information about your vehicle such as model, specification number, serial number, manufacturing date, and other pertinent information. Refer to Figure 1 for the location of your vehicle’s identification plate. NOTE:

BE SURE TO HAVE THE INFORMATION FROM THE VEHICLE IDENTIFICATION PLATE READILY AVAILABLE WHEN CALLING JBT FOR PARTS OR SERVICE.

LOCATION OF THE VEHICLE IDENTIFICATION PLATE (INSIDE OPERATOR’S DOOR)

Figure 1 VEHICLE IDENTIFICATION PLATE

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Halvorsen GENERAL TABLE OF CONTENTS

OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST Volume I – OPERATION AND MAINTENANCE

CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS CHAPTER 2. MAINTENANCE CHAPTER 3. OVERHAUL

Volume II – ILLUSTRATED PARTS LIST

CHAPTER 4. ILLUSTRATED PARTS LIST CHAPTER 5. MANUFACTURERS’ APPENDICES

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Halvorsen

Halvorsen Volume I

OPERATION AND MAINTENANCE MANUAL Original Instructions Version 1 Edition 3, Revision 1 This volume supersedes all editions and revisions prior to:

August 2017 English Language For use with equipment serial numbers AN14511 and subsequent This volume includes the following options: DIESEL TIER 3 ENGINE ALLISON 2100 TRANSMISSION

Refer to Volume II for ILLUSTRATED PARTS LIST JBT, Ground Support Equipment John Bean Technologies Corporation 7300 Presidents Drive Orlando, Florida 32809 USA +1-407-851-3377 Telephone +1-407-850-4221 Fax

CONFIDENTIAL This technical manual contains unpublished work of John Bean Technologies Corporation. All information herein is confidential and proprietary and cannot be duplicated, used or disclosed in whole or in part, except with written permission from John Bean Technologies Corporation, Orlando, Florida USA. © 2011–2017 John Bean Technologies Corporation, all rights reserved.

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Halvorsen RECORD OF REVISIONS All pages in this issue are original. The following pages have had changes incorporated: Change Date Aug. 2011

Edition / Revision

List of Effective Pages

Change Description

Edition 1

Volume I

New edition.

Edition 2

Chapter 1, Section 3 Chapter 2, Section 3 and 5 Chapter 3, Section 2

Updated: warnings and cautions, emergency procedures, maintenance schedules, maintenance procedures, overhaul procedures.

Edition 2 Revision 1

Chapter 1, Section 1, 2, 4, 5 Chapter 2, Section 3, 5, 6 Chapter 3, Section 2

Updated: warnings and cautions, general description, controls and indicators, operation procedures, specifications, shipping procedures, maintenance schedules, maintenance procedures, troubleshooting, overhaul procedures.

Edition 2 Revision 1.1

Chapter 1, Section 3, 5 Chapter 2, Section 3, 5 Chapter 3, Section 2

Updated: warnings and cautions, emergency procedures, shipping procedures, maintenance schedules, maintenance procedures, overhaul procedures.

July 2015

Edition 3

Front matter Chapter 1, Section 1, 2, 5 Chapter 2, Section 3, 5 Chapter 3, Section 2

Updated: general format, DoC, warnings and cautions, general description, winterization system, shipping and transportation, maintenance schedules, overhaul procedures, removal and installation.

Aug. 2017

Edition 3 Revision 1

Front matter Chapter 1, Section 2

Added: emergency stop symbol, warning and notes; fall hazard warnings. Updated: Singapore office address.

June 2012

Mar. 2013

June 2014

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Halvorsen SAFETY SYMBOLS MANDATORY ACTION

PROHIBITION

REFER TO OPERATION AND MAINTENANCE MANUAL INSTRUCTIONS

STOP - AUTHORIZED ACCESS ONLY

WARNING

WARNING

NO PERSONS ON DECK WHEN LIFTING OR WHILE IN MOTION

NO PERSONS ON LADDER WHEN LOADER IS IN OPERATION

WARNING

WARNING

HAZARD - PROCEED WITH CAUTION

OVERHEAD CRUSH HAZARD

WARNING

WARNING

HAND CRUSH HAZARD

HAND PINCH HAZARD

WARNING

WARNING

ELECTRICAL SHOCK HAZARD

ELECTRICAL SHOCK HAZARD

WARNING

WARNING

HOT SURFACE HAZARD

HIGH PRESSURE HYDRAULIC LINE HAZARD

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Halvorsen WARNING

WARNING

FALL HAZARD

BODY CRUSH HAZARD

WARNING

WARNING

FALL HAZARD

xiv

FALL FROM WING HAZARD

WARNING

WARNING

OVERHEAD OBSTRUCTION HAZARD

FAN BLADE HAZARD

Halvorsen

EMERGENCY STOP (E-STOP) BUTTON

WARNING IN CASE OF VEHICLE MALFUNCTION, IMPENDING ACCIDENT OR ANY UNSAFE SITUATION, IMMEDIATELY PUSH THE EMERGENCY STOP BUTTON, APPLY BRAKES AND SET PARKING BRAKE. NOTE:

PUSHING THE EMERGENCY STOP (E-STOP) BUTTON SHUTS DOWN THE ENGINE AND COUPLED HYDRAULIC PUMPS. IT DOES NOT COMPLETELY CUT ELECTRICAL POWER TO THE VEHICLE.

WHAT IS AN EMERGENCY? •

FIRE ON THE VEHICLE

•

VEHICLE MALFUNCTION

•

ENGINE OUT OF CONTROL

•

IMPENDING ACCIDENT

•

ANY UNSAFE SITUATION

WARNING BE EXTREMELY CAREFUL WHEN STEPPING OR WALKING ON WET, SNOWY AND ICY SURFACES. WALKING ON VEHICLE SURFACES, STEPS AND LADDERS DURING THE WINTER OR RAINING REQUIRES SPECIAL ATTENTION TO AVOID SLIPPING AND FALLING. EVEN AFTER REMOVING SNOW AND ICE, OR AFTER RAINING, SURFACES MAY BE VERY SLIPPERY. WEAR APPROPRIATE GLOVES AND ANTI-SLIP BOOTS OR SHOES.

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Halvorsen SAFETY RELATED DECALS

LOADER REAR SECTION

WARNING:

OVERHEAD CRUSH HAZARD. ALWAYS INSTALL SAFETY SUPPORT STANDS BEFORE ACCESSING UNDER THE DECK.

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Halvorsen LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL

DANGER A DANGER STATEMENT INDICATES A SITUATION THAT MUST BE AVOIDED. FAILURE TO COMPLY WITH THE DANGER STATEMENT WILL RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!

WARNING A WARNING INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT MUST BE OBSERVED. FAILURE TO COMPLY WITH THE WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!

CAUTION A CAUTION INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT MUST BE OBSERVED. FAILURE TO COMPLY WITH THE CAUTION MAY RESULT IN DAMAGE TO VEHICLE AND VOID WARRANTY, OR DAMAGES TO OTHER PROPERTY, INCLUDING THE AIRCRAFT!

The following danger, warning and caution statements are used in this manual. Read all of them and follow the instructions when performing the procedures.

DANGER DIESEL FUELS, KEROSENE, HYDRAULIC OIL, LUBRICANTS AND GLYCOLS ARE FLAMMABLE. USE EXTREME CAUTION TO PREVENT SPILLS AND AVOID HEAT OR OPEN FLAMES. DO NOT OVERFILL THE FUEL TANK WHEN REFUELING. ALWAYS ALLOW ROOM FOR EXPANSION OF FUEL.

DANGER ELECTRICAL CURRENT FROM FACILITIES POWER, BATTERY AND LIGHTNING IS HAZARDOUS. TO REDUCE RISK OF ELECTRICAL SHOCK: DO NOT CONNECT OR DISCONNECT ANY ELECTRICAL CABLES DURING AN ELECTRICAL STORM, CONNECT FACILITIES POWER UTILIZING ONLY THE PROPER CONNECTORS PROVIDED, USE ONLY ONE HAND TO CONNECT OR DISCONNECT CABLES AND TURN OFF AND LOCK OUT ALL ELECTRICAL POWER SOURCES BEFORE PERFORMING ANY MAINTENANCE ON THE VEHICLE.

xix

Halvorsen WARNING TO CALIFORNIA CUSTOMERS: CALIFORNIA PROPOSITION 65 STATES THAT DIESEL EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS.

WARNING THE DECK MUST BE FULLY LOWERED AND THE VEHICLE MUST BE PROPERLY PARKED BEFORE BOARDING OR LEAVING THE UNIT. USE THE LADDER LOCATED BEHIND THE OPERATOR'S CAB TO GET ON AND GET OFF THE DECK. ENSURE THE LADDER AND DECK AREA, BOTH ON AND BELOW, ARE CLEAR OF PERSONS AND FREE OF ANY OBJECTS WHILE OPERATING THE VEHICLE. DO NOT RELY SOLELY ON SENSORS AND WARNING LIGHTS.

WARNING IT IS MANDATORY THAT ALL PERSONNEL WEAR A SAFETY HARNESS, WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” WHEN WORKING ON THE DECK IN THE AREA IDENTIFIED AND MARKED AS “HARNESS REQUIRED AREA”.

WARNING USE EXTREME CAUTION AT ALL TIMES WHEN WALKING ON THE DECK DO NOT STEP ON ROLLERS OR ROLLER ASSEMBLIES.

WARNING ENSURE THE LADDER AND DECK ARE CLEAR OF PERSONS WHILE DRIVING AND OPERATING THE VEHICLE.

WARNING APPLY THE PARKING BRAKE AND TURN OFF THE IGNITION SWITCH BEFORE LEAVING THE VEHICLE UNATTENDED.

WARNING DO NOT ALLOW PERSONS ON THE DECK WHILE IN MOTION OR IN AN ELEVATED POSITION. DECK MAINTENANCE MAY BE PERFORMED FROM UNDERNEATH USING SAFETY SUPPORTS.

xx

Halvorsen WARNING NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.

WARNING NORMAL LOADING OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING REFUELED WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE VEHICLE.

WARNING USE CAUTION WHILE REFUELING THE VEHICLE TO AVOID FUEL SPILLS. CLEAN SPILLS PROMPTLY.

WARNING AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF THE VEHICLE.

WARNING AN OBSERVER ON THE GROUND SHOULD BE USED TO GUIDE THE OPERATOR WHEN DRIVING THE VEHICLE IN REVERSE.

WARNING THE VEHICLE IS DESIGNED TO BE DRIVEN ON PAVED OR CEMENT SURFACES APPROVED TO SUPPORT THE WEIGHT AND USE OF GROUND SUPPORT EQUIPMENT VEHICLES.

WARNING DO NOT LIFT PERSONS WITH THE VEHICLE. THE LOADER IS NOT INTENDED FOR LIFTING OF PERSONS OTHER THAN THE DRIVER.

WARNING DO NOT ALLOW PERSONS UNDER THE DECK UNLESS ADEQUATE SUPPORTS ARE IN PLACE.

WARNING ALWAYS WEAR GLOVES TO PREVENT CONTACT WITH VERY COLD OR VERY HOT METAL AND SURFACES WITH BARE HANDS.

xxi

Halvorsen WARNING BEFORE STARTING ANY PROCEDURE, ENSURE THE LOADER IS ON A LEVEL SURFACE AND HAS SUFFICIENT CLEARANCE IN FRONT AND BACK. ENSURE ALL PERSONS ARE CLEAR OF THE LOADER IN THE EVENT OF UNEXPECTED MOVEMENT. PLACE CHOCKS APPROXIMATELY TWO (2) INCHES FROM THE FRONT AND REAR OF TIRES TO PREVENT EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD OR REVERSE DIRECTION SHOULD THE PARKING BRAKE FAIL.

WARNING SUPPORT THE FOLDING WALK-DECK AND HANDRAIL SECTIONS WHEN REMOVING RETAINING PINS TO PREVENT SERIOUS PERSONAL INJURIES. PERSONNEL MUST GO UNDER THE FOLDING DECK TO REMOVE THE RETAINING PINS.

WARNING DO NOT ACCESS WALK-DECK WHEN NOT SECURED BY BOTH LOCKS. FULLY LOCK TELESCOPING WALK-DECK IN PLACE BEFORE ACCESSING OR WALKING ON IT.

WARNING ALL CARGO, PALLETS AND ROLLING STOCK MUST BE SECURED TO THE LOADER DECK TO PREVENT MOVEMENT IN ANY DIRECTION WHEN THE LOADER IS IN MOTION.

WARNING CAB DOORS MUST BE LATCHED CLOSED WHEN DRIVING AND OPERATING THE LOADER.

WARNING WEAR THE SEAT BELT AT ALL TIMES WHILE OPERATING THE LOADER.

WARNING THE OPERATOR’S VISIBILITY WILL BE IMPAIRED TOWARDS THE RIGHT WHEN A PALLET OR CARGO IS ON THE FRONT POSITION OF THE DECK. FOR SAFE OPERATION, AN OBSERVER SHOULD ALWAYS BE USED TO KEEP THE OPERATOR INFORMED OF CLEARANCE, TRAFFIC OR ANY HAZARD WHEN TRANSPORTING CARGO WHEN VISIBILITY IS IMPAIRED.

WARNING APPLY E-STOP TO DISABLE THE VEHICLE ONLY IN CASE OF EMERGENCY. PRESSING THE EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE.

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Halvorsen WARNING DECK CUT-OFF VALVE MUST BE RETURNED TO THE ON POSITION AFTER USE. LOADER STEERING AND SERVICE BRAKES ARE DISABLED WHEN CUTOFF VALVE IS LEFT IN THE OFF POSITION.

WARNING BEFORE TOWING, ATTACH TOW VEHICLE WITH TOW BAR OR CHOCK WHEELS BEFORE DISENGAGING PARK BRAKE.

WARNING BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS SWITCHED OFF.

WARNING BEFORE PERFORMING ANY PROCEDURE THAT REQUIRES THE DECK TO BE IN AN ELEVATED POSITION, INSTALL THE MAINTENANCE STANDS AND LOWER THE DECK FULLY AGAINST THE MAINTENANCE STANDS.

WARNING LIFT VEHICLE ONLY BY PROPER HOISTING POINTS AND IN ACCORDANCE WITH THE DESCRIBED METHOD. DO NOT USE FORKLIFTS.

WARNING BRIDLES AND CHAINS MUST HAVE EQUAL LEG LENGTH OF A MINIMUM OF 3.60 M (12 FT.) AND HAVE THE MINIMUM RECOMMENDED CAPACITY.

WARNING PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING THE VEHICLE INTO SERVICE AFTER STORAGE.

WARNING FOLLOW THE REQUIRED PROCEDURES TO PREPARE THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT).

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Halvorsen WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, ENSURE THE VEHICLE IS ON A CLEAN AND LEVEL SURFACE, WHEELS ARE SECURELY CHOCKED, POWER UNIT IS OFF, HYDRAULIC PRESSURE IS DEPLETED AND BATTERIES HAVE BEEN DISCONNECTED. PLACE A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL VEHICLE IS BEING WORKED ON.

WARNING VEHICLE MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS.

WARNING LOCK OUT AND TAG OUT THE VEHICLE BEFORE PERFORMING ANY MAINTENANCE, ADJUSTMENTS OR REPAIRS TO THE VEHICLE.

WARNING MAINTENANCE SUPPORT STANDS MUST BE INSTALLED WHILE PERSONNEL ARE WORKING UNDER THE RAISED DECK.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.

WARNING TURN THE BATTERY DISCONNECT SWITCH TO THE “OFF” POSITION TO AVOID ELECTRICAL HAZARDS WHILE WORKING ON THE ELECTRICAL SYSTEM.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, START ENGINE, RAISE DECK TO SUFFICIENT HEIGHT TO INSTALL THE MAINTENANCE STANDS, THEN LOWER THE DECK UNTIL SCISSORS ROLLERS ARE IN CONTACT WITH THE MAINTENANCE STANDS OR BLOCKS. CHOCK WHEELS TO PREVENT MOVEMENT OF THE LOADER IN EITHER DIRECTION, APPLY THE PARK BRAKE AND TURN OFF THE ENGINE.

WARNING BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF THE VEHICLE AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONS.

xxiv

Halvorsen WARNING USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN PERFORMING VEHICLE MAINTENANCE.

WARNING HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF THE POWER UNIT AND DEPLETE SYSTEM PRESSURE BEFORE INSPECTING OR LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP AWAY FROM HYDRAULIC LEAKS. DO NOT ATTEMPT TO “FEEL” FOR THE SOURCE OF A LEAK. PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER SERIOUS INJURY.

WARNING TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS.

WARNING OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE POISONOUS.

WARNING KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE BURNS.

WARNING COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO RELEASE BEFORE COMPLETELY REMOVING IT.

WARNING INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH MAINTENANCE SCHEDULE.

WARNING AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE EXPLOSIVE HYDROGEN GAS.

xxv

Halvorsen WARNING USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE VEHICLE (REFER TO JACKING REQUIREMENTS IN SPECIFICATIONS SECTION).

WARNING DO NOT ALLOW ANY PERSONS UNDER THE VEHICLE UNLESS PROPERLY RATED MAINTENANCE STANDS ARE USED FOR SAFE SUPPORT OF THE VEHICLE.

WARNING AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL, LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN IRRITATION.

WARNING DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL SYSTEM.

WARNING REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE VEHICLE AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT. REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS.

WARNING THIS IS A MANDATORY SAFETY PRECAUTION. THE NORMAL SCISSORS MAINTENANCE STANDS CANNOT BE INSTALLED WHEN REMOVING AND REPLACING ROLLERS. ENSURE TO PROPERLY SUPPORT THE DECK AND SCISSORS.

WARNING HEAVY-DUTY LIFTING PROVISIONS SUCH AS SLINGS OR CHAINS USED TO SUPPORT THE DECK PLATFORM SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.).

WARNING HEAVY-LIFTING EQUIPMENT USED TO SUPPORT THE DECK PLATFORMS SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.) AND BE CAPABLE OF MOVING THE DECK PLATFORM FORWARD APPROXIMATELY 0.60 M (2 FT.) ONCE THE DECK AND SCISSORS ARE DISCONNECTED.

xxvi

Halvorsen WARNING THE DECK LINKAGE MUST BE PROPERLY SUPPORTED WHILE REMOVING THE FRONT PIN TO AVOID PERSONAL INJURY.

WARNING CHOCK THE BOGY WHEELS ON THE OPPOSITE SIDE OF THE LOADER, TO PREVENT MOVEMENT IN EITHER DIRECTION, APPLY THE PARKING BRAKE AND TURN OFF THE ENGINE.

WARNING STORAGE OF BATTERIES GENERATE HYDROGEN GAS THAT IS EXPLOSIVE. KEEP ALL OPEN FLAMES AND SPARKS AWAY FROM BATTERIES.

WARNING A COMPLETELY DISCHARGED OR FROZEN BATTERY CAN EXPLODE IF POWER IS APPLIED. FROZEN BATTERIES MUST BE ALLOWED TO WARM GRADUALLY TO NORMAL ROOM TEMPERATURE BEFORE USING.

WARNING WHEN REMOVING A BATTERY, ALWAYS DISCONNECT THE CABLES ON THE GROUND TERMINALS FIRST TO PREVENT A SPARK. ALWAYS CONNECT THE GROUND CABLE LAST WHEN CONNECTING CABLES.

WARNING ENGINE MUST BE SHUT DOWN AND THE EXTERNAL POWER CORD MUST BE DISCONNECTED WHEN REMOVING AND REPLACING BATTERIES.

WARNING DO NOT REMOVE GAUGE PORT PLUGS AND GAUGES OR LOOSEN HYDRAULIC CONNECTIONS WITH THE POWER UNIT RUNNING. HYDRAULIC PRESSURE IN THE SYSTEMS COULD CAUSE HYDRAULIC OIL TO SPRAY ON PERSONNEL.

WARNING THE ENGINE MUST BE TURNED OFF WHEN MAKING ANY SWITCH ADJUSTMENT TO PREVENT AN UNCONTROLLED MOVEMENT OF THE LOADER.

xxvii

Halvorsen WARNING WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS, IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL AND PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION.

WARNING ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. BLEED AIR FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.

WARNING TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN PANEL.

WARNING DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED, AFTER BLEEDING BRAKES.

WARNING SECURE THE WALK-DECK SO THAT IT IS COMPLETY SUPPORTED, SO THAT WHEN IT IS DISCONNECTED FROM THE HINGES IT WILL NOT FALL.

WARNING THE EDGES ON THE METAL ARE SHARP AND CAN CAUSE INJURY.

WARNING DRAIN ALL FUEL FROM THE HEATER FUEL TANK BEFORE PROCEEDING.

WARNING FULLY LOCK TELESCOPING WALK-DECK IN PLACE TO AVOID SERIOUS INJURY OR DEATH.

CAUTION WHEN OPERATING THE VEHICLE IN FREEZING CONDITIONS, OCCASIONALLY TURN THE STEERING WHEEL SLOWLY TO PREVENT THERMAL SHOCK IN THE STEERING VALVE.

CAUTION DO NOT PLACE THE EQUIPMENT INTO SERVICE WITHOUT PERFORMING ALL THE RECOMMENDED MAINTENANCE.

xxviii

Halvorsen CAUTION THE AIR CONDITIONER DOES NOT DRAW FRESH AIR INTO THE CAB. IT WILL NOT REMOVE SMOKE OR EXHAUST FUMES. CHECK FOR PROPER VENTILATION PRIOR TO OPERATION.

CAUTION CIRCUIT BREAKER MUST BE IN THE “OFF” POSITION WHENEVER AC POWER CABLE IS INSTALLED OR REMOVED FROM RECEPTACLE ON WINTERIZATION BOX.

CAUTION AC POWER CABLE MUST BE REMOVED FROM RECEPTACLE BEFORE STARTING ENGINE.

CAUTION ENGINE CAN BE STARTED WHEN AC POWER CABLE IS NOT ENERGIZED OR CIRCUIT BREAKER IS IN THE “OFF” POSITION.

CAUTION DO NOT OPERATE EQUIPMENT WITH DEFECTIVE WARNING INDICATOR LIGHTS.

CAUTION WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO START WITHIN 15 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE.

CAUTION CONFIGURE THE LOADER DECK FOR THE SIZE PALLET OR ROLLING STOCK THAT WILL BE CONVEYED.

CAUTION ALL RETAINING QUICK RELEASE PIN HANDLES AND LANYARDS SHOULD POINT TOWARDS GROUND.

CAUTION THE LOADER MAY ONLY BE DRIVEN IN A STRAIGHT LINE WITH THE LEFT FOLDING WING IN THE DOWN POSITION. THE LOADER SHOULD NEVER BE DRIVEN WITH THE RIGHT FOLDING WING IN THE DOWN POSITION.

xxix

Halvorsen CAUTION DO NOT EXCEED 15 KM (9 MILES) OF TRAVEL IN A ONE HOUR PERIOD OF TIME. IF THAT DISTANCE IS REACHED, TIRES MUST BE ALLOWED TO COOL FOR ONE HOUR.

CAUTION DO NOT DRIVE THE LOADER WITH THE DIFFERENTIAL LOCK ENGAGED WHEN OPERATING IN NORMAL CONDITIONS ON HARD SURFACES.

CAUTION THE FRONT LOAD STOPS WILL REMAIN IN THE DOWN POSITION AND THE RED INDICATOR LIGHT WILL BE ILLUMINATED WITH THE SWITCH IN THE DOWN POSITION. THE FRONT LOAD STOP SWITCH MUST BE PLACED IN THE UP POSITION WHEN TRANSPORTING CARGO, LOADING CARGO FROM THE REAR OF THE DECK OR WHENEVER THE FRONT OF THE DECK IS LOWER THAN THE REAR OF THE DECK.

CAUTION ROLLING STOCK MUST HAVE PARKING BRAKES APPLIED AND SECURED WITH RESTRAINTS ATTACHED TO THE TIE DOWN RINGS ON THE DECK BEFORE DRIVING THE LOADER.

CAUTION DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE OPERATION.

CAUTION CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN 30 SECONDS WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES CANNOT BE COMPLETED WITHIN 30 SECONDS, PUMP MUST BE ALLOWED TO COOL FOR AT LEAST 10 MINUTES BEFORE CONTINUING.

CAUTION NEVER USE THE HYDRAULIC EMERGENCY PUMP FOR OPERATING THE LOADER WHILE TOWING IT.

CAUTION DO NOT TOW THE LOADER FOR MORE THAN 150 M (500 FT.) WITHOUT DISCONNECTING DRIVE SHAFT FROM DIFFERENTIAL.

xxx

Halvorsen CAUTION NEVER TOW THE LOADER FROM THE REAR END WITH THE CHASSIS RAISED.

CAUTION WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY MASS) AND THE ENGINE EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3 ENGINES), LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED. CONSULT THE ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED.

CAUTION DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY MASS) IN EPA TIER 4 ENGINES.

CAUTION DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR SPECIFIC RECOMMENDATIONS.

CAUTION THE LOADER MUST ONLY BE DRIVEN IN AIR TRANSPORT MODE WHILE LOADING ON AND OFF FROM SPECIFIED TRANSPORT VEHICLE OR FOR GROUND CLEARANCE, BUT NEVER FOR MORE THAN 60 M (200 FT.).

CAUTION IF THE ENGINE SPEEDS UP WHILE ACTIVATING THE LIFT JOYSTICK WHILE IN AIR TRANSPORT MODE, RELEASE THE LIFT JOYSTICK IMMEDIATELY AND LOWER THE DECK. STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE

CAUTION USE OBSERVERS WHEN DRIVING THE LOADER ONTO THE TRANSPORT VEHICLE (AIRCRAFT OR TRAILER) FOR SAFETY AND TO ENSURE THAT THERE IS ALWAYS ADEQUATE CLEARANCE TO PREVENT DAMAGE TO THE TRANSPORT VEHICLE AND THE LOADER.

CAUTION IF THE DECK IS TO BE RAISED AND LOWERED WHILE THE CAB IS IN ITS RETRACTED SHIPPING CONFIGURATION, ENSURE ADEQUATE CLEARANCE IS AVAILABLE BENEATH THE CAB SO THE HYDRAULIC HOSES AND ELECTRICAL CABLES UNDER THE CAB ARE NOT PINCHED BETWEEN THE DECK AND CHASSIS.

xxxi

Halvorsen CAUTION ENSURE THE CHAINS DO NOT CONTACT THE LEFT SIDE HEADLIGHT HOUSING.

CAUTION COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS.

CAUTION USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS.

CAUTION DO NOT USE PLASTIC SHEETING FOR STORAGE. PLASTIC SHEETING USED FOR STORAGE WILL CREATE CONDENSATION WHICH MAY CAUSE METAL SURFACES TO RUST OR PIT.

CAUTION WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS, CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.

CAUTION WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE OR MOTOR COMPARTMENT.

CAUTION WHEN WASHING OR RINSING THE LOADER, PREVENT WATER FROM INTRUDING THE TRANSMISSION BREATHER VALVE.

CAUTION WHEN PERFORMING A BATTERY “JUMP START” ON THE VEHICLE, ENSURE JUMP CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND COMPONENTS.

xxxii

Halvorsen CAUTION WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND COMPONENTS.

CAUTION DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS, RUBBER HOSES OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS SUCH AS KEROSENE, GASOLINE OR FUEL OIL.

CAUTION DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE ‘MIN’ MARK OR ABOVE THE ‘MAX’ MARK ON THE DIPSTICK.

CAUTION ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT.

CAUTION ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.

CAUTION USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO PREVENT FREEZING AT THE AMBIENT TEMPERATURE.

CAUTION DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE COOLANT SYSTEM OR BATTERIES.

CAUTION DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE ALTERNATOR CHARGING SYSTEM.

CAUTION DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED.

xxxiii

Halvorsen CAUTION BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES. PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE THE WELDER’S GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO THE WELDING OPERATION AS POSSIBLE.

CAUTION PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED. ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER UNIT.

CAUTION AFTER REPLACING THE PUMP, FILL THE CASE DRAIN PUMP CAVITY WITH NEW HYDRAULIC OIL BEFORE STARTING THE VEHICLE.

CAUTION DO NOT MIX SYNTETHIC OILS WITH NON-SYNTHETIC OILS!

CAUTION BIO-DIESEL BLENDS GREATER THAN 5% CAN REDUCE THE LIFE OF THE ENGINE IF USED. FAILURES ATTRIBUTED TO THE USE OF BIO-DIESEL WILL NOT BE COVERED UNDER THE WARRANTY.

CAUTION BIO-DIESEL BLENDS CAN REDUCE THE LIFE OF THE HEATER IF LEFT IN THE FUEL SYSTEM FOR EXTENDED PERIODS OF TIME. FAILURES ATTRIBUTED TO THE USE OF BIODIESEL WILL NOT BE COVERED UNDER THE WARRANTY.

CAUTION WHEN REPLACING A SPROCKET, ALWAYS REPLACE THE CHAIN. USING AN OLD CHAIN ON NEW SPROCKETS WILL CAUSE PREMATURE WEAR OF THE SPROCKETS.

CAUTION OVER-TIGHTENING THE CHAIN CAN CAUSE RAPID CHAIN AND SPROCKET WEAR, CHAIN BREAKAGE, HYDRAULIC MOTOR FAILURE OR BEARING FAILURE ON THE ROLLER SHAFT.

xxxiv

Halvorsen CAUTION WHEN HYDRAULIC JACKS ARE USED TO RAISE THE CHASSIS, THEY MUST BE PLACED DIRECTLY UNDER THE AXLE MOUNTING PADS.

CAUTION AXLE HOUSING MOUNTING PAD AND FRAME PAD SURFACES MUST BE SMOOTH WITH NO NICKS AND CLEAN OF ALL DEBRIS AND LUBRICANTS.

CAUTION DUST CAP MUST BE REMOVED BY HAND. THE USE OF A STRAP WRENCH IS PERMITTED, IF REQUIRED, TO INITIALLY LOOSEN THE DUST CAP.

CAUTION PIVOT SHAFT CAP SCREWS MUST BE REMOVED OR DAMAGE TO THE CAP SCREWS OR THE PIVOT SHAFT WILL OCCUR.

CAUTION DO NOT PUSH PIVOT SHAFT PAST THE WELDMENT. THE SCISSORS ALSO PIVOT ON THIS SHAFT.

CAUTION INSTALLING MAIN LIFT CYLINDERS MAY BE POTENTIALLY HAZARDOUS DUE TO THE SIZE, WEIGHT AND POSITION OF THE CYLINDERS. USE EXTREME CAUTION WHEN PERFORMING THESE PROCEDURES.

CAUTION DO NOT START ENGINE, USE THE EMERGENCY PUMP TO PROVIDE HYDRAULIC FLUID WHEN BLEEDING AIR FROM THE MAIN LIFT CYLINDERS.

CAUTION USE EXTREME CARE WHEN REMOVING CYLINDER WHEN PORTABLE ENGINE HOIST IS NOT AVAILABLE. PERSONAL INJURY CAN OCCUR IF CYLINDER IS DROPPED.

CAUTION TO PREVENT ENGINE DAMAGE AND POSSIBLE COMPLETE DESTRUCTION OF THE TURBOCHARGER, ALWAYS COVER TURBOCHARGER INLET AND EXHAUST OPENINGS TO PREVENT THE ENTRANCE OF ANY FOREIGN OBJECT.

xxxv

Halvorsen CAUTION DO NOT ALLOW THE FRONT OF THE TRANSMISSION TO BE LOWER THAN LEVEL TO PREVENT THE TORQUE CONVERTER FROM SLIDING FORWARD AND OUT OF THE TRANSMISSION.

CAUTION IF A CONDITION OCCURS THAT INTRODUCES DEBRIS INTO THE TRANSMISSION HYDRAULIC SYSTEM, A COMPLETE CLEANUP OF THE OIL COOLER AND HYDRAULIC LINES IS REQUIRED BEFORE REPLACEMENT TRANSMISSION IS INSTALLED.

CAUTION CONTAINERS OR FILLERS THAT HAVE BEEN USED TO HANDLE ANTIFREEZE OR ENGINE COOLANT SOLUTION MUST NEVER BE USED FOR TRANSMISSION FLUID. ANTIFREEZE AND COOLANT SOLUTIONS CONTAIN ETHYLENE GLYCOL WHICH, IF INTRODUCED INTO THE TRANSMISSION, CAN CAUSE THE CLUTCH PLATES TO FAIL.

CAUTION DO NOT REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY UNTIL ALL REPLACEMENT SERVICE PARTS ARE ON HAND AND READY TO BE INSTALLED. THE FRONT SIDE SHIFT BOGY ASSEMBLY IS A MAJOR STRUCTURAL ITEM. TO AVOID DAMAGE, THE LOADER MUST NOT BE LEFT IN THIS DISASSEMBLED STATE FOR A LONG PERIOD OF TIME.

CAUTION DO NOT OPERATE THE LOADER WHILE THE FRONT SIDE SHIFT BOGY IS REMOVED TO PREVENT DAMAGING THE LOADER. THE HEAVY LIFTING EQUIPMENT SHOULD REMAIN.

CAUTION FAILURE TO POSITION AND ORIENT THE COUPLING CORRECTLY COULD CAUSE DAMAGE TO THE COUPLING AND PUMP.

CAUTION DO NOT PLACE HYDRAULIC JACK UNDER THE BOWL IN THE CENTER OF THE AXLE HOUSING.

CAUTION USE A WHEEL CHANGING JACK OR TWO PERSONS, TO REMOVE AND INSTALL THE WHEEL ASSEMBLY.

xxxvi

Halvorsen CAUTION TO PREVENT FATIGUE AND FRACTURING OF THE WHEEL BOLTS WHEN USING IMPACT TOOLS, DO NOT ALLOW THE IMPACT TOOLS TO “HAMMER” AFTER THE NUT IS SEATED.

CAUTION DO NOT OVERFILL THE HYDRAULIC RESERVOIR. RESERVOIR CAN BE DAMAGED IF THE OIL LEVEL IS ABOVE THE “FULL” MARK, ON THE AFT END OF THE RESERVOIR, WHEN THE DECK IS FULLY LOWERED.

CAUTION WHENEVER THE COOLING SYSTEM HAS BEEN DRAINED, YOU MUST BLEED ALL AIR FROM THE COOLING SYSTEM TO AVOID SERIOUS ENGINE DAMAGE.

CAUTION ALL OF THE SERVICE PROCEDURES DESCRIBED ARE ONLY PERFORMED AFTER AIR CONDITIONER SYSTEM REFRIGERANT HAS BEEN RECOVERED. NEVER USE REGULAR SHOP OIL OR JOINT COMPOUND TO LUBRICATE OR SEAL ANY A/C CONNECTIONS. ENSURE THE MANUFACTURER’S MANUAL IS PRESENT FOR REFERENCE.

CAUTION EVEN WHEN TOLD OF AIR CONDITIONING SYSTEM DEFECT, ALWAYS PERFORM A VISUAL INSPECTION PRIOR TO CONNECTING THE MANIFOLD GAUGE SET. NEVER ATTEMPT TO ADD REFRIGERANT TO A SYSTEM UNTIL YOU HAVE MADE A COMPLETE VISUAL AND PERFORMANCE INSPECTION OF ALL OF THE COMPONENTS.

CAUTION BE CAREFUL NOT TO BEND PINCH-WELD WHEN REMOVING THE GLASS FROM THE ADHESIVE.

CAUTION DO NOT RUN ENGINE HIGHER THAN 1200 RPM DURING BRAKE FUNCTION TESTS.

CAUTION WHEN INSTALLING BACK-UP RINGS, IT IS ESSENTIAL THAT SURFACES OF DIAGONAL SPLICE MATCH WITH EACH OTHER AFTER BACK-UP RING IS INSTALLED IN GROOVE.

xxxvii

Halvorsen CAUTION ONLY SELECT PREDRILLED HOLES THAT WILL NOT ALLOW YOU TO DRILL INTO THE BLIND CAVITIES BEHIND THE DECK BEAM, AS A NUT IS GOING TO BE INSTALLED ON THE BACK SIDE OF THE DECK BEAM.

CAUTION THE DECK MUST BE CENTERED AND LEVEL BEFORE ANY MODIFICATIONS ARE TO BE PERFORMED. FAILURE TO CENTER AND LEVEL THE DECK MAY CAUSE MISALIGNMENT ISSUES LATER IN THE PROCEDURES.

CAUTION DO NOT CUT INTO OR REMOVE MATERIAL FROM THE DECK BUMPER WHEN REMOVING ITEMS USING CUTTING OR GRINDING TOOLS.

CAUTION DO NOT CONTINUE TO ENGAGE THE LIFT JOYSTICK IF THE ENGINE REVS UP WHILE THE AIR TRANSPORT SYSTEM CLEVIS AND PIN ARE INSTALLED. STRUCTURAL DAMAGE WILL OCCUR. TROULESHOOT THE ISSUE BEFORE PROCEEDING.

CAUTION TO PREVENT DAMAGE TO ENCLOSURE WHEN DRILLING HOLES DO NOT PUSH ON DRILL WITH EXCESSIVE FORCE.

CAUTION SECURE BRACE IN REQUIRED POSITION BEFORE TIGHTENING HARDWARE. DO NOT TORQUE UNTIL INSTRUCTED AT THE END OF THE INSTALLATION.

xxxviii

Halvorsen TABLE OF CONTENTS CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Section 1. Description 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

CAPABILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3.

MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

A.

CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

B.

POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

C.

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

D.

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

E.

DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

F.

REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

G.

PLATFORM LIFT SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

H.

LOAD TRANSFER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

I.

OPERATOR’S CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

J.

WINTERIZATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

K.

AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Section 2. Operation 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3.

CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

A.

DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

B.

CONVEY PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

C.

WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

D.

AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

A.

PRE-OPERATION DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Table 1 - OPERATOR’S DAILY INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . .

13

B.

STARTING POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

C.

STOPPING LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

4.

TABLE OF CONTENTS

1-Contents Page 1 August 2017

Halvorsen 5.

D.

MAINTENANCE STANDS INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .

24

E.

DECK CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

F.

DRIVING THE LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

LOADING AND UNLOADING CARGO PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

A.

LOADING CARGO ON THE LOADER - FRONT END OPERATION . . . . . . . . . . . . . . . . . . .

39

B.

OFF LOADING CARGO ON THE LOADER - FRONT END OPERATION . . . . . . . . . . . . . . .

40

C.

LOADING CARGO ON THE LOADER - BACK END OPERATION . . . . . . . . . . . . . . . . . . . . .

41

D.

OFF LOADING CARGO ON THE LOADER - BACK END OPERATION. . . . . . . . . . . . . . . . .

42

E.

LOADING ROLLING STOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

Section 3. Emergency Procedures 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

EMERGENCY PROCEDURES‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

EMERGENCY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

B.

EMERGENCY MANOUVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

C.

TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

D.

LIFTING AND TOWING LOADER WITH A TOW VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Section 4. Specifications 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

MODEL DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3.

AIRCRAFT ACCOMODATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

4.

OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

5.

GENERAL DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

A.

DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

B.

WEIGHTS AND VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Table 1 - WEIGHTS AND VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 2 - ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . . . .

5

FUEL SPECIFICATIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 3 - FUEL SPECIFICATIONS AND DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

A.

FUEL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

B.

FUEL TANK CAPACITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

C.

FILTER TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6. 7. 8.

1-Contents Page 2 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 9.

RADIATOR (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

10.

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

11.

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

12.

AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

A.

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

B.

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Table 4 - TRANSMISSION RATIOS (MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

A.

FLUID TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

B.

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

C.

EMERGENCY ELECTRIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

D.

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

E.

HOSE ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

F.

OPERATING PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

A.

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

B.

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

16.

OTHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

17.

PAINT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

18.

ADDITIONAL FEATURES AND EMERGENCY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

19.

VEHICLE JACKING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

A.

JACK CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

B.

MAINTENANCE STANDS CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

C.

PRESSURE EXERTED BY VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

D.

JACK AND MAINTENANCE STANDS SUPPORT SURFACE . . . . . . . . . . . . . . . . . . . . . . . .

10

ENVIRONMENTAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

A.

OPERATING TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Table 5 - AMBIENT OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

WINTERIZATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

OPERATOR'S VIBRATION AND SOUND LEVELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

A.

SOUND LEVEL EMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Table 6 - SOUND LEVEL EMISSION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

VIBRATION LEVEL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Table 7 - METRIC AND STANDARD UNITS AND CONVERSIONS . . . . . . . . . . . . . . . . . . .

12

13. 14.

15.

20.

B. 21.

B. 22.

TABLE OF CONTENTS

1-Contents Page 3 August 2017

Halvorsen Section 5. Shipping and Transportation 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

SHIPPING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3.

PREPARATION FOR TRANSPORTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

A.

PREPARE DECK FOR CAB RETRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

B.

CAB AND WALK-DECK INTO SHIPPING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . .

6

C.

REMOVE THE LADDER AND STOW ON TOP OF THE DECK . . . . . . . . . . . . . . . . . . . . . . .

6

D.

CONFIGURE THE FOLDING WALK-DECK AND HANDRAIL SECTIONS . . . . . . . . . . . . . . .

9

LOADING ONTO AIRCRAFT AND SURFACE TRANSPORT VEHICLES . . . . . . . . . . . . . . . . . . . .

9

A.

SETTING INTO AIR TRANSPORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

B.

LOADING THE VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

LOADING OFF FROM AIRCRAFT AND SURFACE TRANSPORT VEHICLES. . . . . . . . . . . . . . . .

11

A.

PREPARE FOR UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

B.

START THE ENGINE AND VERIFY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

SLING LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

A.

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

B.

SECURE THE FRONT OF THE CHASSIS TO THE DECK ASSEMBLY . . . . . . . . . . . . . . . .

15

7.

TIE-DOWN POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

8.

PREPARE THE LOADER FOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

A.

CONFIGURE FOLDING WALK-DECK AND HANDRAIL SECTIONS . . . . . . . . . . . . . . . . . . .

18

B.

INSTALL THE LADDER FOR OPERATOR ACCESS TO THE CAB . . . . . . . . . . . . . . . . . . . .

18

C.

CONFIGURE THE CAB INTO OPERATIONAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

4.

5.

6.

1-Contents Page 4 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 6. Storage 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

STORAGE - ONE MONTH (MAXIMUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

B.

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

C.

BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

D.

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

E.

AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

F.

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

G.

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

H.

GENERAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

STORAGE - INDEFINITE PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

A.

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

B.

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

C.

BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

D.

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

E.

AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

F.

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

G.

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

H.

GENERAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

I.

EQUIPMENT SHELTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

RETURNING VEHICLE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

A.

RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE . . . . . . . . . . . . . . . . . . . .

5

B.

RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY . . . . . . . . . . . . . .

5

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

A.

SHORT-TERM STORAGE - ONE MONTH MAXIMUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

B.

LONG-TERM STORAGE - THREE YEARS MAXIMUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

3.

4.

5.

TABLE OF CONTENTS

1-Contents Page 5 August 2017

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen LIST OF FIGURES CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Section 1. Description 1-1

Figure 1

HALVORSEN LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1-1

Figure 2

VEHICLE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1-1

Figure 3

POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1-1

Figure 4

SCISSORS - LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1-1

Figure 5

LOAD TRANSFER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1-1

Figure 6

OPERATOR’S CAB - EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

1-1

Figure 7

DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1-1

Figure 8

CONVEY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

1-1

Figure 9

CONVEY DIRECTION AND SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . .

11

1-1

Figure 10

WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

1-1

Figure 11

SPOTLIGHTS HANDLES AND DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . .

13

1-1

Figure 12

CAB’S ROOF SPOTLIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

1-1

Figure 13

WINTERIZATION RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

1-1

Figure 14

AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Section 2. Operation 1-2

Figure 1

DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1-2

Figure 2

CONVEY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1-2

Figure 3

WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1-2

Figure 4

AIR CONDITIONING SYSTEM EVAPORATOR BOX. . . . . . . . . . . . . . . . . . . . . .

10

1-2

Figure 5

ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

1-2

Figure 6

HYDRAULIC RETURN FILTER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

1-2

Figure 7

BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

1-2

Figure 8

MAIN PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

1-2

Figure 9

WINTERIZATION RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

1-2

Figure 10

DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

1-2

Figure 11

TRANSMISSION RANGE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

1-2

Figure 12

DASH PANEL - LOWER RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

1-2

Figure 13

MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

LIST OF FIGURES

1-Figures Page 1 August 2017

Halvorsen 1-2

Figure 14

RETAINING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

1-2

Figure 15

TRAY WITH SMOOTH SIDE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1-2

Figure 16

DECK CONFIGURED FOR FORKLIFT LOADING FROM THE REAR . . . . . . . . .

27

1-2

Figure 17

CASTERS IN THE UP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

1-2

Figure 18

DECK CONFIGURED FOR FORKLIFT LOADING FROM THE SIDE . . . . . . . . . .

29

1-2

Figure 19

CASTERS IN THE UP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

1-2

Figure 20

CONVEY MODULE LATCH HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

1-2

Figure 21

LOWER LOBE INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

1-2

Figure 22

FOLDING WINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

1-2

Figure 23

RIGHT SIDE HANDRAIL AND WALK-DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

1-2

Figure 24

TRANSMISSION RANGE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

1-2

Figure 25

DASH PANEL - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

1-2

Figure 26

DASH PANEL - LOWER-RIGHT CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

1-2

Figure 27

PALLET LOCK IN RELEASED POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

1-2

Figure 28

PALLET LOCK IN LOCKED POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

1-2

Figure 29

SAFETY HARNESS AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

1-2

Figure 30

LOADER DECK FOR ROLLING STOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

Section 3. Emergency Procedures 1-3

Figure 1

DASH PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1-3

Figure 2

MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1-3

Figure 3

CHASSIS MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1-3

Figure 4

LOADER TOW POINTS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Section 4. Specifications 1-4

Figure 1

1-Figures Page 2 August 2017

GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 5. Shipping and Transportation 1-5

Figure 1.

OVERALL SHIPPING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1-5

Figure 2.

RETAINING PIN AND HINGE DECK WELDMENT LOCK . . . . . . . . . . . . . . . . . .

4

1-5

Figure 3.

HINGED DECK WELDMENT AND ROLLER TRAY . . . . . . . . . . . . . . . . . . . . . . .

5

1-5

Figure 4.

CAB AND WALK-DECK SHIPPING CONFIGURATION. . . . . . . . . . . . . . . . . . . .

6

1-5

Figure 5.

UPPER LADDER SUPPORT RETAINING PIN. . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1-5

Figure 6.

LOWER LADDER SUPPORT RETAINING PIN . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1-5

Figure 7.

LADDER STOWED ON DECK IN THE MIDDLE RIGHT SIDE. . . . . . . . . . . . . . .

8

1-5

Figure 8.

LADDER SUPPORT RETAINING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

1-5

Figure 9

AIR TRANSPORT CLEVIS AND PIN IN LATCHED POSITION . . . . . . . . . . . . . .

10

1-5

Figure 10

BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

1-5

Figure 11

AIR TRANSPORT PIN AND CLEVIS IN STOWING POSITION . . . . . . . . . . . . . .

13

1-5

Figure 12

HELPER CYLINDER SUPPORT CASTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

1-5

Figure 13

CHASSIS TOWING EYE CHAIN ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

1-5

Figure 14

LIFTING PROVISION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

1-5

Figure 15

TRANSPORT TIE-DOWN POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Section 6. Storage

LIST OF FIGURES

1-Figures Page 3 August 2017

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Section 1. Description 1.

GENERAL NOTE:

REFER TO CHAPTER 1, SECTION 3 FOR EMERGENCY PROCEDURES.

The Halvorsen, 25 000 lb. Loader for Aircraft, is a self-propelled, hydraulically-operated and electrically-controlled cargo loading vehicle. Refer to Figure 1. A six-cylinder turbocharged diesel engine, coupled to a four-speed automatic transmission, provides the power to propel the vehicle and operate the hydraulic and electrical systems. A battery-powered electric motor drives an auxiliary hydraulic pump that is incorporated in the hydraulic system for emergency operation in the event of a failure of the main power unit. The automatic transmission provides precise control and inching capability for approaching aircraft and loading docks. The loader is capable of negotiating rain, snow, sleet, sand, standing water and mud at reduced speeds while operating on improved surfaces, as well as operating at reduced speeds on level, semi-prepared surfaces, including gravel, perforated steel planking (PSP) and rapid runway repair (RRR) slab. The loader has an enclosed cab mounted on the deck that contains the driving and operating controls. It provides comfort and safety for operating in all types of weather conditions. The cab is equipped with an air conditioning system which gives the operator comfort during hot weather. The air conditioning system can be used in conjunction with the heater (controlled separately) to defog windows and dehumidify and cool the cab as required. NOTE: 2.

REFER TO CHAPTER 2, SECTION 2, “SYSTEM OVERVIEW” FOR MORE DETAILED INFORMATION ABOUT ASSEMBLIES AND COMPONENTS.

CAPABILITIES The deck powered convey system moves palletized and platform cargo along the deck. The powered rollers can be lowered for moving cargo by hand or for loading and off-loading cargo from forklifts on either the right side or at the rear of the loader. Rolling stock can be driven on and off the deck from either the front or the rear. NOTE:

DESCRIPTION

REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR DETAILED INFORMATION ON CAPABILITIES, AIRCRAFT ACCOMMODATION, WEIGHTS AND OTHER RELATED DATA.

1-1 Page 1 August 2017

Halvorsen

Figure 1 HALVORSEN LOADER

1-1 Page 2 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 3.

MAJOR COMPONENTS A.

CHASSIS The chassis assembly is a welded steel frame and provides the base for the mounting of the front drive steer axle, rear axle, power unit and the electrical, hydraulic and fuel systems. The scissors lifting system is attached to the chassis. Towing and tie-down points are incorporated in the chassis frame. Refer to Figure 2.

MAIN PANEL DRIVE/STEER AXLE

FUEL TANK POWER UNIT RADIATOR HELPER CYLINDER

WINTERIZATION PANEL & RECEPTACLE EMERGENCY PUMP CHASSIS HYDRAULIC MANIFOLD HYDRAULIC RESERVOIR

REAR AXLE ASSEMBLY TOWING/TIE-DOWN POINTS

Figure 2 VEHICLE CHASSIS

DESCRIPTION

1-1 Page 3 August 2017

Halvorsen B.

POWER UNIT The power unit consists of a six-cylinder turbocharged diesel engine with an automatic transmission coupled to the flywheel and a variable displacement hydraulic pump coupled to the front end of the crankshaft. The power unit is mounted in the center of the chassis and the transmission is connected to the front drive and steer axle with a drive shaft. Refer to Figure 3. TRANSMISSION

ENGINE

HYDRAULIC PUMP

GENERATOR ALTERNATOR

ENGINE AIR CLEANER

Figure 3 POWER UNIT The diesel engine provides powers the automatic transmission to propel the loader, the pump to operate the hydraulic systems and the alternator to keep the batteries in a fully charged state. A compressor is powered by an hydraulic motor attached to the compressor that cools the operator’s cab on the loader. 1-1 Page 4 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen C.

COOLING SYSTEM The engine cooling system for dissipating heat is a closed-loop system consisting of a radiator in a housing and a fan driven by a hydraulic motor. The radiator is remotely mounted outside the right-side chassis frame. The fan motor has two speeds and is controlled by sensors in the cooling system. The engine-driven water pump circulates coolant in the system and a thermostat controls engine temperature by regulating the flow of the coolant. A tank mounted, on top of the engine, serves as a reservoir for the fluid volume required to maintain the cooling system temperature within the operating range. The coolant recovery tank, mounted at the rear of the engine, allows coolant recovery to maintain a constant fluid level and prevents the introduction of air in the closed loop system.

D.

TRANSMISSION A four-speed automatic transmission is coupled to the engine flywheel for directional control. The torque converter provides inching capability and smooth acceleration in any range selected. The transmission output shaft is directly connected to the differential pinion shaft with a drive shaft. Range selection is accomplished by an electrically controlled joystick lever with digital readout in the operator’s cab, which actuates a hydraulic cylinder mounted on the transmission, for positioning the transmission control valve. A remote-mounted oil cooler is incorporated in the engine coolant system to remove excessive heat from the transmission fluid and warm the transmission fluid when operating in cold weather conditions.

E.

DRIVE AND STEER FRONT AXLE The front axle is the loader’s drive and steer axle and is rigidly attached to the chassis frame. Incorporated in the axle are the differential assembly, planetary wheel ends and power steering cylinders. A brake disc is attached to the companion flange on the differential pinion shaft and the front axle service brake and parking brake calipers react on the disc. A differential lock is provided for positive driving of both wheels should one wheel lose traction on slippery surfaces.

F.

REAR AXLE ASSEMBLY The rear axle assembly provides support for the loader chassis at the back end and consists of a framework that has an axle pivot shaft at the front and two attaching lugs at the back end. A bogy assembly, consisting of an arm with two wheel assemblies attached and a telescoping hydraulic cylinder, is assembled on each end of the axle shaft. The helper cylinders are telescoping hydraulic cylinders used to assist the deck main lift cylinders in raising the deck when the deck is at the lowest position and provide additional chassis clearance when driving up and down ramps. The bogy assemblies pivot on the axle shaft when traveling over irregular surfaces and each wheel assembly remains on the surface to support the load. Each wheel assembly has an external disc brake assembly incorporated in the wheel hub. The rear axle assembly is underneath the chassis at the back end of the loader and is attached to the chassis with pivot pins. In the normal operating configuration, the chassis rests on the axle shaft. When the loader is to be air transported additional chassis height is required to provide clearance at the crest of the aircraft loading ramp. To obtain the additional clearance, the airportability latch is engaged to physically lock the deck to the chassis at rear of the loader and the DECK RAISE switch is actuated. The helper cylinders, attached to the axle assembly shaft, will extend and force the deck and chassis up to provide the required additional clearance.

DESCRIPTION

1-1 Page 5 August 2017

Halvorsen G.

PLATFORM LIFT SCISSORS The scissors provide the means to raise and lower the deck and pitch the deck for alignment of roll plane of the aircraft, loading dock and other MHE. Refer to Figure 4.

Figure 4 SCISSORS - LEFT SIDE VIEW The forward ends of the outer scissors pivot on the main lift cylinder pivot pins and the back ends of the inner scissors have rollers that travel on the main frame as the deck rises. The forward ends of the inner scissors and the back ends of the outer scissors have lugs for securing the roll cylinders. The outer scissors legs are made in two parts to permit the rear sections to pivot on the joints for pitching the deck up and down.

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GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen H.

LOAD TRANSFER DECK The deck is an aluminum structure that is raised and lowered by the scissors and contains the powered convey system for moving cargo on and off the top surface. Refer to Figure 5. Fixed rollers are in removable trays that can be removed and inverted to make a smooth surface to accommodate the movement of rolling stock on the deck. Cargo can be conveyed fore and aft on the deck and provision has been made for placing and removing cargo on the deck with forklifts at the rear and right side. Adjustable pallet guides are incorporated in the deck for conveying 88-inch or 108-inch pallets. Pallet locks are incorporated in the guides to restrain pallets during transport. The deck includes tie-down points for securing cargo and rolling stock, removable handrails and a ladder for operator access and safety.

HANDRAIL FOLDING WINGS

ROLLER TRAYS PALLET GUIDE

PALLET LOCK

HANDRAIL

PALLET GUIDE PALLET LOCK

Figure 5 LOAD TRANSFER DECK

DESCRIPTION

1-1 Page 7 August 2017

Halvorsen I.

OPERATOR’S CAB The fully enclosed cab, mounted on the left side of the deck, provides optimum visibility, air conditioned comfort for the operator when needed and contains all controls for driving and operating the loader. Refer to Figure 6. FIRE EXTINGUISHER

FILL POINT WINDSHIELD WASHER FLUID WASHER FLUID LEVEL GAUGE

REAR DOOR

SIDE DOOR

Figure 6 OPERATOR’S CAB - EXTERIOR NOTE:

1-1 Page 8 August 2017

DUE TO THE CAB WINDOWS BEING TINTED IN THE LOADER, THE OPERATOR’S VISION MAY BE LIMITED AT NIGHT. THE OPERATOR MUST REMAIN ALERT WHILE OPERATING THE LOADER AT NIGHT.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (1)

Dash Panel This panel is located directly in front of the operator, has all switches, gauges and indicator lights for starting and shutting down the engine and monitoring the engine and hydraulic system conditions. Refer to Figure 7.

Figure 7 DASH PANEL

DESCRIPTION

1-1 Page 9 August 2017

Halvorsen All panels have illumination lights with a dimmer control for lowering light intensity and reducing glare. (2)

Deck Convey Panel at the operator’s right side, contains the controls that activate the convey system for moving cargo on and off the deck. Refer to Figure 8.

CONVEY JOYSTICK CONVEY JOYSTICK LATCH

Figure 8 CONVEY PANEL

1-1 Page 10 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (3)

Convey Direction and Speed Control Joystick Switch Both located on the convey control panel to the operator’s right side is latched in the neutral position to prevent accidental movement of the joystick handle. Refer to Figure 9. The operator must unlatch the handle by lifting the latch with the fingers to move out of the neutral position, then move the joystick in the direction that cargo is to be conveyed on the deck. Convey speed is variable and is controlled by the distance the joystick handle is moved, forward or aft, of the neutral position.

TRANSMISSION RANGE SELECTOR

CONVEY PANEL

CONVEY DIRECTION AND SPEED CONTROL

Figure 9 CONVEY DIRECTION AND SPEED CONTROL

DESCRIPTION

1-1 Page 11 August 2017

Halvorsen (4)

Accelerator and Brake Pedals Both pedals are conventional and located on the floor of the cab (not shown).

(5)

Wipers and Washers Panel Located overhead in the upper-right corner of the cab enclosure. It contains the switches and circuit breakers for the front and rear wipers and washers. Refer to Figure 10.

Figure 10 WIPERS AND WASHERS PANEL

1-1 Page 12 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (6)

Spotlights Control Handles Two spotlights with inside cab controls, are mounted on the cab roof for illuminating the work area. Refer to Figure 11 and Figure 12.

FAN

INTERIOR LIGHT WIPER PANEL

SPOTLIGHT CONTROL HANDLE CAB INTERIOR, TOP FRONT

WIPER WIPER MOTOR

DOOR LATCH

Figure 11 SPOTLIGHTS HANDLES AND DOOR LATCH

DESCRIPTION

1-1 Page 13 August 2017

Halvorsen SPOTLIGHTS

SLIDING HANDRAIL

Figure 12 CAB’S ROOF SPOTLIGHTS

1-1 Page 14 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen J.

WINTERIZATION SYSTEM For operating in cold weather conditions, an external AC power source of either 120 or 240 VAC can be connected to the winterization receptacle located on the left side of the loader. Refer to Figure 13. The system automatically senses the voltage applied and adjusts the output voltage for the heating elements installed for operating in cold weather. Heating elements installed warm the engine oil, engine coolant, transmission fluid, hydraulic fluid and batteries. When the external power source is connected, the WINTERIZATION CONNECTED indicator light illuminates on the dash panel and the loader engine cannot be operated.

EMERGENCY PUMP WINTERIZATION RECEPTACLE

CIRCUIT BREAKER

WEATHER CAP

Figure 13 WINTERIZATION RECEPTACLE NOTE:

DESCRIPTION

EXTERNAL POWER CORD MUST BE ENERGIZED TO ILLUMINATE THE INDICATOR LIGHT ON THE DRIVER’S DASH PANEL.

1-1 Page 15 August 2017

Halvorsen K.

AIR CONDITIONING SYSTEM Heating and air conditioning systems provide temperature control inside the operator’s cab. These systems also provide defogging of windows and humidity control. The air conditioning system can be used to cool the cab prior to use as well as during loader operation. The air conditioning system requires regular operator maintenance. The operator must refer any malfunctions, damage or irregular operation to the maintenance section as soon as possible. Operator must keep the unit clean and refrain from placing papers and other objects on the return air inlet. Refer to Figure 14.

3 POSITION FAN SWITCH 3 POSITION A/C MODE SWITCH

POWER CONNECTIONS

DIRECTIONAL VENT LOUVERS

EVAPORATOR BOX FILTER INLET Figure 14 AIR CONDITIONING SYSTEM NOTE:

1-1 Page 16 August 2017

REFER TO THE MANUFACTURER’S MANUAL WHEN PERFORMING MAINTENANCE ON THE AIR CONDITIONING SYSTEM.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 2. Operation 1.

GENERAL NOTE:

REFER TO CHAPTER 1, SECTION 3 FOR EMERGENCY PROCEDURES.

This section contains operation instructions for the Halvorsen. A discussion of the principles of operation is given to aid in understanding of its operation. The operator must use approved procedures for approaching and departing aircraft, loading, unloading, conveying or transferring cargo. All procedures followed should be approved by the airline and the local aviation authority and based on the recommendations of the aircraft manufacturer.

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS.

WARNING THE DECK MUST BE FULLY LOWERED AND THE VEHICLE MUST BE PROPERLY PARKED BEFORE BOARDING OR LEAVING THE UNIT. USE THE LADDER LOCATED BEHIND THE OPERATOR'S CAB TO GET ON AND GET OFF THE DECK. ENSURE THE LADDER AND DECK AREA, BOTH ON AND BELOW, ARE CLEAR OF PERSONS AND FREE OF ANY OBJECTS WHILE OPERATING THE VEHICLE. DO NOT RELY SOLELY ON SENSORS AND WARNING LIGHTS.

WARNING IT IS MANDATORY THAT ALL PERSONNEL WEAR A SAFETY HARNESS, WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” WHEN WORKING ON THE DECK IN THE AREA IDENTIFIED AND MARKED AS “HARNESS REQUIRED AREA”.

WARNING USE EXTREME CAUTION AT ALL TIMES WHEN WALKING ON THE DECK DO NOT STEP ON ROLLERS OR ROLLER ASSEMBLIES.

WARNING ENSURE THE LADDER AND DECK ARE CLEAR OF PERSONS WHILE DRIVING AND OPERATING THE VEHICLE.

OPERATION

1-2 Page 1 August 2017

Halvorsen WARNING APPLY THE PARKING BRAKE AND TURN OFF THE IGNITION SWITCH BEFORE LEAVING THE VEHICLE UNATTENDED. 2.

SAFETY PRECAUTIONS •

Before operating the vehicle, the operator should read this manual and become completely familiarized with the vehicle.

•

Learn how your vehicle is operated. Know the location and functions of all controls, indicators, caution instructions and warning and safety devices.

•

Always perform the maintenance checks. Proper maintenance is necessary to ensure the maximum performance of your equipment.

•

Follow the correct starting, warm-up, operating, stopping and parking procedures.

•

Remember that it only takes one unsafe action to cause an accident. Use the general safety guidelines recommended by S.A.E., specification S.A.E. J153. Follow your employer’s safety rules and instructions to develop safe working habits. A careful operator is the best safety device there is.

WARNING DO NOT ALLOW PERSONS ON THE DECK WHILE IN MOTION OR IN AN ELEVATED POSITION. DECK MAINTENANCE MAY BE PERFORMED FROM UNDERNEATH USING SAFETY SUPPORTS.

WARNING NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.

WARNING NORMAL LOADING OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING REFUELED WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE VEHICLE.

WARNING USE CAUTION WHILE REFUELING THE VEHICLE TO AVOID FUEL SPILLS. CLEAN SPILLS PROMPTLY.

WARNING AN OBSERVER ON THE GROUND SHOULD BE USED TO GUIDE THE OPERATOR WHEN DRIVING THE VEHICLE IN REVERSE.

1-2 Page 2 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen WARNING AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF THE VEHICLE.

WARNING THE VEHICLE IS DESIGNED TO BE DRIVEN ON PAVED OR CEMENT SURFACES APPROVED TO SUPPORT THE WEIGHT AND USE OF GROUND SUPPORT EQUIPMENT VEHICLES.

WARNING DO NOT LIFT PERSONS WITH THE VEHICLE. THE LOADER IS NOT INTENDED FOR LIFTING OF PERSONS OTHER THAN THE DRIVER.

WARNING DO NOT ALLOW PERSONS UNDER THE DECK UNLESS ADEQUATE SUPPORTS ARE IN PLACE.

WARNING ALWAYS WEAR GLOVES TO PREVENT CONTACT WITH VERY COLD OR VERY HOT METAL AND SURFACES WITH BARE HANDS.

CAUTION WHEN OPERATING THE VEHICLE IN FREEZING CONDITIONS, OCCASIONALLY TURN THE STEERING WHEEL SLOWLY TO PREVENT THERMAL SHOCK IN THE STEERING VALVE.

CAUTION DO NOT PLACE THE EQUIPMENT INTO SERVICE WITHOUT PERFORMING ALL THE RECOMMENDED MAINTENANCE. 3.

CONTROLS AND INDICATORS A.

DASH PANEL The dash panel is located directly in front of the operator and contains all switches, gauges and indicator lights for starting and monitoring the engine, hydraulic system conditions and shutting down the engine. Refer to Figure 1. At the lower-right side of the dash panel are the EMERGENCY STOP push and pull switch and the EMERGENCY PUMP switch. The PARKING BRAKE, HYDRAULIC PREHEAT and DIFFERENTIAL LOCK switches have indicating lights to alert the operator when these switches are actuated and are located to the left of the engine control switches.

OPERATION

1-2 Page 3 August 2017

Halvorsen The deck control switches are located at the lower-left side of the panel with indicator lights directly above at the top of the panel that indicate that the deck has been re-positioned for alignment to the aircraft, loading dock or other material handling equipment. Directly to the right of the deck control switches is the deck LIFT joystick. Directional signal and headlight high beam indicator lights are at the top center of the dash panel.

1-2 Page 4 August 2017

(1)

ENGINE PREHEAT (AMBER) - Light indicating engine glow plugs are in the heating cycle.

(2)

DIFFERENTIAL LOCK ON (AMBER) - Light indicating the differential lock is engaged for driving on slippery surfaces.

(3)

HYDRAULIC FLUID COLD (AMBER) - Light indicating hydraulic fluid is below -9 ºC (10 ºF).

(4)

HYDRAULIC FLUID HOT (RED) - Light indicating hydraulic fluid is above 82 ºC (180 ºF). Engine will shut down when illuminated.

(5)

TRANSMISSION FLUID HOT (RED) - Light indicating transmission fluid is above 108 ºC (225 ºF). Engine will shut down when illuminated.

(6)

GENERATOR (RED) - Light indicating generator is not charging.

(7)

ENGINE HOT (RED) - Light indicating engine coolant is above 108 ºC (225 ºF). Engine will shut down when illuminated.

(8)

ENGINE OIL PRESS (RED) - Light indicating engine oil pressure is below 27.5 kPa (4 psi). Engine will shut down when illuminated.

(9)

EMERGENCY PUMP (E-PUMP) and LOW PRESSURE (RED) - Flashing light indicating the emergency hydraulic pump is operating.

(10)

PARKING BRAKE ON (RED) - Light indicating parking brake is applied.

(11)

AIR TRANSPORT (RED) - Light indicating the deck-to-chassis lock pin is installed.

(12)

HIGH BEAM (BLUE) - Light indicating headlights are on high beam.

(13)

WINTERIZATION CONNECTED (RED) - Light indicating an external AC power cord is connected to the winterization receptacle and the circuit is energized.

(14)

- GREEN light indicating left-turn directional signal lights are illuminated.

(15)

- GREEN light indicating right-turn directional signal lights are illuminated.

(16)

SHIFTED LEFT (AMBER) - Light indicating deck is shifted to the left.

(17)

SHIFTED RIGHT (AMBER) - Light indicating deck is shifted to the right.

(18)

ROLL LEFT (AMBER) - Light indicating the deck is raised on the right side.

(19)

ROLL RIGHT (AMBER) - Light indicating the deck is raised on the left side.

(20)

PITCH UP (AMBER) - Light indicating the deck is lowered at the back.

(21)

PITCH DOWN (AMBER) - Light indicating the deck is higher at the back.

(22)

NO PITCH (RED) - Light indicating deck cannot be pitched.

(23)

PANEL LIGHT - Illuminates the dash panel.

(24)

IGNITION SWITCH - Three-position switch for starting and shutting down engine. Start position is momentary contact.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

OPERATION

32

31

35

21

18

22

36

20

34

19

HOUR METER

33

23 16

37 38

HYD OIL TEMP

17

39 40

OIL PRESS

14

12

2

WATER TEMP

15

28

3

27

VOLT METER

11

10

4

26

FUEL GAUGE

9

25

5 23

23

SPEEDOMETER

6

24

1

TACHOMETER

8

13

7

30

29

42

41

Halvorsen

Figure 1 DASH PANEL

1-2 Page 5 August 2017

Halvorsen

B.

(25)

SHUTDOWN OVERRIDE and WARNING LIGHT TEST - Three-position momentary contact switch, center position OFF. UP position for starting engine when engine safety shutdown is active and DOWN position to test light bulbs in warning indicator lights.

(26)

PARK BRAKE - Two-position switch for applying and releasing parking brake.

(27)

HYDRAULIC PREHEAT - Two-position switch that activates the convey system to circulate hydraulic fluid to raise the temperature of the hydraulic fluid.

(28)

DIFFERENTIAL LOCK - Two-position switch that engages the front axle differential lock.

(29)

EMERGENCY STOP - Two-position push and pull switch that shuts the engine down and de-energizes all control circuits.

(30)

EMERGENCY PUMP - Two-position momentary contact switch that turns on the emergency pump when there is no fluid flow from the main hydraulic pump.

(31)

PITCH AND ROLL - Four-position joystick switch with momentary contacts that raises and lowers the rear of the deck when actuated fore and aft, as well as raises and lowers the deck on the left or right side when actuated to the left or right.

(32)

AUTO CENTER AND LEVEL - Two-position momentary contact switch that returns the deck to the normal level position.

(33)

LIFT - Two-position momentary joystick that raises the deck when pressed forward and lowers the deck when pulled to the rear.

(34)

SHIFT - Two-position momentary switch that shifts the deck to the left or right of the centerline.

(35)

HOURMETER - Indicates total accumulated hours of engine operation.

(36)

HYDRAULIC OIL TEMP - Indicates temperature of hydraulic oil in degrees Fahrenheit.

(37)

OIL PRESSURE - Indicates oil pressure of engine lubrication system.

(38)

WATER TEMP - Indicates temperature of engine coolant in degrees Fahrenheit.

(39)

VOLTMETER - Indicates voltage of the electrical system.

(40)

FUEL GAUGE - Indicates quantity of fuel in fuel tank.

(41)

SPEEDOMETER - Indicates speed of vehicle in miles per hour.

(42)

TACHOMETER - Indicates engine revolutions per minute.

CONVEY PANEL The deck convey panel at the operator’s right, contains the controls that activate the convey system for moving cargo onto and off the deck. Refer to Figure 2. The CONVEY MODE PALLET WIDTH switch, at the upper-right side of the panel, determines which convey rollers will rotate as the pallet is moved over each section of the deck. The CONVEY SECTION switches activate a section of the deck and each switch that is selected is indicated by a GREEN indicator light to alert the operator which sections are selected to be active during cargo movement on the deck. The FRONT STOP LOWERED and REAR STOP LOWERED switches control the front and rear pallet stops located on each end of the deck. The RED indicator light illuminates to alert the operator that the stop is lowered for transfer of cargo on and off the deck.

1-2 Page 6 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (1)

FRONT STOP LOWERED (RED) - Light indicating front pallet stop is lowered.

(2)

CONVEY FRONT SECTION (GREEN) - Light indicating front convey section is active.

(3)

CONVEY MID SECTION (GREEN) - Light indicating middle convey section is active.

(4)

CONVEY AFT SECTION (GREEN) - Light indicating aft convey section is active.

(5)

REAR STOP LOWERED (RED) - Light indicating rear pallet stop is lowered.

(6)

PANEL LIGHT - Illuminates the convey panel.

(7)

CONVEY - Two-way joystick control for selecting direction to convey cargo and the speed of the convey rollers. Joystick will latch in the center position (neutral) to prevent accidental actuation. Convey speed increases as the joystick handle is moved farther away from the neutral position.

Figure 2 CONVEY PANEL

OPERATION

1-2 Page 7 August 2017

Halvorsen

C.

(8)

CONVEY MODE PALLET WIDTH - Three-position switch that raises the convey modules and selects the rollers in each section to rotate for the pallet width selected, 2235 or 2743 mm (88 or 108 in.). When the OFF position is selected, the convey modules are lowered.

(9)

FRONT STOP LOWERED - Two-position switch that raises and lowers the front cargo stop.

(10)

CONVEY FRONT SECTION - Two-position switch that activates the rollers on the front convey section.

(11)

CONVEY MID SECTION - Two-position switch that activates the rollers on the middle convey section.

(12)

CONVEY AFT SECTION - Two-position switch that activates the rollers on the aft convey section.

(13)

REAR STOP LOWERED - Two-position switch with a momentary contact that lowers the rear cargo stop.

WIPERS AND WASHERS PANEL The wiper panel is an overhead panel located in the upper-right corner of the cab enclosure and contains the FRONT WIPER, REAR WIPER, FRONT WASHER and REAR WASHER switches at the left side of the panel. The FRONT WIPER and REAR WIPER circuit breakers are adjacent to the left of the switches. Refer to Figure 3. The HEADLIGHTS and CAB LIGHT switches are in the center of the panel, while the DOME LIGHT and CABIN DASH AND GAUGE LIGHTS dimmer switches are on the right side of the panel.

1-2 Page 8 August 2017

(1)

FRONT WIPER - Three-position switch for operating the windshield wiper motor with two speeds.

(2)

REAR WIPER - Three-position switch for operating the rear door wiper motor with two speeds.

(3)

FRONT WASHER - Two-position switch with a momentary contact that actuates the pump for the windshield washer.

(4)

REAR WASHER - Two-position switch with a momentary contact that actuates the pump for the rear door washer.

(5)

HEADLIGHTS - Three-position switch for operating the parking lights and headlights.

(6)

DOME LIGHT SWITCH - Rotary switch for turning dome light OFF and ON and adjusting the brightness.

(7)

DIMMER, CABIN AND DASH - Rotary switch that adjusts the brightness of the dash panel illumination lights and the gauge illumination lights.

(8)

PANEL LIGHT - Illuminates the overhead panel.

(9)

FRONT WIPER BREAKER - Resettable circuit breaker for front wipers.

(10)

REAR WIPER BREAKER - Resettable circuit breaker for rear wipers.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 9

10

1

3

2

4

8

6

5

7

Figure 3 WIPERS AND WASHERS PANEL D.

AIR CONDITIONING SYSTEM The air conditioning system evaporator box is located in the right rear of the loader’s cab behind the operator. There are two switches located on top of the evaporator box. Next to the switches at the top of the evaporator box, it is located a directional louver with air vents for distribution of conditioned air for dehumidifying and defogging. Refer to Figure 4. (1)

Air Conditioning Mode Switch This mode switch has three positions.

(2)

(a)

OFF - Turns off the evaporator box fan and A/C unit.

(b)

FAN - Turns on the Fan only for circulation.

(c)

A/C - Turns on the air conditioning inside the loaders cab.

Fan Switch The fan speed switch controls air flow by allowing one of three fan speed selections.

OPERATION

(a)

HIGH Speed - Fan operates at high speed.

(b)

MED Speed - Fan operates at medium speed.

(c)

LOW Speed - Fan operates at low speed.

1-2 Page 9 August 2017

Halvorsen 3 POSITION FAN SWITCH 3 POSITION A/C MODE SWITCH

DIRECTIONAL AIR LOUVERS

EVAPORATOR BOX

AIR FILTER INLET

Figure 4 AIR CONDITIONING SYSTEM EVAPORATOR BOX (3)

1-2 Page 10 August 2017

Air Conditioning Operation (a)

Conduct equipment pre-operational maintenance to ensure all associated components are clean and serviceable prior to operation.

(b)

At the A/C mode switch, select A/C position.

(c)

At the fan speed switch located on the evaporator box, select the high position.

(d)

Position the directional louvers for desired air distribution.

(e)

Adjust the temperature by lowering or raising the fan speed switch.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (4)

NOTE:

Air Conditioning Shutdown (a)

Ensure the engine has cooled down.

(b)

Set the fan speed switch to the low position.

(c)

Switch the A/C mode switch to the OFF position.

(d)

Shutdown the loader.

WHEN COOLING IS NOT NEEDED, CIRCULATION CAN BE PROVIDED BY MOVING THE MODE SWITCH TO THE FAN POSITION.

CAUTION THE AIR CONDITIONER DOES NOT DRAW FRESH AIR INTO THE CAB. IT WILL NOT REMOVE SMOKE OR EXHAUST FUMES. CHECK FOR PROPER VENTILATION PRIOR TO OPERATION. NOTE:

4.

WHEN FIRST STARTING THE AIR CONDITIONER, IF AFTER TWO MINUTES THE COMPRESSOR WILL NOT RUN FOR MORE THAN A FEW SECONDS, SWITCH THE BLOWER TO “LOW” UNTIL THE COMPRESSOR CONTINUES TO RUN AND THE CAB STARTS TO COOL. THEN SWITCH TO THE “MEDIUM” POSITION AND THEN TO THE “HIGH” POSITION.

OPERATING PROCEDURES A.

PRE-OPERATION DAILY INSPECTION Operator inspection is to be performed on a daily basis. Inspection ensures optimum loader performance and long life for machine components. The checklist provided will assist in performing daily operational checks.

WARNING BEFORE STARTING ANY PROCEDURE, ENSURE THE LOADER IS ON A LEVEL SURFACE AND HAS SUFFICIENT CLEARANCE IN FRONT AND BACK. ENSURE ALL PERSONS ARE CLEAR OF THE LOADER IN THE EVENT OF UNEXPECTED MOVEMENT. PLACE CHOCKS APPROXIMATELY TWO (2) INCHES FROM THE FRONT AND REAR OF TIRES TO PREVENT EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD OR REVERSE DIRECTION SHOULD THE PARKING BRAKE FAIL.

OPERATION

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THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST PROCEDURE

CHECK ()

Deck of Loader Check casters and rollers on deck for damage and ease of rolling. Check rubber bumpers. Check folding wings for damage, free movement and pin engagement. External cab inspection. Check heater fuel level. Check windows and mirrors for cracks. Check windshield washer fluid level. Ensure cabin pin is properly installed. Check condition on all handrails, mounting brackets and locking pins. Check general condition power rollers. Check condition of ladder. Lift engine access panel on deck between power rollers 5 and 6. Check engine oil level. Refer to Figure 5. Close and secure engine access panel. Turn battery on. Start loader. Raise loader to first maintenance stand and install maintenance stand and pins. Shut down loader. Chassis Check condition of drive wheels. Check condition of park and service brake (mounting and leaks). Check hydraulic filter high pressure indicator. Check coolant level in coolant recovery tank. Refer to Figure 5. Check coolant reservoir (peephole). Check hydraulic oil level. Check hydraulic breather indicator. Check belts (condition and adjustment).

OPERATION

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Halvorsen TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST (CONT.) PROCEDURE

CHECK ()

Check air filter indicator. Check that engine and transmission dipstick tube is secured and not leaking. Check condition of bogy wheels. Check helper cylinders. Check area around radiator and battery box. Check area around fuel tank and circuit breaker box. Check air pressure in all tires and inflate to specification 690 ± 14 kPa (100 2 psi). NOTE:

REFER TO FIGURE 5 FOR ENGINE OIL AND COOLANT FILL POINTS.

Check condition of hydraulic return filter. NOTE:

TO CHECK FILTER CONDITION, PLACE HYDRAULIC PREHEAT SWITCH IN THE ON POSITION AND OBSERVE READING ON GAUGE. REFER TO FIGURE 5. GAUGE IS LOCATED ON RETURN FILTER HOUSING ON THE TOP OF THE HYDRAULIC RESERVOIR. THE FILTER ELEMENT SHOULD BE REPLACED IF GAUGE INDICATOR IS IN RED AREA.

NOTE:

REFER TO FIGURE 6 FOR HYDRAULIC RETURN FILTER GAUGE.

Underside of Deck Check main lift cylinder. Check pitch cylinders (wear and leaks). Check roll cylinders (wear and leaks). Check side shift cylinders (wear and leaks). Check pallet stops cylinders. Cab Check condition cab seat and controls for adjustments. Check condition seat belt and latch operation. Check test warning lights. Start loader. Check all rear lights. Check all front lights. Check dome light. Check cabin dash light.

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GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST (CONT.) PROCEDURE

CHECK ()

Check heater operation. Check fan. Check wipers and washers for proper operation. Check horn. Check operation of air conditioning system and evaporator box. Deck Operation Check operation of all deck position lights. Check auto center. Check front pallet stop. Check rear pallet stop. Check power rollers. Check hydraulic filter gauge. Check transmission fluid (with engine running). Check case drain gauge. Test emergency pump. Inspect service brakes and rotors. Inspect park brake. Check park brake forward movement. •

Start the loader.

•

Place foot pressure on the service brake foot pedal and release parking brake.

•

Shift transmission to drive.

•

Apply parking brake.

•

Release foot brake.

•

Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm). Ensure loader does not move. If the loader moves report problem to maintenance.

Check park brake reverse movement. •

Start the loader.

•

Place foot pressure on the service brake foot pedal and release parking brake.

OPERATION

1-2 Page 15 August 2017

Halvorsen TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST (CONT.) PROCEDURE

CHECK ()

•

Shift transmission to reverse.

•

Apply parking brake.

•

Release foot brake.

•

Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm). Ensure loader does not move. If the loader moves report problem to maintenance.

Deck

Raise and lower

Deck pitch

Up and down

Deck shift

Left and right

Deck roll

Left and right

Front pallet stop

Up and down

Rear pallet stop

Up and down

Power steering

Left and right

Transmission shifting

All ranges

Deck convey •

Front section

Forward and aft

•

Mid section

Forward and aft

•

Rear section

Forward and aft

Turn battery disconnect switch to the off position after each operation. Additional Notes or Comments

EQUIPMENT SERIAL NUMBER:

HOURMETER:

DAILY CHECK PERFORMED BY:

DATE:

DAILY CHECK VERIFIED BY:

DATE:

NOTE:

1-2 Page 16 August 2017

COPIES OF THIS TABLE CAN BE MADE AS PART OF A LOG.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

Figure 5 ENGINE OIL AND COOLANT FILL POINTS

Figure 6 HYDRAULIC RETURN FILTER GAUGE

OPERATION

1-2 Page 17 August 2017

Halvorsen B.

STARTING POWER UNIT (1)

Turn the BATTERY DISCONNECT switch on the battery box to the ON position. Refer to Figure 7.

Figure 7 BATTERY DISCONNECT SWITCH

1-2 Page 18 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (2)

Ensure the EMERGENCY STOP switch on the forward end of main panel is pulled OUT. Refer to Figure 8.

Figure 8 MAIN PANEL NOTE:

THE IGNITION START SWITCH WILL ONLY BE USED FOR MAINTENANCE PURPOSES TO INCLUDE RAISING OF DECK TO PERFORM OPERATOR CHECKS OF THE LOADER AND PLACEMENT OF THE MAINTENANCE STANDS.

NOTE:

BEFORE USING THE IGNITION SWITCH TO START THE LOADER, ENSURE FLUID LEVELS ARE WITHIN THE PROPER RANGE. UNDER NO CIRCUMSTANCES WILL THE LOADER BE PLACED IN AN OPERATIONAL MODE WITH THE SWITCH IN THE “ON” POSITION AS IT DISABLES THE CAB IGNITION SWITCH.

OPERATION

1-2 Page 19 August 2017

Halvorsen (3)

If operating in cold weather conditions, remove the 120/240 VAC power cord. (a)

Turn circuit breaker to the OFF position then remove power cord from the receptacle on the winterization box on the left side of the chassis. Refer to Figure 9.

(b)

Refer to ‘B. CONVEY PANEL’ for connecting power cord to winterization box after shutting engine down.

EMERGENCY PUMP WINTERIZATION RECEPTACLE

CIRCUIT BREAKER WEATHER CAP

Figure 9 WINTERIZATION RECEPTACLE

CAUTION CIRCUIT BREAKER MUST BE IN THE “OFF” POSITION WHENEVER AC POWER CABLE IS INSTALLED OR REMOVED FROM RECEPTACLE ON WINTERIZATION BOX.

CAUTION AC POWER CABLE MUST BE REMOVED FROM RECEPTACLE BEFORE STARTING ENGINE.

1-2 Page 20 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen CAUTION ENGINE CAN BE STARTED WHEN AC POWER CABLE IS NOT ENERGIZED OR CIRCUIT BREAKER IS IN THE “OFF” POSITION. (4)

Ensure the dash panel EMERGENCY STOP switch is pulled out. Refer to Figure 10.

(5)

Ensure the PARK BRAKE switch is in the ON position. Refer to Figure 10.

Figure 10 DASH PANEL (6)

Check warning lights. (a)

OPERATION

Move the IGNITION switch to the ON position and observe that the following indicator lights are illuminated on the dash panel. Refer to Figure 10. •

Generator . . . . . . . . . . . . . . . . . . .

RED indicator light

•

Engine oil pressure. . . . . . . . . . . .

RED indicator light

•

Parking brake ON . . . . . . . . . . . . .

RED indicator light

1-2 Page 21 August 2017

Halvorsen (b)

Hold the SHUTDOWN OVERRIDE in the down position (LIGHT TEST) and observe that the following indicator lights illuminate. Refer to Figure 10. •

Hydraulic fluid hot . . . . . . . . . . . . .

RED indicator light

•

Transmission fluid hot . . . . . . . . . .

RED indicator light (Only applies to Reg. #07E00051 and below)

•

Engine hot . . . . . . . . . . . . . . . . . . .

RED indicator light

CAUTION DO NOT OPERATE EQUIPMENT WITH DEFECTIVE WARNING INDICATOR LIGHTS. (7)

Select N in the digital display with the TRANSMISSION RANGE SELECTOR. Refer to Figure 11.

TRANSMISSION RANGES THAT CAN BE SELECTED (DISPLAYED) DIGITAL DISPLAY

1 2 3 D N R

(RANGE 1) (RANGE 2) (RANGE 3) (DRIVE) (NEUTRAL) (REVERSE)

LEVER

Figure 11 TRANSMISSION RANGE SELECTOR (8)

1-2 Page 22 August 2017

Move and hold the SHUTDOWN OVERRIDE switch to the ON position and hold while moving the IGNITION switch to the START position until the engine starts, then release the IGNITION and SHUTDOWN OVERRIDE switches allowing the IGNITION switch to return to the ON position.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen CAUTION WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO START WITHIN 15 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE. NOTE:

IF THE ENGINE PREHEAT INDICATOR LIGHT IS ILLUMINATED, WAIT UNTIL THE LIGHT GOES OUT BEFORE MOVING THE IGNITION SWITCH TO THE START POSITION.

NOTE:

IF THE ENGINE STARTS THEN SHUTS DOWN WHEN THE SWITCH IS RELEASED, MOVE AND HOLD THE SHUTDOWN OVERRIDE SWITCH IN THE ON POSITION WHEN STARTING THE ENGINE. HOLD THE SHUTDOWN OVERRIDE SWITCH IN THE ON POSITION AND OBSERVE THE ENGINE OIL PRESSURE GAUGE. RELEASE THE SHUTDOWN OVERRIDE SWITCH WHEN THE OIL PRESSURE GAUGE INDICATES 5 PSI OR HIGHER.

(9) NOTE:

(10) C.

Observe all gauges and indicator lights on the dash panel for normal engine operation. ENGINE WILL SHUT DOWN WHENEVER THE FOLLOWING INDICATOR LIGHTS ILLUMINATE: •

Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . .

RED indicator light

•

Engine hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RED indicator light

•

Transmission fluid hot . . . . . . . . . . . . . . . . . . . . . .

RED indicator light

•

Hydraulic fluid hot . . . . . . . . . . . . . . . . . . . . . . . . .

RED indicator light

Allow engine to warm up before driving or operating the loader.

STOPPING LOADER (1)

Place the PARKING BRAKE switch on the dash panel to the ON position and observe that the PARK BRAKE ON red indicator light is illuminated. Refer to Figure 12.

(2)

Place the TRANSMISSION RANGE SELECTOR in the N position.

(3)

Allow engine to idle for 3 to 4 minutes for the temperature to stabilize.

(4)

Place the IGNITION switch in the OFF position to shut down the engine. Refer to Figure 12.

(5)

When the mission is completed and the loader is parked, turn the BATTERY DISCONNECT switch on the battery box to the OFF position.

(6)

When operating in cold weather, connect an AC power cord to the receptacle on the winterization box. Refer to Figure 9.

CAUTION CIRCUIT BREAKER MUST BE IN THE “OFF” POSITION WHENEVER AC POWER CABLE IS INSTALLED OR REMOVED FROM RECEPTACLE ON WINTERIZATION BOX.

OPERATION

1-2 Page 23 August 2017

Halvorsen Turn circuit breaker to the ON position to energize the circuit and supply power to the heating elements for the engine and hydraulic fluid. The WINTERIZATION CONNECTED indicator light (RED) on the dash will be illuminated when the circuit is energized. Refer to Figure 10.

FUEL GAUGE

SPEEDOMETER

PARKING BRAKE

TACHOMETER

IGNITION

Figure 12 DASH PANEL - LOWER RIGHT SIDE D.

MAINTENANCE STANDS INSTALLATION AND REMOVAL Refer to Figure 13. (1)

(2)

1-2 Page 24 August 2017

Maintenance Stands Installation (a)

Raise the deck high enough to complete required work.

(b)

Install both maintenance stands into the chassis and install retaining pins.

(c)

Lower deck until the lower scissor rollers come into contact with the maintenance stands.

Maintenance Stands Removal (a)

Raise deck until the lower scissor roller clears the maintenance stands.

(b)

Remove retaining pins.

(c)

Remove both maintenance stands and stow in holders and install retaining pins.

(d)

Lower the deck.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen SUPPORT BLOCK LOCATIONS

MAINTENANCE SUPPORT BLOCKS

Figure 13 MAINTENANCE STANDS E.

DECK CONFIGURATIONS

CAUTION CONFIGURE THE LOADER DECK FOR THE SIZE PALLET OR ROLLING STOCK THAT WILL BE CONVEYED.

CAUTION ALL RETAINING QUICK RELEASE PIN HANDLES AND LANYARDS SHOULD POINT TOWARDS GROUND. (1)

OPERATION

Deck configuration for 2235 mm (88 in.) biased pallets. (a)

Remove the two retaining pins from each pallet lock, then remove the pallet lock assembly from the guide rail by pulling the assembly out from the cavity. There are six pallet locks on the left side guide rails and six pallet locks on the right side guide rails. Refer to Figure 14.

(b)

Remove the two retaining pins that secure each side guide to the pivot lugs.

(c)

Lift and rotate the side guides up and reinstall the retaining pins in the pivot lugs to secure the side guide in the new position.

1-2 Page 25 August 2017

Halvorsen (d)

Install the pallet locks in the new cavities exposed and secure with the retaining pins that were removed in the first step.

RETAINING PINS

Figure 14 RETAINING PINS (2)

(3)

1-2 Page 26 August 2017

Deck configuration for 2743 mm (108 in.) biased pallets. (a)

Remove the two retaining pins from each pallet lock, then remove the pallet lock assembly from the guide rail by pulling the assembly out from the cavity. There are six pallet locks on the left side guide rails and six pallet locks on the right side guide rails. Refer to Figure 14.

(b)

Remove the two retaining pins that secure each side guide to the pivot lugs.

(c)

Lift and rotate the side guides down; reinstall the retaining pins in the pivot lugs to secure the side guide in the new position.

(d)

Install the pallet locks in the new cavities exposed and secure with the retaining pins that were removed in the first step.

Deck configuration for rolling stock, invert all caster and roller trays. (a)

The smooth side of the tray must be up. Refer to Figure 15.

(b)

Release the latch retaining the tray, pick up and invert the tray, replace the tray in the cavity and ensure the latch engages to retain the tray.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

Figure 15 TRAY WITH SMOOTH SIDE UP (4)

Deck configuration for forklift loading from the rear. (a)

Remove and stow the forklift tine trough covers when loading and off loading from the rear. Refer to Figure 16.

(b)

Invert all caster trays to have casters in the UP position. Refer to Figure 17.

REMOVE ALL FIVE TINE TROUGH COVERS

Figure 16 DECK CONFIGURED FOR FORKLIFT LOADING FROM THE REAR

OPERATION

1-2 Page 27 August 2017

Halvorsen

Figure 17 CASTERS IN THE UP POSITION (5)

1-2 Page 28 August 2017

Deck configuration for forklift loading from the side. (a)

Remove and stow the two handrails at the right rear of the deck when loading and off loading from the right side of the deck.

(b)

Remove and stow the forklift tine trough covers. Refer to Figure 18.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen REMOVE ALL FIVE INE TROUGH OVERS

Figure 18 DECK CONFIGURED FOR FORKLIFT LOADING FROM THE SIDE (c)

Invert all caster trays to have casters in the UP position. Refer to Figure 19.

Figure 19 CASTERS IN THE UP POSITION (d) NOTE:

OPERATION

Support the walk-deck sections and remove the retaining pins.

THERE ARE TWO WALK-DECK SECTIONS AT THE RIGHT REAR OF THE DECK THAT ARE REQUIRED TO BE LOWERED.

1-2 Page 29 August 2017

Halvorsen WARNING SUPPORT THE FOLDING WALK-DECK AND HANDRAIL SECTIONS WHEN REMOVING RETAINING PINS TO PREVENT SERIOUS PERSONAL INJURIES. PERSONNEL MUST GO UNDER THE FOLDING DECK TO REMOVE THE RETAINING PINS. (e) (6)

NOTE:

Deck configuration for air drop platforms. (a)

On the convey panel, place pallet width switch in the OFF position. Refer to Figure 2.

(b)

Rotate convey module latch handles to release the modules for increased height. Refer to Figure 20.

ALL HANDLES WILL BE “IN LINE” WITH THE DECK. (c)

1-2 Page 30 August 2017

Lower the walk-decks and pallet guides to provide access for the forklift tines when loading and unloading cargo.

To re-configure the deck for standard pallets turn the convey switch to the OFF position and step on the convey module and rotate the latch handle. Refer to Figure 20.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

Position handle as shown for air drop pallet configuration

Handle as shown for standard pallet configuration

Figure 20 CONVEY MODULE LATCH HANDLES

OPERATION

1-2 Page 31 August 2017

Halvorsen (7)

Deck configuration for lower lobes. Refer to Figure 21. (a)

Remove and stow front guide rail sections. Refer to Figure 23.

(b)

For left folding wing:

(c)

1)

Have assistant support folding wing.

2)

Fully depress and hold square pin.

3)

Have assistant lower folding wing to stop.

For right removable wing: 1)

Have assistant support wing.

2)

Slide forward pin outboard to its fullest extent.

3)

Remove hinge pin from the rear of wing.

4)

Stow wing on hooks provided on right side walk deck.

CAB HANDRAIL PUSHED IN

RIGHT SIDE WALKDECK/HANDRAIL IN RETRACTED POSITION RIGHT WING IN STOWING LOCATION

Figure 21 LOWER LOBE INTERFACE

1-2 Page 32 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen CAUTION THE LOADER MAY ONLY BE DRIVEN IN A STRAIGHT LINE WITH THE LEFT FOLDING WING IN THE DOWN POSITION. THE LOADER SHOULD NEVER BE DRIVEN WITH THE RIGHT FOLDING WING IN THE DOWN POSITION.

SPRING LATCH QUICK RELEASE PIN

RIGHT SIDE HANDRAIL/WALKDECK FRONT GUIDE RAIL

RIGHT WING

LEFT WING

FRONT GUIDE RAIL

NORMAL OPERATING CONFIGURATION

Figure 22 FOLDING WINGS (8)

Walk-deck and right front handrail configuration for aircraft door. Refer to Figure 23.

WARNING DO NOT ACCESS WALK-DECK WHEN NOT SECURED BY BOTH LOCKS. FULLY LOCK TELESCOPING WALK-DECK IN PLACE BEFORE ACCESSING OR WALKING ON IT. (a) NOTE:

OPERATION

When loading or unloading certain aircraft, the telescoping handrail and walk-deck must be retracted to provide clearance to prevent damage to the aircraft.

TELESCOPING HANDRAIL AND WALK-DECK HAS THREE (3) POSITIONS (FULLY EXTENDED, FULLY RETRACTED AND MIDDLE POSITION).

1-2 Page 33 August 2017

1-2 Page 34 August 2017

RIGHT SIDE HANDRAIL/WALKDECK FULLY RETRACKED

RIGHT WING IN STOWING LOCATION

GUIDE RAILS IN 88 MODE STOW FRONT GUIDE RAILS IN TOOL BOX

SQUARE PIN PUSHED IN

LEFT WING FOLDED DOWN

CAB HANDRAIL PUSHED IN

Halvorsen

Figure 23 RIGHT SIDE HANDRAIL AND WALK-DECK

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

F.

(b)

To reposition the handrail and walk-deck, remove the lower quick release pin that is painted yellow and is attached to a lanyard, then unlatch the upper pin that has a ball handle.

(c)

Slide the handrail and walk-deck to the required position and ensure that upper pin latches in place.

(d)

Insert the lower quick release pin fully to lock the handrail and walk-deck in position. Yellow handle will be fully visible when pin is in place.

DRIVING THE LOADER

WARNING ALL CARGO, PALLETS AND ROLLING STOCK MUST BE SECURED TO THE LOADER DECK TO PREVENT MOVEMENT IN ANY DIRECTION WHEN THE LOADER IS IN MOTION.

WARNING CAB DOORS MUST BE LATCHED CLOSED WHEN DRIVING AND OPERATING THE LOADER.

WARNING WEAR THE SEAT BELT AT ALL TIMES WHILE OPERATING THE LOADER.

CAUTION DO NOT EXCEED 15 KM (9 MILES) OF TRAVEL IN A ONE HOUR PERIOD OF TIME. IF THAT DISTANCE IS REACHED, TIRES MUST BE ALLOWED TO COOL FOR ONE HOUR. (1)

Refer to ‘B. STARTING POWER UNIT’ for detailed procedure on starting engine.

(2)

Release park brake and depress the foot brake pedal to apply the service brakes simultaneously, then select the range for driving: (a)

To move forward, move the TRANSMISSION RANGE SELECTOR forward to select range D in the digital display. Refer to Figure 24.

(b)

To move in reverse, move the TRANSMISSION RANGE SELECTOR to the rear to select range R in the digital display.

NOTE:

FOOT BRAKE MUST BE APPLIED BEFORE THE TRANSMISSION CAN BE SHIFTED OUT OF NEUTRAL.

NOTE:

TRANSMISSION WILL SHIFT UP, AS THE SPEED INCREASES, TO RANGE 4 FOR MAXIMUM FORWARD SPEED WHEN THE TRANSMISSION RANGE SELECTOR IS IN RANGE D.

OPERATION

1-2 Page 35 August 2017

Halvorsen

TRANSMISSION RANGES THAT CAN BE SELECTED (DISPLAYED) 1 2 3 D N R

DIGITAL DISPLAY

(RANGE 1) (RANGE 2) (RANGE 3) (DRIVE) (NEUTRAL) (REVERSE)

LEVER

Figure 24 TRANSMISSION RANGE SELECTOR (3)

Slowly depress the accelerator pedal and as soon as the loader begins to move, release the accelerator pedal and depress the brake pedal to check for smooth and positive brake action.

(4)

Drive the loader to within 15 feet of the aircraft or loading dock and stop the loader, using the brake pedal, to ensure the brakes are properly operating.

NOTE:

ALWAYS SELECT “RANGE 1” OR “R” FOR REVERSE, IN THE DIGITAL DISPLAY WITH THE TRANSMISSION RANGE SELECTOR WHEN OPERATING NEAR AIRCRAFT OR WHEN THE DECK IS ELEVATED. Range 1 or R for reverse, will allow the foot throttle to control the engine speed for driving and will prohibit the transmission from up-shifting to the next speed range.

NOTE:

1-2 Page 36 August 2017

WHEN THE DECK IS ELEVATED AND RANGE D, 3 OR 2 IS SELECTED, THE FOOT THROTTLE WILL BE INACTIVE AND THE ENGINE WILL REMAIN AT IDLE SPEED. A NO-DRIVE CONDITION EXISTS.

(5)

Select range 1 in the digital display with the TRANSMISSION RANGE SELECTOR.

(6)

Raise the deck to the approximate height of the aircraft door ramp, aircraft door sill or loading dock.

(7)

Drive the loader slowly and stop when the deck is approximately four inches from the aircraft door ramp, aircraft door sill or the loading dock.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (8)

Apply the PARKING BRAKE and select N (neutral) with the TRANSMISSION RANGE SELECTOR.

(9)

Align the deck parallel with the aircraft, loading dock or other material handling equipment for smooth cargo transfer using the PITCH and ROLL joystick control.

NOTE:

FOR THE POWERED ROLLERS TO BE EFFECTIVE ON THE CARGO CONVEY SYSTEMS, THE LOADER DECK MUST BE ALIGNED IN ALL DIRECTIONS. THE NON-POWERED ROLLERS MUST PROPERLY SUPPORT THE PALLET DURING CARGO TRANSFER OPERATIONS.

(10)

When cargo transfer operation is complete, actuate and hold the dash panel AUTO CENTER AND LEVEL switch to return deck to the normal level position before lowering the deck. Refer to Figure 25.

NOTE:

WHEN THE DECK HAS RETURNED TO THE NORMAL LEVEL POSITION, THE ROLL LEFT AND ROLL RIGHT INDICATOR LIGHTS WILL NOT BE ILLUMINATED. REFER TO FIGURE 25.

Figure 25 DASH PANEL - LEFT SIDE (11)

OPERATION

When operating on slippery surfaces and a loss of traction occurs on one drive wheel, engage the differential lock to power both wheels on the front axle.

1-2 Page 37 August 2017

Halvorsen CAUTION DO NOT DRIVE THE LOADER WITH THE DIFFERENTIAL LOCK ENGAGED WHEN OPERATING IN NORMAL CONDITIONS ON HARD SURFACES. (a)

Select N with the TRANSMISSION RANGE SELECTOR.

(b)

With the loader stopped, place the differential lock switch in the ON position. The amber indicator light on the dash will be illuminated. Refer to Figure 26.

(c)

Select a driving range with the TRANSMISSION RANGE SELECTOR and slowly drive the loader until back on normal operating surfaces.

(d)

Stop the loader, then disengage the differential lock by placing the switch in the OFF position.

AMBER INDICATOR LIGHT

DIFFERENTIAL LOCK

Figure 26 DASH PANEL - LOWER-RIGHT CENTER

1-2 Page 38 August 2017

(12)

When an operation is complete, drive the loader to the assigned area, select N in the transmission digital display and apply parking brake.

(13)

Allow the engine to operate at idle speed for 3–4 minutes to stabilize the temperatures, then shut down the engine.

(14)

Chock wheels to prevent movement in either direction.

(15)

When operating in arctic conditions, connect external power cord to receptacle on left side of loader and move the circuit breaker to the ON position.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 5.

LOADING AND UNLOADING CARGO PROCEDURES

WARNING IT IS MANDATORY THAT ALL PERSONNEL WEAR A SAFETY HARNESS, WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” WHEN WORKING ON THE DECK IN THE AREA IDENTIFIED AND MARKED AS “HARNESS REQUIRED AREA”.

WARNING THE OPERATOR’S VISIBILITY WILL BE IMPAIRED TOWARDS THE RIGHT WHEN A PALLET OR CARGO IS ON THE FRONT POSITION OF THE DECK. FOR SAFE OPERATION, AN OBSERVER SHOULD ALWAYS BE USED TO KEEP THE OPERATOR INFORMED OF CLEARANCE, TRAFFIC OR ANY HAZARD WHEN TRANSPORTING CARGO WHEN VISIBILITY IS IMPAIRED.

CAUTION THE FRONT LOAD STOPS WILL REMAIN IN THE DOWN POSITION AND THE RED INDICATOR LIGHT WILL BE ILLUMINATED WITH THE SWITCH IN THE DOWN POSITION. THE FRONT LOAD STOP SWITCH MUST BE PLACED IN THE UP POSITION WHEN TRANSPORTING CARGO, LOADING CARGO FROM THE REAR OF THE DECK OR WHENEVER THE FRONT OF THE DECK IS LOWER THAN THE REAR OF THE DECK. NOTE:

A.

PERSONS ASSISTING IN HANDLING AND SECURING OF CARGO, MUST WEAR A SAFETY HARNESS WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” IN THE AREA DEFINED AS “HARNESS REQUIRED AREA”. REFER TO FIGURE 29.

LOADING CARGO ON THE LOADER - FRONT END OPERATION Refer to Figure 2 for convey panel. NOTE:

ENSURE ALL PALLET LOCKS ARE PULLED BACK AND ROTATED TO THE RELEASED POSITION IN THE GUIDES BEFORE MOVING PALLETS ONTO THE DECK. REFER TO FIGURE 27.

(1)

Select pallet width of 2235 mm (88 in.) or 2743 mm (108 in.) that the deck is configured for with the CONVEY MODE PALLET WIDTH switch on the convey panel.

(2)

Place FRONT STOP switch on the convey panel in the down position to lower the forward pallet stop. The RED indicator light will illuminate.

(3)

Place the three convey section switches in the ON position. The three GREEN indicator lights will illuminate indicating that all three convey sections are active when the CONVEY joystick switch is moved.

(4)

Hold the convey joystick towards the back as the pallet is being transferred onto the deck to activate all the convey rollers aft and move the pallet to the rear section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with the pallet locks.

OPERATION

1-2 Page 39 August 2017

Halvorsen

B.

(5)

Rotate the pallet locks and ensure they enter the pallet recesses to prevent movement of the pallet during the transport operation. Refer to Figure 30.

(6)

Place the CONVEY AFT SECTION switch in the OFF position. The GREEN indicator light must not be illuminated.

(7)

Hold the convey joystick towards the back as the second pallet is being transferred onto the deck to activate the convey rollers aft in the front and middle sections and move the pallet to the middle section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with the pallet locks.

(8)

Rotate the pallet locks and ensure they enter the pallet recesses to prevent movement of the pallet during the transport operation.

(9)

Place the CONVEY MID SECTION switch to the OFF position. The GREEN indicator light must not be illuminated.

(10)

Hold the convey joystick towards the back as the third pallet is being transferred onto the deck to activate the convey rollers aft in the front section and move the pallet to the front section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with the pallet locks.

(11)

Rotate the pallet locks and ensure they enter the recesses in the pallet to prevent movement of the pallet during the transport operation.

(12)

Place the CONVEY FRONT SECTION switch in the OFF position. The GREEN indicator light must not be illuminated.

(13)

Place the FRONT STOP switch in the UP position. The RED indicator light must not be illuminated.

OFF LOADING CARGO ON THE LOADER - FRONT END OPERATION Refer to Figure 2 for convey panel.

1-2 Page 40 August 2017

(1)

Pull back and rotate all pallet locks to the released position in the guides. Refer to Figure 27.

(2)

Place FRONT STOP switch on the convey panel in the down position to lower the forward pallet stop; the RED indicator light illuminates.

(3)

Place the CONVEY FRONT SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the front convey section will be active when the CONVEY joystick switch is moved.

(4)

Hold the CONVEY joystick forward to transfer the front pallet forward on the deck and into the aircraft or onto the loading dock.

(5)

Place the CONVEY MID SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the middle convey section will be active when the CONVEY joystick is moved.

(6)

Hold the CONVEY joystick forward to transfer the second pallet forward on the deck and into the aircraft or onto the loading dock.

(7)

Place the CONVEY AFT SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the aft convey section will be active when the CONVEY joystick is moved.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen C.

(8)

Hold the CONVEY joystick forward to transfer the third pallet forward on the deck and into the aircraft or onto the loading dock.

(9)

Place the FRONT STOP switch in the UP position. The RED indicator light must not be illuminated.

LOADING CARGO ON THE LOADER - BACK END OPERATION Refer to Figure 2 for convey panel. NOTE:

(1) NOTE:

ENSURE ALL PALLET LOCKS ARE PULLED BACK AND ROTATED TO THE RELEASED POSITION IN THE GUIDES BEFORE MOVING PALLETS ONTO THE DECK. REFER TO FIGURE 27. Hold REAR STOP switch on the convey panel in the down position to lower the rear pallet stop; the RED indicator light illuminates. THE REAR STOP SWITCH HAS A MOMENTARY CONTACT AND MUST BE HELD ACTUATED WHEN CONVEYING CARGO ON AND OFF THE DECK.

(2)

Place the three convey section switches in the ON position. The three GREEN indicator lights illuminate indicating that all three convey sections will be active when the CONVEY joystick switch is moved.

(3)

Hold the convey joystick towards the front as the pallet is being transferred onto the deck to activate all the convey rollers forward and move the pallet to the front section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with the pallet locks.

(4)

Rotate the pallet locks and ensure they enter the recesses in the pallet to prevent movement of the pallet during the transport operation. Refer to Figure 28.

(5)

Place the CONVEY FRONT SECTION switch in the OFF position. The GREEN indicator light must not be illuminated.

(6)

Hold the convey joystick towards the front as the second pallet is being transferred onto the deck to activate the convey rollers forward in the middle and aft sections and move the pallet to the middle section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with the pallet locks.

(7)

Rotate the pallet locks and ensure they enter the recesses in the pallet to prevent movement of the pallet during the transport operation.

(8)

Place the CONVEY MID SECTION switch in the OFF position. The GREEN indicator light must not be illuminated.

(9)

Hold the convey joystick towards the front as the third pallet is being transferred onto the deck to activate the convey rollers forward on the aft section and move the pallet to the aft section of the deck. Using the convey joystick, shift the pallet fore and aft to align the recesses with the pallet locks.

(10)

Rotate the pallet locks and ensure they enter the pallet recesses to prevent movement of the pallet during the transport operation.

(11)

Place the CONVEY AFT SECTION switch in the OFF position. The GREEN indicator light must not be illuminated.

OPERATION

1-2 Page 41 August 2017

Halvorsen (12) D.

Place the REAR STOP switch in the UP position. The RED indicator light must not be illuminated.

OFF LOADING CARGO ON THE LOADER - BACK END OPERATION Refer to Figure 2 for convey panel. (1) NOTE:

Hold REAR STOP switch on the convey panel in the DOWN position to lower the rear pallet stop; the RED indicator light illuminates. THE REAR STOP SWITCH HAS A MOMENTARY CONTACT AND REQUIRES THAT IT BE HELD ACTUATED WHEN CONVEYING CARGO ON AND OFF THE DECK.

(2)

Pull back and rotate all pallet locks to the released position in the guides. Refer to Figure 27.

(3)

Place the CONVEY AFT SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the aft convey section will be active when the CONVEY joystick switch is moved.

(4)

Hold the CONVEY joystick aft to transfer the rear pallet aft on the deck and into the aircraft or onto the loading dock.

(5)

Place the CONVEY MID SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the middle convey section will be active when the CONVEY joystick is moved.

(6)

Hold the CONVEY joystick aft to transfer the second pallet aft on the deck and into the aircraft or onto the loading dock.

(7)

Place the CONVEY FRONT SECTION switch in the ON position. The GREEN indicator light illuminates indicating that the front convey section will be active when the CONVEY joystick is moved.

(8)

Hold the CONVEY joystick aft to transfer the third pallet aft on the deck and into the aircraft or onto the loading dock. •

E.

Release the REAR STOP switch and the rear stop rises fully up. The RED indicator light must not be illuminated.

LOADING ROLLING STOCK Refer to Figure 30 for convey panel. (1)

Invert all caster and roller trays next to pallet guides, both left and right sides, for the smooth sides to be facing up.

(2)

Folding wings at the front of the deck must be in the up position when placing and removing rolling stock on loader deck.

CAUTION ROLLING STOCK MUST HAVE PARKING BRAKES APPLIED AND SECURED WITH RESTRAINTS ATTACHED TO THE TIE DOWN RINGS ON THE DECK BEFORE DRIVING THE LOADER.

1-2 Page 42 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

RELEASED POSITION

Figure 27 PALLET LOCK IN RELEASED POSITION

LOCKED POSITION

Figure 28 PALLET LOCK IN LOCKED POSITION

OPERATION

1-2 Page 43 August 2017

Halvorsen

Figure 29 SAFETY HARNESS AREA

1-2 Page 44 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen FOLDING WING

FOLDING WING

ROLLER TRAYS

ROLLER TRAYS

TIE DOWNS

TIE DOWNS

CASTER TRAYS

CASTER TRAYS

Figure 30 LOADER DECK FOR ROLLING STOCK

OPERATION

1-2 Page 45 August 2017

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 3. Emergency Procedures 1.

GENERAL

WARNING APPLY E-STOP TO DISABLE THE VEHICLE ONLY IN CASE OF EMERGENCY. PRESSING THE EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE. The vehicle is equipped with an electrical-driven emergency hydraulic pump activated from the driver’s cab actuating on a spring-loaded two-position switch. This pump allows for emergency maneuvers, such as lowering the deck. Also, a hand-operated emergency hydraulic pump is provided with the vehicle. This pump has a removable handle that can be used for emergency operations when no other hydraulic source or electrical power is available. Emergency procedures in this section describe the necessary steps to follow, in case of mechanical breakdown or equipment malfunctions. NOTE:

IT IS IMPORTANT TO COMPLETELY READ AND UNDERSTAND THIS EMERGENCY PROCEDURES SECTION BEFORE OPERATING THE LOADER.

CAUTION DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE OPERATION. 2.

EMERGENCY PROCEDURES‘ Should a condition arise that would require an immediate shutdown of the loader, the EMERGENCY STOP switch can be actuated for an immediate shutdown of the power unit. Refer to Figure 1. NOTE:

WHEN THE ENGINE IS SHUTDOWN WITH THE EMERGENCY STOP SWITCH, THE ELECTRIC DRIVEN EMERGENCY HYDRAULIC PUMP WILL AUTOMATICALLY BE ACTUATED TO PROVIDE HYDRAULIC POWER FOR OPERATING THE POWER STEERING, SERVICE BRAKES, PARKING BRAKES AND TRANSMISSION FOR 30 SECONDS.

CAUTION CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN 30 SECONDS WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES CANNOT BE COMPLETED WITHIN 30 SECONDS, PUMP MUST BE ALLOWED TO COOL FOR AT LEAST 10 MINUTES BEFORE CONTINUING.

EMERGENCY PROCEDURES

1-3 Page 1 August 2017

Halvorsen NOTE:

THE PURPOSE OF THE HYDRAULIC EMERGENCY PUMP IS TO PROVIDE POWER FOR STEERING, BRAKING AND PROPULSION TO GET THE LOADER TO A SAFE PLACE.

CAUTION NEVER USE THE HYDRAULIC EMERGENCY PUMP FOR OPERATING THE LOADER WHILE TOWING IT.

VOLT METER

FUEL GAUGE

SPEEDOMETER

PARKING BRAKE SWITCH

IGNITION SWITCH

TACHOMETER

EMERGENCY PUMP SWITCH

Figure 1 DASH PANEL Follow these steps after a loader experiences an emergency (even if no mishap occurred): •

Take the loader out of service and notified maintenance as soon as possible.

•

Report details of the events related to the emergency to JBT field support.

•

Wait for direction and instructions from JBT GSE support office, before beginning diagnostics or repairs.

1-3 Page 2 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen A.

EMERGENCY SYSTEM (1)

NOTE:

In case of an engine or hydraulic pump failure while driving, the electrically powered emergency hydraulic pump, incorporated in the hydraulic system, will instantly and automatically operate for 30 seconds. This will provide hydraulic pressure for the power steering, service brakes and parking brake. Refer to Figure 2. THE AUTOMATIC FEATURE IS ACTIVE ONLY WHEN THE PARKING BRAKE SWITCH IS IN THE OFF POSITION.

AUXILIARY DECK RAISE AND LOWER WORK LIGHTS

EMERGENCY PUMP SWITCH

IGNITION AND START SWITCH (MAINTENANCE USE ONLY)

SHUTDOWN OVERRIDE SWITCH

EMERGENCY STOP SWITCH

Figure 2 MAIN PANEL NOTE:

THE IGNITION START SWITCH WILL ONLY BE USED FOR MAINTENANCE PURPOSES TO INCLUDE RAISING OF DECK TO PERFORM OPERATOR CHECKS OF THE LOADER AND PLACEMENT OF THE MAINTENANCE STANDS.

NOTE:

BEFORE USING THE IGNITION SWITCH TO START THE LOADER, ENSURE FLUID LEVELS ARE WITHIN THE PROPER RANGE. UNDER NO CIRCUMSTANCES WILL THE LOADER BE PLACED IN AN OPERATIONAL MODE WITH THE SWITCH IN THE “ON” POSITION AS IT DISABLES THE CAB IGNITION SWITCH.

EMERGENCY PROCEDURES

1-3 Page 3 August 2017

Halvorsen (2)

B.

The emergency pump switch on the dash panel can be held actuated by the operator to provide hydraulic pressure for operating all the loader functions that are required to raise and lower the deck, transfer cargo off the deck and release the parking brakes. A second emergency pump switch is located on the forward end of the main panel that is used for maintenance.

EMERGENCY MANOUVERS (1)

Turn the ignition switch ON and place the PARKING BRAKE switch in the ON position.

(2)

Actuate and hold the EMERGENCY PUMP switch in the ON position and complete the transfer of cargo, on or off the deck, by actuating the CONVEY switches in the normal manner.

(3)

Actuate and hold the EMERGENCY PUMP switch and the AUTO CENTER AND LEVEL switch to return the deck to a level position.

(4)

Lower the deck fully by actuating the deck LIFT switch and the EMERGENCY PUMP switches.

(5)

Raise the deck. (a)

Rotate the handle on the deck supply cutoff valve to the OFF position before raising the deck. Refer to Figure 3.

(b)

Actuate the deck LIFT switch and the EMERGENCY PUMP switch to raise the deck.

(c)

Rotate the handle on the deck supply cutoff valve to the ON position after the deck has been raised. Refer to Figure 3.

WARNING DECK CUT-OFF VALVE MUST BE RETURNED TO THE ON POSITION AFTER USE. LOADER STEERING AND SERVICE BRAKES ARE DISABLED WHEN CUTOFF VALVE IS LEFT IN THE OFF POSITION. (6)

1-3 Page 4 August 2017

Turn the IGNITION switch to the OFF position after transferring the cargo and lowering the deck to the full down position.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

DECK SUPPLY CUTOFF VALVE

Figure 3 CHASSIS MANIFOLD NOTE: C.

REPOSITIONING OF THE DECK SUPPLY CUTOFF VALVE IS ONLY REQUIRED FOR RAISING THE DECK WITH THE EMERGENCY PUMP.

TOWING

WARNING BEFORE TOWING, ATTACH TOW VEHICLE WITH TOW BAR OR CHOCK WHEELS BEFORE DISENGAGING PARK BRAKE.

CAUTION DO NOT TOW THE LOADER FOR MORE THAN 150 M (500 FT.) WITHOUT DISCONNECTING DRIVE SHAFT FROM DIFFERENTIAL. NOTE:

DRIVE SHAFT MUST BE DISCONNECTED FROM THE DIFFERENTIAL IF TOWING DISTANCE MORE THAN 150 m (500 ft.) TO PREVENT DAMAGE TO THE TRANSMISSION.

EMERGENCY PROCEDURES

1-3 Page 5 August 2017

Halvorsen (1)

Connect a towing vehicle to the loader tow points on the end of the chassis frame. Refer to Figure 4.

(2)

Turn the IGNITION switch to the ON position. Refer to Figure 1.

(3)

Release the parking brakes by placing the PARKING BRAKE switch in the OFF position while holding the EMERGENCY PUMP switch actuated. Refer to Figure 1.

(4)

Slowly tow the loader away from the aircraft to an area where repairs can be accomplished.

(5)

Turn the IGNITION and BATTERY DISCONNECT switches to the OFF position.

(6)

Chock loader wheels to prevent movement in either direction.

TOW POINT

TOW POINT

Figure 4 LOADER TOW POINTS - REAR D.

LIFTING AND TOWING LOADER WITH A TOW VEHICLE Lift the loader with the tow vehicle from the front by attaching to the tow points provided on the front of the main frame. NOTE:

THE FRONT END OF THE DECK MAY REQUIRE PROTECTION FROM DAMAGE DURING TOWING, DEPENDING ON THE TOWING VEHICLE AND EQUIPMENT.

CAUTION NEVER TOW THE LOADER FROM THE REAR END WITH THE CHASSIS RAISED.

1-3 Page 6 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 4. Specifications 1.

GENERAL This vehicle specification outlines the product definition of the Halvorsen, 25 000 lb. Loader for Aircraft, offered by JBT, Ground Support Equipment. This aircraft loading and unloading vehicle is self-propelled and air transportable. Vehicles in this line are equipped with a diesel powered engine driving a hydraulic services pump. The vehicle’s traction is driven by a drive shaft providing propulsion to the front wheels.

2.

3.

NOTE:

MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4. ALL REFERENCES TO GALLONS ARE FOR U.S. GALLONS.

NOTE:

VEHICLE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE, DUE TO DESIGN IMPROVEMENTS AND CUSTOMERS’ SPECIFIC REQUIREMENTS.

MODEL DEFINITION Vehicle name:

Halvorsen, 25 000 lb. Loader for Aircraft

Designation:

Halvorsen

Vehicle type:

25 000 lb. Loader for Aircraft

Power unit:

Diesel (standard)

Gross vehicle weight:

14 220 kg (31 350 lb.)

Maximum cargo load:

11 340 kg (25 000 lb.)

AIRCRAFT ACCOMODATION The Halvorsen can interface with lower deck aircraft, loading docks and other material handling equipment (MHE), as well as main deck of commercial cargo aircraft. The Halvorsen can efficiently and safely transfer and transport cargo from other MHE or a loading dock onto aircraft and vice versa. Cargo includes pallets, platforms, containers and rolling stock. It can be loaded and off loaded from the front end, back end and side. The Halvorsen loader is designed for transport on rail car, ship or 96-inch wide commercial semi-trailer and can be sling loaded. Also, for air transport on C-5, C-17 and C-130 aircraft, the loader features drive on and drive off capabilities. The deck can be side-shifted to the left or right of the centerline and roll to the left or right side for alignment with aircraft doors that are not level with the loader deck. In addition, for alignment to the aircraft roll plane when operating on irregular surfaces, the deck can also be pitched up or down from horizontal.

SPECIFICATIONS

1-4 Page 1 August 2017

Halvorsen 4.

OPERATING CHARACTERISTICS General Performance •

Deck lift capacity (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . .

11 340 kg (25 000 lb.)

•

Load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiple pallets, sizes and rolling stock.

•

Maximum speed (level, dry, paved surface) . . . . . . . . . . . . . . .

27 km/h (17 mph) forward 8 km/h ( 8 mph) in reverse

•

Wind speed (maximum during operation). . . . . . . . . . . . . . . . .

74 km/h (46 mph / 40 knots)

•

Wind speed (withstand stability) . . . . . . . . . . . . . . . . . . . . . . . .

160 km/h (100 mph)

Deck Transfer Heights •

Fully raised (maximum at roll plane). . . . . . . . . . . . . . . . . . . . .

5588 mm (220 in.)

•

Fully lowered (minimum at roll plane). . . . . . . . . . . . . . . . . . . .

991 mm ( 39 in.)

•

Transfer speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.48 m/s (95 fpm) maximum

Side Shift, Roll and Pitch •

Side shifting (to left or right or centerline). . . . . . . . . . . . . . . . .

76 mm (3 in.) each side

•

Roll capability (to left or right side) . . . . . . . . . . . . . . . . . . . . . .

4º each side

•

Pitch capability (up or down from horizontal) . . . . . . . . . . . . . .

6º up, 6º down

Folding Wing Capacity

5.

•

Per axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6800 kg (15 000 lb.)

•

Per wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3400 kg ( 7500 lb.)

GENERAL DIMENSIONS AND WEIGHTS A.

DIMENSIONS Refer to Figure 1. •

Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

•

Overall width

•

1-4 Page 2 August 2017

8890 mm (350 in.)

- Operating configuration . . . . . . . . . . . . . . . . . . . . .

4318 mm (170 in.

- Transport configuration. . . . . . . . . . . . . . . . . . . . . .

2819 mm (111 in.)

Overall height - Operating configuration . . . . . . . . . . . . . . . . . . . . .

2489 mm (98 in.)

- Operating configuration (without work light) . . . . . .

2388 mm (94 in.)

- Transport configuration. . . . . . . . . . . . . . . . . . . . . .

2489 mm (98 in.)

- Transport configuration (without work light) . . . . . .

2388 mm (94 in.)

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen CENTER OF GRAVITY

2896 (114) 1372 (54)

787 (31)

5359 (211) 8890 (350)

CENTER OF GRAVITY

2489 (98)

660 (26)

1245 (49) 2565 (101) 2819 (111)

NOTE:

DIMENSIONS IN MILLIMETERS (INCHES) ARE APPROXIMATE ONLY AND SUBJECT TO MANUFACTURING VARIANCES.

Figure 1 GENERAL DIMENSIONS

SPECIFICATIONS

1-4 Page 3 August 2017

Halvorsen •

•

- Front axle and rear bogy wheel . . . . . . . . . . . . . . .

6731 mm (265 in.)

- Front axle and forward bogy wheel . . . . . . . . . . . .

5359 mm (211 in.)

Track width (centerline of wheels) - Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2083 mm (82 in.)

- Forward bogy wheels . . . . . . . . . . . . . . . . . . . . . . .

2438 mm (96 in.)

- Rear bogy wheels. . . . . . . . . . . . . . . . . . . . . . . . . .

2438 mm (96 in.)

•

Chassis ground clearance . . . . . . . . . . . . . . . . . . . . . . .

127 mm ( 5 in.)

•

Turning diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.24 m (50 ft.)

•

Turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30.48 m (100 ft.)

NOTE: B.

Wheel base

THE LOADER CAN MAKE A 3-POINT TURN ON A 15 M (50 FT.) WIDE TAXIWAY.

WEIGHTS AND VOLUME

TABLE 1 - WEIGHTS AND VOLUME Description

kg

lb.

Shipping weight

14 220

31 350

Front axle weight

5307

11 700

Mid axle weight (Forward bogy wheels)

4468

9850

Rear axle weight (Rear bogy wheels)

4445

9800

Loading volume

60 m3

2120 cu.ft.

NOTE:

1-4 Page 4 August 2017

THE SINGLE WHEEL LOAD IS 1588 kg (3500 lb.) ON THE CENTER OF THE DECK, ON A TIRE TREAD FOOT PRINT NO SMALLER THAN 200 mm x 305 mm (8.25 in. x 12 in.). THE CENTER OF THE DECK IS 254 mm (10 in) LEFT OR RIGHT OF CENTER AS MEASURED FROM THE CONVEY MODULE LINER.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 6.

ENGINE

TABLE 2 - ENGINE SPECIFICATIONS AND OPERATING RPM ENGINE MODEL* Detroit Diesel VM Motori R750 series, D756IE3 4.5 L (272 cu.in.) EPA Tier 3, EU Stage IIIA

LOW IDLE (NO LOAD)

PEAK TORQUE**

RATED POWER**

750 ± 50 rpm

535 N·m (395 lbf-ft.) @ 1350 rpm

121 kW (165 hp) @ 3000 rpm

* Engine is four-stroke turbocharged, direct injection, six cylinders in line, liquid cooling system. **Approximate information data. Refer to specific placard on the engine and to the engine manual in Chapter 5, MANUFACTURERS’ APPENDICES for additional information. 7.

FUEL SPECIFICATIONS AND RECOMMENDATIONS

TABLE 3 - FUEL SPECIFICATIONS AND DESIGNATIONS FUEL TYPE Non-road Diesel fuel Highway Diesel fuel* Non-road Diesel fuel** Highway Diesel fuel*

SULFUR CONTENTS

% BY MASS

FUEL DESIGNATION

< 500 ppm

< 0.05%

Low Sulfur Fuel

≤ 5 ppm

≤ 0.0015%

Ultra-Low Sulfur**

EPA REQUIREMENT EPA Tier 2 EPA Tier 3 EPA Tier 3 EPA Tier 4

* EPA mandated for the U.S. that by October 2010 all on-road Diesel fuel must be 15 ppm Ultra-Low Sulfur Diesel (ULSD) and off-road Diesel fuel must be 500 ppm. The exception was the State of California that required all Diesel fuel to be 15 ppm ULSD since January 2007 and it applies to all vehicles and equipment with no exceptions. EPA also required for all the U.S. that 2007 model year and newer vehicles must use ULSD fuel, called also ‘Sulfur-free’ Diesel fuel. **In 2004, EPA defined Tier 4 standards to be phased-in over 2008–2015, requiring substantial emission reductions and more stringent limits through the use of control technologies.

CAUTION WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY MASS) AND THE ENGINE EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3 ENGINES), LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED. CONSULT THE ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED.

CAUTION DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY MASS) IN EPA TIER 4 ENGINES.

SPECIFICATIONS

1-4 Page 5 August 2017

Halvorsen CAUTION DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR SPECIFIC RECOMMENDATIONS. 8.

FUEL SYSTEM A.

FUEL TYPE Refer to FUEL SPECIFICATIONS AND RECOMMENDATIONS and cautions above.

B.

10.

Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASTM D975-07, No. 1-D and No. 2-D

•

Turbine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JP-8 or Jet A-1 (only if fuel lubricity is adequate; special filters required)

FUEL TANK CAPACITY

C.

9.

•

•

Main tank fill capacity . . . . . . . . . . . . . . . . . . . . .

89.9 L (23.8 gal.)

•

Cab heater fill capacity (D3). . . . . . . . . . . . . . . .

7.5 L ( 2.0 gal.)

•

Cab fuel tank capacity (D4) . . . . . . . . . . . . . . . .

5.7 L ( 1.5 gal.)

FILTER TYPE •

Primary filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cartridge separator

type,

•

Secondary filter . . . . . . . . . . . . . . . . . . . . . . . . .

Canister type

•

Heated fuel and water separator . . . . . . . . . . . .

Optional

fuel

and

water

NOTE:

FUEL WAXING MAY OCCUR AT LOW TEMPERATURES, CLOGGING THE FUEL SYSTEM AND REDUCING THE ENGINE EFFICIENCY. IF THE AMBIENT TEMPERATURE IS LESS THAN 0 ºC (32 ºF), WINTER-GRADE FUEL (SUITABLE DOWN TO -23 ºC [-10 ºF]) SHOULD BE USED. FOR TEMPERATURES BELOW -9 ºC (16 ºF) REFER TO THE ENGINE OPERATION MANUAL IN CHAPTER 5.

NOTE:

FOR OPERATION AT TEMPERATURES BELOW -23 ºC (-10 ºF), A FUEL FILTER HEATER IS RECOMMENDED. REFER TO ENGINE MANUFACTURER’S MANUAL IN CHAPTER 5 FOR FURTHER INFORMATION.

RADIATOR (COOLING) •

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tube and fin (remote mounted)

•

Fan, cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic (remote mounted)

WHEELS AND TIRES •

Front and rear axle wheels . . . . . . . . . . . . . . . . . . . . . .

Three-piece modified, R15 381 mm (15 in.)

•

Front and rear tires (standard) . . . . . . . . . . . . . . . . . . .

355/65 R15, radial tubeless

•

Minimum load rating (each) . . . . . . . . . . . . . . . . . . . . .

8165 kg (18 000 lb.)

•

Inflation air pressure (pneumatic tires only) . . . . . . . . .

Refer to Chapter 2, Section 4, “Maintenance Specifications”.

1-4 Page 6 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 11.

BRAKES •

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic

•

Service brakes (all wheels) . . . . . . . . . . . . . . . . . . . . .

Caliper disc type acting on front and rear wheels, hydraulically powered, mechanically applied with pedal.

•

Parking brake (on front axle) . . . . . . . . . . . . . . . . . . . .

Caliper brake, Spring-applied, hydraulically released

•

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil from services system

•

Front axle brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disc on differential pinion shaft (disk attached to drive flange)

• 12.

- Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

292 mm (11.5 in.)

- Thickness, max. . . . . . . . . . . . . . . . . . . . . . . . . . .

12.7 mm (0.50 in.)

- Thickness, min. . . . . . . . . . . . . . . . . . . . . . . . . . .

11.13 mm (0.438 in.)

Rear axle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discs on all four (4) rear wheels

AXLES A.

FRONT AXLE Drive and steering axle with differential lock.

B.

•

Differential gear ratio . . . . . . . . . . . . . . . . . . . . .

4.780:1

•

Planetary wheel hub gear ratio . . . . . . . . . . . . .

3.103:1

•

Total gear reduction of axle . . . . . . . . . . . . . . . .

14.83:1

•

Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . .

30º max.

•

Differential lock . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic actuated

•

Steering cylinders . . . . . . . . . . . . . . . . . . . . . . .

Two (2)

REAR AXLE Forward and rear bogy wheels, two (2) wheels on each side.

13.

TRANSMISSION •

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic, four (4) speed

•

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100 SP

•

Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four forward, neutral, reverse

TABLE 4 - TRANSMISSION RATIOS (MECHANICAL) Gear

First

Second

Third

Fourth

Reverse

Ratio

3.51:1

1.90:1

1.44:1

1.00:1

5.09:1

SPECIFICATIONS

1-4 Page 7 August 2017

Halvorsen

14.

•

Auxiliary oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External spin-on

•

Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote mounted

•

Fluid temperature, normal operation, sump . . . . . . . . .

71 ºC to 93 ºC (160 ºF to 200 ºF)

•

Max fluid temperature, sump . . . . . . . . . . . . . . . . . . . .

121 ºC (250 ºF)

HYDRAULIC SYSTEM A.

FLUID TYPE NOTE:

SPECIFICATIONS AND CHARACTERISTICS OF THE HYDRAULIC FLUID TO BE USED WITH THE VEHICLE WILL DEPEND ON THE WEATHER OPERATING CONDITIONS.

This vehicle is shipped with a specified hydraulic fluid, but depending on weather operating conditions it may be required to replace it with a fluid of the proper characteristics. NOTE:

B.

HYDRAULIC PUMP •

C.

FOR FLUID TYPES AND OIL OPERATING TEMPERATURE RANGES, REFER TO HYDRAULIC OIL RECOMMENDATIONS IN CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS”.

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement

EMERGENCY ELECTRIC PUMP An electrical motor-driven hydraulic pump is provided for emergency operations (refer to Chapter 1, Section 3, “Emergency Procedures”). This pump must be manually activated by the operator when the vehicle is moving and the braking or steering pressure drops. Also, it can be manually activated to return to zero position, release parking brake or other emergency procedures.

D.

E.

FILTERS •

Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replaceable, furnished with water disposal element

•

Pressure filter (optional) . . . . . . . . . . . . . . . . . . .

Replaceable, 3-micron element

•

Return filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replaceable, in-tank return filter with 5-micron element

•

Case drain filters . . . . . . . . . . . . . . . . . . . . . . . .

Cartridge type, replaceable

HOSE ASSEMBLIES Pressure Hoses •

Diameter 6.4–12.7 mm (0.25–0.50 in.) . . . . . . .

SAE 100R2, SAE standard J517

•

Diameter 19–31.8 mm (0.75–1.25 in.) . . . . . . . .

SAE 100R12, SAE standard J517

Suction Hoses •

1-4 Page 8 August 2017

All diameters . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAE 100R4, SAE standard J517

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen F.

OPERATING PRESSURES NOTE:

15.

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.

18.

SPECIFICATIONS”

FOR

24 VDC

BATTERY

B.

17.

SECTION 4,.”MAINTENANCE

ELECTRICAL SYSTEM •

16.

REFER TO CHAPTER 2, OPERATING PRESSURES.

•

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two (2), 12 VDC

•

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance free

•

Cold cranking capacity . . . . . . . . . . . . . . . . . . .

930 A @ -18 ºC (0 ºF)

•

Cranking capacity . . . . . . . . . . . . . . . . . . . . . . .

1175 A @ 0 ºC (32 ºF)

•

Reserve capacity. . . . . . . . . . . . . . . . . . . . . . . .

156 minutes

•

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26.6 kg (58.7 lb.)

ALTERNATOR •

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transistor regulator, negative ground

•

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 VDC

•

Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 A

OTHER COMPONENTS •

Cab heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrically controlled, diesel oil fuel

•

Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulically controlled compressor, 3 lb. 10 oz. Freon

PAINT SPECIFICATIONS Color

Gloss

Standard

Number

Forest Green

Semi-gloss

FED-STD-595

24052

N-8891A / T-422R

Dessert Rose

Semi-gloss

FED-STD-595

23448

F92Y1030 / V93V28

Black

Flat

FED-STD-595

37038

G-4075A / T-422R

NCP Part No.

ADDITIONAL FEATURES AND EMERGENCY DEVICES •

Engine safety

•

Emergency stop push-button switches

•

Warning indicators

SPECIFICATIONS

1-4 Page 9 August 2017

Halvorsen 19.

VEHICLE JACKING REQUIREMENTS A.

JACK CAPACITY •

B.

10 800 kg (24 000 lb. [12 ton])

MAINTENANCE STANDS CAPACITY

C.

•

Minimum number of stands . . . . . . . . . . . . . . . .

Four (2 front, 2 rear)

•

Minimum working capacity (each) . . . . . . . . . . .

9070 kg (20 000 lb. [10 ton])

PRESSURE EXERTED BY VEHICLE

D.

•

Minimum at maintenance stands (unloaded) . . .

2070 kPa / 21 bar (300 psi)

•

Maximum pressure exerted by vehicle. . . . . . . .

3860 kPa / 39 bar (560 psi)

JACK AND MAINTENANCE STANDS SUPPORT SURFACE •

20.

Minimum working capacity (each axle) . . . . . . .

Reinforced concrete surface (required) . . . . . . .

24 MPa (3500 psi) minimum

NOTE:

SOME CONCRETE AND MOST ASPHALT SURFACES MAY NOT COMPLY WITH THE MINIMUM RESISTANCE REQUIRED. INCREASING SUPPORT PAD AREA OF JACKS AND MAINTENANCE STANDS CAN REDUCE THE STRESS ON THE GROUND SUPPORT SURFACE.

NOTE:

ENSURE THE SUPPORT SURFACE IS STRONG ENOUGH TO WITHSTAND THE STRESS EXERTED BY THE VEHICLE WEIGHT, TRANSFERED THROUGH THE JACKS AND MAINTENANCE STANDS.

ENVIRONMENTAL LIMITATIONS A.

OPERATING TEMPERATURES

TABLE 5 - AMBIENT OPERATING CONDITIONS OPERATING CONDITION* Normal

AMBIENT TEMPERATURE RANGE** -29 ºC to +51 ºC (-20 ºF to +123 ºF)

RECOMMENDATION Engine does not require assisted starts.

Extremely cold

Below -29 ºC (-20 ºF)

Requires vehicle to be pre-heated (engine block, oil pan and fuel filter).

Extremely hot

Above 51 ºC (123 ºF)

Refer to engine manual for requirements.

* Outside the normal operating temperature range, consider the use of an environment package that corresponds to the extreme weather conditions in which the equipment will operate. **Refer to Chapter 5, MANUFACTURERS’ APPENDICES for engine operating temperature ranges and oil specifications and related information for other components. Contact JBT, Ground Support Equipment for operating conditions in extreme weather.

1-4 Page 10 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen B.

WINTERIZATION OPTION The Halvorsen is designed with an engine that will start with no additional aids other than the standard grid heater set down to -18 ºC (0 ºF). The winterization option includes battery heaters, immersion engine block heater and hydraulic tank immersion heaters which maintain functionality at a minimum of -40 ºC (-40 ºF). Wiring harness connections are fitted with boot seals for harsh environments.

21.

OPERATOR'S VIBRATION AND SOUND LEVELS A.

SOUND LEVEL EMISSION DATA

TABLE 6 - SOUND LEVEL EMISSION DATA Test Locations and Conditions* Driver’s Cab

Exterior

Engine

Standstill

Driving

Driving

R756IE3**

Not available

Not available

Not available

* Tests performed without a hush kit installed. ** Halvorsen with Detroit engine not tested to CE standards.

B.

•

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EN 1915-4 and ISO 11201

•

Driver or operator position. . . . . . . . . . . . . . . . . . . . . . . .

Standing

•

Sound power tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stationary, driving

•

Test uncertainty (K = 1.6·R). . . . . . . . . . . . . . . . . . . . . .

4 dB

•

Technical measures for noise reduction . . . . . . . . . . . . .

Hush kit

•

Possible ways to minimize noise exposure . . . . . . . . . . .

Wear hearing protection

VIBRATION LEVEL DATA •

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EN 1915-3

•

Driver position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standing

•

Vibration values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

aWZF = 28.2 m/s2 (92.5 ft./s2)

•

Coefficient of variation. . . . . . . . . . . . . . . . . . . . . . . . . . .

CV  0.13

•

Test uncertainty (K = 0.3 aWZ). . . . . . . . . . . . . . . . . . . . .

2.0 m/s2 (6.6 ft./s2)

•

Technical measures for vibration reduction . . . . . . . . . . .

Not applicable

•

Possible ways to minimize vibration exposure . . . . . . . .

Not applicable

SPECIFICATIONS

1-4 Page 11 August 2017

Halvorsen 22.

UNITS OF MEASUREMENT Base and derived units of measurement used in this manual are in accordance to the International System of Units (SI) of the International Bureau of Weights and Measures (BIPM).

TABLE 7 - METRIC AND STANDARD UNITS AND CONVERSIONS Metric to Standard mm (millimeter)

Standard to Metric

x

0.039

= in.

x

25.4

x

39.37

= in.

x

0.0254

= m

x

3.281

= ft.

ft. (foot)

x

0.3048

= m

x

1.094

= yd.

yd. (yard)

x

0.914

= m

km (kilometer)

x

0.621

= mi.

mi. (mile)

x

1.609

= km

km/h (kilometers per hour)

x

0.621

= mph

mph (miles per hour)

x

1.609

= km/h

m2 (square meter)

x

10.764

= sq.ft.

sq.ft. (square foot)

x

0.093

= m2

m3 (cubic meter)

x

35.315

= cu.ft.

cu.ft. (cubic foot)

x

0.028

= m3

x

61.024

= cu.in.

cu.in. (cubic inch)

x

0.0164

= L

x

0.264

= gal.

gal. (gallon)

x

3.785

= L

x

1.057

= qt.

qt. (quart of a gallon)

x

0.946

= L

x

0.035

= cu.ft.

cu.ft. (cubic foot)

x

28.317

= L

L/min. (liters per minute)

x

0.264

= gpm

gpm (gallons per minute)

x

3.785

= L/min.

kg (kilogram)

x

2.205

= lb.

x

0.454

= kg

2204.6

= lb.

x

1.102

= tn

tn (ton) (short)

x

0.907

= t

bar (pressure)

x

14.504

= psi

x

0.069

= bar

kPa (kilopascal)

x

0.145

= psi

psi (pounds per square inch)

x

6.895

= kPa

x

0.738

= lbf-ft.

lbf-ft. (foot-pound)

x

1.356

= N·m

x

8.851

= lbf-in.

lbf-in. (inch-pound)

x

0.113

= N·m

N (Newton)

x

0.225

= lbf

lbf (pound force)

x

4.448

= N

kW (kilowatt)

x

1.341

= hp

hp (horse power)

x

0.746

= kW

ºC (Celsius)

x 1.8 + 32 = ºF

ºF (Fahrenheit)

- 32 / 1.8 = ºC

ºC (temperature differential*)

x

ºF (temperature differential*)

x

m (meter)

L (liter)

t (tonne) (metric ton)

N·m (Newton·meter)

1.8

= ºF (diff.)

in. (inch)

lb. (pound)

= mm

x 0.00045 = t

0.556

= ºC (diff.)

* Temperature differential refers to the difference between two temperature points as opposed to a specific temperature expressed in both ºC and ºF.

1-4 Page 12 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 5. Shipping and Transportation 1.

GENERAL This section contains general information on preparation of the vehicle for transportation. Check regulations of the states and countries through which the vehicle will be transported for specific requirements such as dimensional limitations, whether or not the vehicle can be transported with fuel, fluids, etc. Also, review Chapter 1, Section 6 for storage requirements and information on protection that may be required if time enroute is expected to be more than a week. NOTE:

THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” SHOULD BE UTILIZED WHEN COMMISSIONING NEW EQUIPMENT AND FOR RE-COMMISSIONING AFTER A MAJOR REPAIR, OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THEROAD TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR MORE THAN SIX MONTHS.

NOTE:

REFER TO THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” IN CHAPTER 2, SECTION 3.

NOTE:

REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR WEIGHT, GENERAL DIMENSIONS AND OTHER DETAILS BEFORE TRANSPORTING THE VEHICLE.

WARNING BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS SWITCHED OFF.

WARNING BEFORE PERFORMING ANY PROCEDURE THAT REQUIRES THE DECK TO BE IN AN ELEVATED POSITION, INSTALL THE MAINTENANCE STANDS AND LOWER THE DECK FULLY AGAINST THE MAINTENANCE STANDS.

WARNING LIFT VEHICLE ONLY BY PROPER HOISTING POINTS AND IN ACCORDANCE WITH THE DESCRIBED METHOD. DO NOT USE FORKLIFTS.

SHIPPING AND TRANSPORTATION

1-5 Page 1 August 2017

Halvorsen CAUTION THE LOADER MUST ONLY BE DRIVEN IN AIR TRANSPORT MODE WHILE LOADING ON AND OFF FROM SPECIFIED TRANSPORT VEHICLE OR FOR GROUND CLEARANCE, BUT NEVER FOR MORE THAN 60 M (200 FT.).

CAUTION IF THE ENGINE SPEEDS UP WHILE ACTIVATING THE LIFT JOYSTICK WHILE IN AIR TRANSPORT MODE, RELEASE THE LIFT JOYSTICK IMMEDIATELY AND LOWER THE DECK. STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE. NOTE:

REPORT THIS ISSUE TO MAINTENANCE IMMEDIATELY.

CAUTION USE OBSERVERS WHEN DRIVING THE LOADER ONTO THE TRANSPORT VEHICLE (AIRCRAFT OR TRAILER) FOR SAFETY AND TO ENSURE THAT THERE IS ALWAYS ADEQUATE CLEARANCE TO PREVENT DAMAGE TO THE TRANSPORT VEHICLE AND THE LOADER. 2.

SHIPPING DIMENSIONS Refer to Chapter 1, Section 4, “Specifications” in for weight, general dimensions and other details before transporting the vehicle. Also, refer to Figure 1.

1-5 Page 2 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

NOTE:

DIMENSIONS IN INCHES ARE APPROXIMATE.

LOAD CAPACITY 25 000 LBS

Figure 1 OVERALL SHIPPING DIMENSIONS

SHIPPING AND TRANSPORTATION

1-5 Page 3 August 2017

Halvorsen 3.

PREPARATION FOR TRANSPORTATION A.

PREPARE DECK FOR CAB RETRACTION (1)

Remove the retaining pin that connects the front cab side guide rail sections. Refer to Figure 2.

(2)

Invert the two roller trays adjacent to the hinged deck weldment so that the smooth side of the roller tray is facing upwards. Refer to Figure 3.

(3)

Position the hinged deck weldment in the shipping configuration. (a)

Unscrew the hinged deck weldment lock. Refer to Figure 2.

(b)

Lift the hinged deck weldment and fold it onto the deck. Refer to Figure 3.

RETAINING PIN

HINGED DECK WELDMENT LOCK

CAB RETAINING PIN

Figure 2 RETAINING PIN AND HINGE DECK WELDMENT LOCK

1-5 Page 4 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen ROLLER TRAY

HINGED DECK WELDMENT

ROLLER TRAY

Figure 3 HINGED DECK WELDMENT AND ROLLER TRAY

SHIPPING AND TRANSPORTATION

1-5 Page 5 August 2017

Halvorsen B.

CAB AND WALK-DECK INTO SHIPPING CONFIGURATION (1)

Remove the cab retaining pin from the rear cab support beam. Refer to Figure 2.

(2)

Push the cab towards the deck and into its shipping position. Refer to Figure 4.

(3)

Install the cab retaining pin to retain the cab in the shipping position.

(4)

Fold the rear view mirror against the cab door for clearance.

CAB SHIPPING POSITION FOLDING WALKDECK/HAND RAIL SECTION

REMOVE FOR C-130 AIRCRAFT

FOLDING WALKDECK/HAND RAIL SECTION

Figure 4

CAB AND WALK-DECK SHIPPING CONFIGURATION C.

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REMOVE THE LADDER AND STOW ON TOP OF THE DECK (1)

Remove the pin from the upper ladder support. Refer to Figure 5.

(2)

Remove the pin from the lower ladder support. Refer to Figure 6.

(3)

Remove and stow the ladder on top of the deck. Refer to Figure 7.

(4)

Remove and stow the ladder support arm by removing the two retaining pins. Refer to Figure 8.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

Figure 5 UPPER LADDER SUPPORT RETAINING PIN

Figure 6 LOWER LADDER SUPPORT RETAINING PIN

SHIPPING AND TRANSPORTATION

1-5 Page 7 August 2017

Halvorsen

Figure 7 LADDER STOWED ON DECK IN THE MIDDLE RIGHT SIDE

Figure 8 LADDER SUPPORT RETAINING PINS

1-5 Page 8 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen D.

CONFIGURE THE FOLDING WALK-DECK AND HANDRAIL SECTIONS This procedure allows the configuration of the folding walk-deck and handrail section into shipping position. (1)

Remove the retaining pins on each of the folding walk-deck and handrail section on both sides of the deck.

(2)

Lift up and fold the walk-deck and handrail section on top of the deck. Refer to Figure 4.

(3)

Install all of the retaining pins to secure the folding walk-deck and handrail sections during shipment.

NOTE:

WHEN SHIPPING THE HALVORSEN LOADER IN A C-130 AIRCRAFT, REMOVE THE HANDRAIL AND THE WALK-DECK SECTION DIRECTLY BEHIND THE CAB AND STOW THESE ITEMS ON THE DECK. THIS IS REQUIRED FOR THE OPERATOR TO EXIT THE REAR CAB DOOR WHEN THERE IS INSUFFICIENT CLEARANCE TO OPEN THE SIDE CAB DOOR ON A C-130 AIRCRAFT. REFER TO FIGURE 4.

WARNING SUPPORT THE FOLDING WALK-DECK AND HANDRAIL SECTIONS WHEN REMOVING RETAINING PINS TO PREVENT SERIOUS PERSONAL INJURIES. PERSONNEL MUST GO UNDER THE FOLDING DECK TO REMOVE THE RETAINING PINS. (4)

Secure all loose items to the deck by using cargo straps on the cargo tie down rings on the deck.

(5)

Verify all top locks (34 places) are in the locked position.

CAUTION IF THE DECK IS TO BE RAISED AND LOWERED WHILE THE CAB IS IN ITS RETRACTED SHIPPING CONFIGURATION, ENSURE ADEQUATE CLEARANCE IS AVAILABLE BENEATH THE CAB SO THE HYDRAULIC HOSES AND ELECTRICAL CABLES UNDER THE CAB ARE NOT PINCHED BETWEEN THE DECK AND CHASSIS. 4.

LOADING ONTO AIRCRAFT AND SURFACE TRANSPORT VEHICLES A.

SETTING INTO AIR TRANSPORT MODE At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air transport pin to lock the deck and chassis frame together. Verify the following loader functions before proceeding (ignition must be on). Refer to Figure 9. (1)

The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.

(2)

The front and rear pallet stops should be inactive to the operator’s controls when their associated toggle switches are in the “ON” position.

(3)

All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch is in the 108 or 88 position during this process.

SHIPPING AND TRANSPORTATION

1-5 Page 9 August 2017

Halvorsen (4)

The deck ROLL joystick is inactive to the operator’s controls.

(5)

The engine speed (rpm) do not change when the LIFT joystick is in the UP position. Immediately release the LIFT joystick if the engine speed changes during this process. Structural damage to the deck and chassis frame will occur.

CLEVIS

PIN

Figure 9 AIR TRANSPORT CLEVIS AND PIN IN LATCHED POSITION B.

LOADING THE VEHICLE NOTE:

1-5 Page 10 August 2017

THE VEHICLE CAN BE LOADED IN EITHER DIRECTION. BACKING THE LOADER ONTO THE TRANSPORT VEHICLE (AIRCRAFT OR TRAILER) IS THE PREFERRED DIRECTION.

(1)

While the deck is down and resting on the chassis frame, drive the loader to the transport vehicle (aircraft or trailer) and align the loader with the ramp.

(2)

While the loader is stationary and the park brake is engaged, move and hold the lift joystick to the UP position until the red air transport indicator light stops flashing and becomes constant. The chassis frame will have maximum ground clearance in air transport mode, allowing the loader to pass over the ramp crest.

(3)

Depress the brake pedal and move the park brake switch to the OFF position.

(4)

Select the driving range “1” or “R” using the TRANSMISSION RANGE SELECTOR and carefully drive the loader onto the transport vehicle.

(5)

When the loader is fully onto the transport vehicle (aircraft or trailer) depress the brake pedal, place the transmission in Neutral and move the park brake switch to the ON position.

(6)

Move the lift joystick to the DOWN position to lower the chassis frame onto the rear axle assembly and shut down the engine.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen 5.

(7)

Turn the BATTERY DISCONNECT switch on the battery box to the OFF position. Refer to Figure 10.

(8)

Restrain the loader from movement during air transport. Refer to the transport placard on the cab side door for more information.

LOADING OFF FROM AIRCRAFT AND SURFACE TRANSPORT VEHICLES A.

B.

PREPARE FOR UNLOADING (1)

Remove the tie down restraints from the loader.

(2)

Turn the BATTERY DISCONNECT switch on the battery box to the ON position. Refer to Figure 10.

(3)

Verify the air transport clevis and pin is in the correct orientation for air transport operations. Refer to Figure 9.

START THE ENGINE AND VERIFY (1)

The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.

(2)

The front and rear pallet stops should be inactive to the operator’s controls when their associated toggle switches are in the “ON” position.

(3)

All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch is in the 108 or 88 position during this process.

(4)

The deck ROLL joystick is inactive to the operator’s controls.

(5)

The engine RPM do not change when the LIFT joystick is in the UP position. Immediately release the LIFT joystick if the engine RPM change during this process. Structural damage to the deck and chassis frame will occur.

(6)

Move and hold the lift joystick to the UP position until the red air transport indicator light stops flashing and becomes constant. The chassis frame will have maximum ground clearance in air transport mode allowing the loader to pass over the ramp crest.

(7)

Depress the brake pedal and position the park brake switch to the OFF position.

(8)

While the loader is stationary, move the differential lock switch to the ON position.

(9)

Select the driving range “1” or “R” using the TRANSMISSION RANGE SELECTOR and carefully drive the loader off of the transport vehicle.

(10)

When the loader is clear of the transport vehicle, depress the brake pedal, place the transmission in Neutral and move the park brake switch to the ON position.

(11)

Move the lift joystick to the DOWN position to lower the chassis frame onto the rear axle assembly.

(12)

While the loader is stationary, position the differential lock switch to the OFF position.

(13)

Remove the air transport pin and rotate the clevis clockwise. Insert the air transport pin through the clevis and into the chassis frame. Refer to Figure 11.

SHIPPING AND TRANSPORTATION

1-5 Page 11 August 2017

Halvorsen

Figure 10 BATTERY DISCONNECT SWITCH

1-5 Page 12 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen

PIN

CLEVIS

Figure 11 AIR TRANSPORT PIN AND CLEVIS IN STOWING POSITION

SHIPPING AND TRANSPORTATION

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Halvorsen 6.

SLING LIFTING THE LOADER

WARNING BRIDLES AND CHAINS MUST HAVE EQUAL LEG LENGTH OF A MINIMUM OF 3.60 M (12 FT.) AND HAVE THE MINIMUM RECOMMENDED CAPACITY.

CAUTION ENSURE THE CHAINS DO NOT CONTACT THE LEFT SIDE HEADLIGHT HOUSING. A.

PREPARATION (1)

Prepare the loader for “air and surface transport” as described previously.

(2)

Lower the deck so it is resting on the chassis frame.

(3)

Secure the rear axle assembly to the deck assembly on both sides of the loader. (a)

Route a heavy duty chain rated at 4500 kg (10 000 lb.) or greater, under the rear axle shaft between the walking beam and helper cylinder.

(b)

Secure the ends of the chain to the helper cylinder support casting. Refer to Figure 12. The chains should be taut when installed.

Figure 12 HELPER CYLINDER SUPPORT CASTING

1-5 Page 14 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen B.

SECURE THE FRONT OF THE CHASSIS TO THE DECK ASSEMBLY (1)

Route a heavy duty chain rated at 4500 kg (10 000 lb.) or greater, around the inner towing eyes (2 places) on the chassis frame and through the front pallet stop housing. Refer to Figure 13.

CHAIN ROUTING INNER TOW EYES

Figure 13 CHASSIS TOWING EYE CHAIN ROUTING (2)

At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air transport pin to lock the deck and chassis frame together. Refer to Figure 9.

(3)

Turn the BATTERY DISCONNECT switch on the battery box to the OFF position. Refer to Figure 10.

(4)

Attach the four (4) legged bridle or chains of equal length with a minimum of 3.60 m (12 ft.) to the four (4) lifting provisions on top of the deck. Refer to Figure 14.

NOTE:

REMOVE ANY HANDRAILS THAT INTERFERE WITH THE BRIDLE OR CHAINS. SECURE HANDRAIL(S) TO THE DECK.

SHIPPING AND TRANSPORTATION

1-5 Page 15 August 2017

Halvorsen LIFT POINTS 4 PLACES

Figure 14 LIFTING PROVISION LOCATIONS (5) NOTE:

1-5 Page 16 August 2017

Attach the bridle or chains to the lifting equipment. LIFTING EQUIPMENT MUST HAVE A MINIMUM LIFTING CAPACITY OF 18 050 kg (40 000 lb. / 20 tons).

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

SHIPPING AND TRANSPORTATION

DECK TIE DOWN 25 000 LB.

DECK TIE DOWN 25 000 LB.

DECK BOTTOM VIEW - LOOKING UP

CHASSIS BOTTOM VIEW - LOOKING UP

TIE DOWN STRAPS SHOWN FOR TIE DOWN CONFIGURATION

FRONT AXLE TIE DOWN 25 000 LB.

REAR CHASSIS TIE DOWN 25 000 LB.

REAR CHASSIS TIE DOWN 25 000 LB.

DECK TIE DOWN 25 000 LB.

DECK TIE DOWN 25 000 LB.

REAR CHASSIS TIE DOWN 25 000 LB.

REAR CHASSIS TIE DOWN 25 000 LB.

7.

FRONT CHASSIS TIE DOWNS 25 000 LB.

FRONT CHASSIS TIE DOWNS 25 000 LB.

FRONT AXLE TIE DOWN 25 000 LB.

Halvorsen

TIE-DOWN POINTS

Figure 15 TRANSPORT TIE-DOWN POINTS

1-5 Page 17 August 2017

Halvorsen 8.

PREPARE THE LOADER FOR SERVICE A.

CONFIGURE FOLDING WALK-DECK AND HANDRAIL SECTIONS This procedure lists the steps to configure the walk-deck into operation mode.

B.

C.

1-5 Page 18 August 2017

(1)

Remove the retaining pins on each of the folding walk-deck and handrail section on both sides of the deck.

(2)

Fold the walk-deck and handrail sections so the walk-deck is horizontal.

(3)

Install all of the retaining pins to secure the folding walk-deck and handrail sections during shipment.

INSTALL THE LADDER FOR OPERATOR ACCESS TO THE CAB (1)

Install the ladder support arm by installing the two retaining pins. Refer to Figure 8.

(2)

Install the lower ladder support and retaining pin. Refer to Figure 6.

(3)

Install the upper ladder support and retaining pin. Refer to Figure 5.

CONFIGURE THE CAB INTO OPERATIONAL MODE (1)

Remove the cab retaining pin from the rear cab support beam. Refer to Figure 2.

(2)

Pull the cab outwards and into its operation position. Refer to Figure 3.

(3)

Install the cab retaining pin to retain the cab in the operation position.

(4)

Pull the rear view mirror outwards.

(5)

Position the hinged deck weldment in an operational configuration.

(6)

Lift the hinged deck weldment and fold it into the operational position. Refer to Figure 3.

(7)

Lock the hinged deck weldment by tightening the lock. Refer to Figure 2.

(8)

Invert the roller tray adjacent to the hinged deck weldment so that the rollers are facing upwards. Refer to Figure 3.

(9)

Install the retaining pin that connects the front cab side guide rail sections. Refer to Figure 2. Retaining pin and hinge deck weldment lock.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen Section 6. Storage 1.

GENERAL It is very important to properly prepare a vehicle that will be de-commissioned or removed from service for a period of time. The main purpose of a proper preparation before storage is to avoid, or at least minimize, potential damage due to moisture, rust and corrosion and possible component seizing. In addition, a proper preparation of the vehicle previous to storage, as well as periodic verification during storage, will allow to readily place the vehicle back into service with minimum effort and without major problems. NOTE:

THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” SHOULD BE UTILIZED WHEN COMMISSIONING NEW EQUIPMENT AND FOR RE-COMMISSIONING AFTER A MAJOR REPAIR, OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THEROAD TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR MORE THAN SIX MONTHS.

NOTE:

REFER TO THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” IN CHAPTER 2, SECTION 3.

NOTE:

MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4.

CAUTION COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS. 2.

STORAGE - ONE MONTH (MAXIMUM) A.

VEHICLE No special action needed.

B.

ENGINE (1)

Drain the engine crankcase.

(2)

Fill the crankcase to the proper level with the recommended viscosity and grade oil.

(3)

Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two minutes or until the engine is warm, at 1200 rpm at no load.

(4)

Check the air cleaner and service it if necessary.

(5)

If freezing weather is expected during the storage period, add an ethylene-glycol based antifreeze solution in accordance with the manufacturer’s recommendations.

STORAGE

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Halvorsen

C.

(6)

Clean the outside of the engine (except the electrical system) with fuel oil. Dry it with compressed air.

(7)

Seal all of the engine openings. The material used for this purpose must be waterproof, vapor proof and possess sufficient physical strength to resist puncture or damage from the expansion of entrapped air.

BATTERIES Disconnect and remove the two 12 VDC batteries and store them in a cool and dry location.

D.

TRANSMISSION No special action needed.

E.

AXLES No special action needed.

F.

WHEELS AND TIRES Chock drive wheels front and rear to prevent movement in any direction.

G.

HYDRAULIC SYSTEM Minimize exposed cylinder rods by lowering deck fully, retracting powered operator’s cab and ensuring other cylinders are retracted.

H.

GENERAL COMPONENTS Coat all exposed unpainted metal surfaces with rust preventative. Especially important are exposed hydraulic cylinder rods, roller chains and sprockets.

3.

STORAGE - INDEFINITE PERIOD A.

B.

1-6 Page 2 August 2017

VEHICLE (1)

Touch up all worn or damaged paint to prevent rust.

(2)

Ensure that all points are lubricated with specified grease, oil, etc.

(3)

Attach a tag to the steering wheel stating: “CAUTION: ALL LUBRICANTS HAVE BEEN DRAINED FROM THIS VEHICLE”.

(4)

Once all recommended steps are performed, refer to “EQUIPMENT SHELTER” below in this section for recommended protection of the equipment.

ENGINE (1)

Drain the cooling system and flush with clean, soft water. Refill with clean, soft water and add a rust inhibitor to the cooling system.

(2)

Remove, check and recondition the injectors, if necessary, to make sure they will be ready to operate when the engine is restored to service.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (3)

Reinstall the injectors, time them and adjust the exhaust valve clearance.

(4)

Circulate the coolant by operating the engine until normal operating temperature is reached.

(5)

Turn off the engine.

(6)

Drain the engine crankcase, then reinstall and tighten the drain plug. Install new lubricating oil, filter elements and gaskets.

(7)

Fill the crankcase to the proper level with a 30-weight preservative lubricating oil.

(8)

Drain the fuel tank. Refill with enough clean, No. 1 diesel fuel (or pure kerosene) to permit the engine to operate for about ten minutes. If it isn’t convenient to drain the fuel tank, use a separate approved container to supply the recommended fuel.

(9)

Drain and disassemble the fuel filter and strainer. Discard the used elements and gaskets. Wash the shells in clean, No. 1 diesel fuel (or pure kerosene) and insert new elements.

(10)

Fill the cavity between the element and shell with No. 1 diesel fuel (or pure kerosene) and reinstall on the engine. If spin-on fuel filters and strainers are used, discard the used cartridges, fill the new ones with No. 1 diesel fuel (or pure kerosene) and install on the engine.

(11)

Operate the engine for five minutes to circulate the clean fuel oil throughout the fuel system.

(12)

Service the air cleaner.

(13)

Apply a non-friction, rust preventative compound to all exposed parts.

(14)

Drain the engine cooling system.

(15)

Drain the preservative oil from the engine crankcase. Reinstall and tighten the drain plug.

(16)

Remove and clean batteries and battery cables with a baking soda solution and rinse them with fresh water. Do not allow the soda solution to enter the batteries.

(17)

Apply belt dressing to pulleys and belts to prevent sticking.

(18)

Seal all openings in the engine, including the exhaust outlet, with moisture-resistant tape. Use cardboard, plywood or metal covers where practical.

(19)

Clean and dry the exterior, painted surfaces of the engine and spray with a suitable liquid automotive body wax, a synthetic resin varnish or a rust preventative compound.

NOTE:

REFER TO CHAPTER 5, MANUFACTURERS’ APPENDICES FOR ADDITIONAL INFORMATION ON ENGINE MAINTENANCE AND PRESERVATION.

(20)

Protect the engine with a good, weather-resistant tarpaulin and store it under cover, preferably in a dry building which can be heated during the winter months.

(21)

The stored engine should be inspected periodically. If there are any indications of rust or corrosion, corrective steps must be taken to prevent damage to the engine parts. Perform a complete inspection at the end of one year and apply additional treatment as required.

STORAGE

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Halvorsen C.

BATTERIES

D.

(1)

After batteries have been removed from the vehicle, add distilled water to the electrolyte if necessary and applicable. Fully charge them.

(2)

Store the batteries in a cool dry place, between 0 ºC (32 ºF) and 32 ºC (90 ºF), not exposed to direct sunlight.

(3)

Keep batteries fully charged or give them a slow charge every one to two months.

(4)

Check the level and the specific gravity of the electrolyte regularly.

(5)

Batteries must be covered for protection against dirt and moisture.

TRANSMISSION Refer to recommendations for transmissions on Manufacturers’ Data.

E.

AXLES No special action needed.

F.

WHEELS AND TIRES The vehicle should be raised and chassis blocked so that all wheels are off ground. Tires should be sprayed with a rubber preservative.

G.

HYDRAULIC SYSTEM

CAUTION USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS.

H.

(1)

Minimize exposed cylinder rods by fully lowering deck, retracting powered operator’s cab and ensuring other cylinders are retracted.

(2)

Seal all openings with moisture-proof covers or tape.

(3)

Periodically inspect the hydraulic system. If there are any indications of rust or corrosion, corrective steps must be taken to prevent damage to the hydraulic components.

GENERAL COMPONENTS Coat all exposed unpainted metal surfaces with rust preventative. Especially important are exposed hydraulic cylinder rods, roller chains and sprockets.

I.

EQUIPMENT SHELTER Ideally, the vehicle should be stored in a shelter to protect it from the weather, since outdoor storage of engines and transmissions is not recommended. Nevertheless, in some cases, outdoor storage may be unavoidable. If the vehicle must be kept outdoors, follow all preparation and storage instructions.

1-6 Page 4 August 2017

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (1)

Protect the engine with a good, weather-resistant tarpaulin and store it under cover, preferably in a dry building which can be heated during the winter months.

(2)

Protect the vehicle with quality, weather-resistant tarpaulins (or other suitable covers) ensuring proper air circulation.

CAUTION DO NOT USE PLASTIC SHEETING FOR STORAGE. PLASTIC SHEETING USED FOR STORAGE WILL CREATE CONDENSATION WHICH MAY CAUSE METAL SURFACES TO RUST OR PIT.

4.

(3)

If shelter is not available, cover deck and cab with tarpaulins or other protective material. Cover and tape instrument panels to provide a moisture-proof seal.

(4)

The stored vehicle should be inspected periodically. If there are any indications of rust or corrosion, corrective steps must be taken to prevent further damage. Perform a complete inspection at the end of one year and apply additional treatment as required.

RETURNING VEHICLE TO SERVICE

WARNING PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING THE VEHICLE INTO SERVICE AFTER STORAGE. A.

RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE When returning the equipment to service after a short time period, several items should be act upon, as follows:

B.

(1)

Perform a general inspection of the vehicle in accordance to recommendations (refer to the “EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3).

(2)

Replenish or replace all fluids, including oil, fuel and coolant, according to maintenance and lubrication recommendations and guidelines. Refer to Chapter 2, Section 3, “Preventative Maintenance”.

(3)

Inspect tires for damage, cracks and dry rot. Inflate to specifications and remove chocks.

(4)

As a minimum, perform the recommended daily and quarterly maintenance according to maintenance schedules in Chapter 2, Section 3.

RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY It is very important to properly prepare the vehicle, before placing it into service after an extended storage period. An exhaustive inspection and a comprehensive maintenance should be performed on the equipment to ensure proper operation and minimize breakdown and downtime. (1)

STORAGE

Perform a general inspection of the vehicle in accordance to recommendations (refer to the “EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3).

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Halvorsen

5.

(2)

Replenish or replace all fluids, including oil, fuel and coolant, according to maintenance and lubrication recommendations and guidelines (refer to Chapter 2, Section 3, “Preventative Maintenance” and Chapter 5, MANUFACTURERS’ APPENDICES).

(3)

Inspect tires for damage, cracks and dry rot. Inflate to specifications and remove vehicle from raising blocks.

(4)

Before placing the vehicle into operation, fully recharge the batteries before installing them back in the vehicle.

(5)

Perform ALL the recommended maintenance (daily, quarterly and annually) according to maintenance schedules in Chapter 2, Section 3.

STORAGE A.

SHORT-TERM STORAGE - ONE MONTH MAXIMUM

B.

(1)

Whenever possible, the loader should be stored indoors to protect it from the weather.

(2)

Perform all periodic maintenance services that are due as stated in Chapter 2, Section 3, “Preventative Maintenance”.

(3)

Chock drive wheels, front and rear, to prevent movement in either direction.

(4)

Disconnect and remove the batteries and store in a cool, dry location.

(5)

Coat all exposed, unpainted metal surfaces with rust preventative including all exposed hydraulic cylinder rods and roller chains.

(6)

Seal the exhaust pipe outlet with adhesive tape to prevent moisture intrusion.

(7)

When the loader is stored exposed to the elements, cover the operator’s cab with a waterproof tarpaulin to protect the cab electrical components, cab windows and windshield wiper blades.

LONG-TERM STORAGE - THREE YEARS MAXIMUM (1)

NOTE:

1-6 Page 6 August 2017

When the loader is to be stored or remain inactive for an extended period (1 year or longer), specific preservation methods are recommended to prevent damage due to rust, corrosion and organic growth in the oils. Use a waterproof, protective material to cover the entire loader. Place Vapor Corrosion Inhibitor (VCI) pads inside protective material before sealing. Whenever possible, the loader should be stored indoors to protect it from the weather. REFER TO THE MANUFACTURER’S MANUALS (CHAPTER 5) PERTAINING TO THE TRANSMISSION AND ENGINE FOR DETAILED METHODS FOR PRESERVATION WHEN THE LOADER IS TO BE STORED OR REMAIN INACTIVE, FOR AN EXTENDED PERIOD.

(2)

Perform all periodic maintenance services that are due as prescribed in Chapter 2, MAINTENANCE, before placing loader into storage. It is recommended that no preservatives be added to the engine oil, transmission fluid, hydraulic fluid or engine coolant for long term storage.

(3)

If the loader is equipped with air conditioning, the system should be evacuated prior to storage.

GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Halvorsen (4)

Fill fuel tank to three quarts (¾) full with non bio-diesel fuel. Coat the chain on the filler tank cap with approved preservation product(s). Cover filler cap with weatherproof tape.

(5)

Degrease and wash entire loader. Pay specific attention to areas where rust prevention is an issue. Let the loader completely dry before coating exposed metal surfaces and unpainted areas using approved storage preparation methods and preservation products.

(6)

Locate a level surface with adequate drainage for loader storage.

(7)

Place waterproof, protective material across area for loader storage. Drive loader over protective material.

(8)

Raise the chassis with jacks and place shoring under the chassis frame to remove all weight from the front and rear tires. Follow the corresponding procedures for CHANGING WHEELS ON REAR AXLE in Chapter 2, Section 5, “Maintenance Procedures” for the proper procedures on raising the loader and securing the bogy axle pivot shaft to the chassis.

(9)

Disconnect the batteries from the loader and connect an approved solar cell trickle-charger. Secure the solar cell trickle-charger to the outside of the protective material so as to provide maximum exposure to sunlight.

(10)

Verify that all electrical boxes are clean and dry with no moisture or signs of additional rust. Electrical boxes should contain VCI pads inside along with VCI emitters.

(11)

Coat all exposed, unpainted metal surfaces with rust preventative, including all exposed hydraulic cylinder rods, hose fittings, manifolds and roller chains on the deck, chassis and inside the operator’s cab.

(12)

Leave the cab windows and back door open when the loader is wrapped in protective material. This will eliminate mold and galvanic rust and corrosion inside the cab by allowing the VCI vapors to circulate inside the protective material.

(13)

Seal the exhaust pipe outlet with adhesive tape to prevent moisture intrusion.

(14)

Remove windshield wiper blade and arm assemblies, wrap in protective material and stow in the operator’s cab.

(15)

Use waterproof tape when prepping loader for long term storage bagging. Verify loader disconnect switch, located on the battery box, is on the OFF position. Wrap loader in protective material and secure the solar cell trickle-charger to the outside of the protective material.

STORAGE

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Halvorsen TABLE OF CONTENTS CHAPTER 2. MAINTENANCE AND REPAIR

Section 1. Safety Precautions 1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT) . . . . . . . . . . . . . . . .

2

A.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

B.

LOCK-OUT AND TAG-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

C.

UNLOCKING AND REMOVAL OF TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

A.

MAINTENANCE STANDS INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .

4

WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3. 4.

Section 2. System Overview 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

B.

POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

C.

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

D.

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

E.

DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

F.

REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

SOLENOID VALVES, MANIFOLDS AND SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .

10

A.

SOLENOID VALVE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Table 1 - SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

B.

HYDRAULIC MANIFOLD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

C.

LIMIT SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.

Section 3. Preventative Maintenance 1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

BEFORE COMMISSIONING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

TABLE OF CONTENTS

2-Contents Page 1 August 2017

Halvorsen 3.

EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Table 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . .

3

BREAK-IN PERIOD AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

A.

BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

B.

BREAK-IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Table 2 - MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Table 3 - AIR CONDITIONER MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . .

12

6.

MAINTENANCE AND FLUID KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

7.

HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

8.

OPERATIONAL CHECKS SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Table 4 - OPERATIONAL CHECKS SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

A.

14

4.

5.

9.

GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 5 - GREASE POINTS - CHASSIS AND SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Table 6 - FRONT AXLE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Table 7 - GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT . . . . . . . . . . .

20

B.

LIMITER PIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

C.

CHAINS LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

D.

FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Section 4. Maintenance Specifications 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Table 1 - OIL OPERATING TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3.

OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

4.

FLUIDS CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

5.

RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Table 2 - ENGINE OIL, TRANSMISSION FLUID AND COOLANT . . . . . . . . . . . . . . . . . . . . .

3

Table 3 - ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Table 4 - BIODIESEL ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Table 5 - HEATER FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Table 6 - HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 7 - LUBRICATING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2-Contents Page 2 August 2017

Table 8 - ELECTRICAL GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 9 - AIR CONDITIONER LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 10 - AIR CONDITIONING SYSTEM REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Table 11 - 1000-HOUR (ANNUAL) FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

MAINTENANCE AND REPAIR

Halvorsen 6.

EQUIPMENT ADJUSTMENT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Table 12 - ADJUSTMENT SETTINGS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Table 13 - FRONT AXLE TORQUE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Table 14 - BRACE ASSEMBLY TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .

6

7.

HYDRAULIC PRESSURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

8.

PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Table 15 - ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . .

7

BOLT IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Table 16 - STANDARD AND METRIC STEEL BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . .

8

BOLT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Table 17 - STANDARD STEEL BOLTS TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . .

9

Table 18 - METRIC STEEL BOLTS TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . .

10

Table 19 - 18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS . . . . . .

10

9. 10.

Section 5. Maintenance Procedures 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

SPROCKETS AND ROLLER CHAINS INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . .

2

A.

SPROCKETS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

B.

ROLLER CHAINS INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

C.

ROLLER CHAINS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

D.

CONVEY MODULE CHAINS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

FRONT AXLE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

A.

DRIVE AND STEER FRONT AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

B.

DRIVE AND STEER FRONT AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

MAIN LIFT CYLINDERS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

A.

MAIN LIFT CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

B.

MAIN LIFT CYLINDERS INSTALLATION AND BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . .

9

HELPER CYLINDERS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

A.

HELPER CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

B.

HELPER CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

C.

HELPER CYLINDERS BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

SCISSORS LOWER ROLLERS REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .

15

A.

REMOVE LOWER ROLLERS ON INNER SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

B.

INSTALL LOWER ROLLER ON INNER SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

BRAKES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

A.

PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

B.

PARKING BRAKE FORWARD MOVEMENT FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . .

18

3.

4.

5.

6.

7.

TABLE OF CONTENTS

2-Contents Page 3 August 2017

Halvorsen 8.

9.

10.

11.

12.

13.

14.

C.

PARKING BRAKE REVERSE MOVEMENT FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . .

18

D.

FRONT SERVICE BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

E.

FRONT SERVICE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

A.

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

B.

ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

TRANSMISSION REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

A.

TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

B.

TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

FORWARD DECK SHIFT AND ROLL CYLINDERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .

24

A.

LOADER DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

B.

CENTER AND LEVEL THE DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

C.

REMOVE MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

D.

DISCONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

E.

SECURE LIFTING PROVISIONS TO THE DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

F.

REMOVE UPPER FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

G.

DISCONNECT ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

H.

DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . .

29

I.

REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

FORWARD DECK SHIFT AND ROLL CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

31

A.

INSTALL THE FRONT SIDE SHIFT BOGY ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

B.

CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

C.

CONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

D.

CONNECT ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

E.

INSTALL UPPER FASTENERS TO SECURE ROLL CYLINDERS . . . . . . . . . . . . . . . . . . . . .

34

F.

INSTALL MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

REAR DECK SHIFT AND ROLL CYLINDERS REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

A.

CENTER AND LEVEL THE DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

B.

DISCONNECT THE REAR ROLL CYLINDER HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . .

35

C.

DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . .

36

D.

REMOVE REAR SCISSOR ROLLER TRACKS FROM THE DECK . . . . . . . . . . . . . . . . . . . .

38

REAR DECK SHIFT AND ROLL CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

A.

INSTALL REAR SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

B.

CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

C.

CONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

D.

INSTALL REAR SCISSOR ROLLER TRACKS ON THE DECK . . . . . . . . . . . . . . . . . . . . . . .

40

REPLACE FAN BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

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MAINTENANCE AND REPAIR

Halvorsen 15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

HYDRAULIC PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

A.

HYDRAULIC PUMP REMOVAL FROM CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

B.

HYDRAULIC PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

CHANGING WHEELS ON FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

A.

FRONT AXLE WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

B.

FRONT AXLE WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

CHANGING WHEELS ON REAR AXLE (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

A.

REAR AXLE WHEEL REMOVAL (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

B.

REAR AXLE WHEEL INSTALLATION (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

HYDRAULIC FLUID LEVEL AND REFILLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

A.

CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

B.

REFILLING HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

BATTERY MAINTENANCE CHARGING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

A.

BATTERIES CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

B.

CHARGER OUTPUT VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

C.

CHARGER TYPE - AUTOMATIC OR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

D.

SELECTING BATTERY TYPE ON YOUR CHARGER OUTPUT . . . . . . . . . . . . . . . . . . . . . .

52

E.

BATTERIES STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

BATTERY REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

A.

REMOVE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

B.

INSTALL BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

RADIATOR REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

A.

RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

B.

RADIATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

COOLANT SYSTEM LEVEL AND REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

A.

COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

B.

REFILL AND BLEED AIR FROM COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

C.

COLD WEATHER OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

AIR CONDITIONER INSPECTION AND MAINTENANCE (WITHOUT GAUGES) . . . . . . . . . . . . .

58

A.

CONSIDERATIONS BEFORE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

B.

COMPONENTS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

AIR CONDITIONING COMPONENT REPAIR OR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .

59

A.

HOSES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

B.

AIR CONDITIONING LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

C.

AIR CONDITIONING EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

D.

RECEIVER-DRYER AND ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

E.

COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

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Halvorsen 25.

LEFT SIDE SKYLIGHT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

A.

LEFT SIDE SKYLIGHT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

B.

LEFT SIDE SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION. . . . . . . . . .

62

C.

APPLY CAB PRIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

D.

PREPARE LEFT SKYLIGHT GLASS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .

64

E.

APPLY GLASS PRIMER TO LEFT SKYLIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

F.

LEFT SIDE SKYLIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

Table 1 - SEALANT DRYING TIMES (HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

TOP SKYLIGHT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

A.

TOP SKYLIGHT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

B.

TOP SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION . . . . . . . . . . . . . . .

71

C.

APPLY PRIMER TO TOP SKYLIGHT PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

D.

PREPARE TOP SKYLIGHT GLASS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

E.

APPLY GLASS PRIMER TO TOP SKYLIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

F.

TOP SKYLIGHT GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

Table 2 - SEALANT DRYING TIMES (HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77

27.

HYDRAULIC SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

28.

CHASSIS MANIFOLD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

A.

LOAD SENSE MARGIN PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

B.

MAIN RELIEF VALVE AND PUMP COMPENSATOR PRESSURE . . . . . . . . . . . . . . . . . . . .

79

C.

HELPER CYLINDER PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

D.

PARK BRAKE RELEASE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

E.

SECONDARY SERVICE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

F.

THROTTLE PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

INNER AND OUTER SCISSORS MANIFOLD ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

A.

SHIFT LEFT SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

B.

SHIFT RIGHT SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

REAR PITCH MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

A.

REAR PITCH CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

B.

REAR PITCH SPEED, PITCH DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

C.

REAR PITCH SPEED, PITCH UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

PALLET STOPS AND CONVEY LIFT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

A.

PALLET STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

B.

TRACTION ROLLER LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

32.

CONVEY MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

33.

ENGINE COOLANT FAN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

A.

94

26.

29.

30.

31.

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FAN MOTOR PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AND REPAIR

Halvorsen 34.

35.

PROXIMITY SWITCH ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

A.

PROXIMITY SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

B.

PROXIMITY SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

ELECTRICAL SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

A.

POTENTIOMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

B.

LIMIT SWITCH ARM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

C.

DECK FULLY DOWN (2LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

D.

FRONT OF DECK FULLY DOWN (4LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

E.

REAR OF DECK FULLY DOWN (5LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

F.

DECK ROLL RIGHT (14LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

G.

DECK ROLL LEFT (15LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

H.

DECK SHIFTED LEFT (17LS) AND DECK SHIFTED RIGHT (18LS) ADJUSTMENT . . . . . . 104

I.

AIR TRANSPORT PIN (16LS) AND CLEVIS (16LS-A) ADJUSTMENTS . . . . . . . . . . . . . . . . 105

J.

AIR TRANSPORT MODE (3LS-A) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

K.

RPM ADJUSTMENT (TRANSMISSION ACCESSORY BOX) . . . . . . . . . . . . . . . . . . . . . . . . 108

L.

PITCH UP AND DOWN (4PRS AND 5PRS) ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 111

Section 6. Troubleshooting 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

BEFORE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

B.

HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

PRESSURE READINGS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

B.

MALFUNCTIONS ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

C.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3.

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

4.

TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

A.

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

B.

DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

C.

COMPONENTS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

D.

SENSORS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

TROUBLESHOOTING GUIDE TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Table 1 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2.

5.

Table 2 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Table 3 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Table 4 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

TABLE OF CONTENTS

2-Contents Page 7 August 2017

Halvorsen 6.

D3 AND D4 HEATER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.

15

BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Table 5 - D3 AND D4 HEATER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

B.

SELF DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

C.

HEATER FAULT CODES, CAUSES AND ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Table 6 - D3 AND D4 HEATER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Section 7. System Schematics 1.

2.

3.

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

A.

BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

B.

HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

ELECTRICAL SCHEMATIC - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

521-3504

INTERCONNECT DIAGRAM - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

624-3491-001

SP2100 HE WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

625-9070

Table 1 - WIRE HARNESS - SP2100 - 625-9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

HYDRAULIC SYSTEM SCHEMATIC - 2100SP. . . . . . . . . . . . . . . . . . . . . . .

623-5420-001

Table 2 - HYDRAULIC SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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61

MAINTENANCE AND REPAIR

Halvorsen LIST OF FIGURES CHAPTER 2. MAINTENANCE AND REPAIR

Section 1. Safety Precautions 2-1

Figure 1

ENERGY SOURCES AND DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2-1

Figure 2

MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Section 2. System Overview 2-2

Figure 1

VEHICLE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2-2

Figure 2

VEHICLE CHASSIS COMPONENTS - TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . .

3

2-2

Figure 3

POWER UNIT COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

2-2

Figure 4

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2-2

Figure 5

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2-2

Figure 6

DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

2-2

Figure 7

REAR AXLE ASSEMBLY - BOGY WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

2-2

Figure 8

REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

2-2

Figure 9

HYDRAULIC MANIFOLD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

2-2

Figure 10

LIMIT SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Section 3. Preventative Maintenance 2-3

Figure 1

ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2-3

Figure 2

HYDRAULIC RETURN FILTER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2-3

Figure 3

ENGINE OIL, COOLANT AND TRANSMISSION FLUID FILL POINTS . . . . . . . .

11

2-3

Figure 4

HELPER CYLINDER BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

2-3

Figure 5

GREASE POINTS - CHASSIS AND SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . .

14

2-3

Figure 6

GREASE POINTS - HELPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

2-3

Figure 7

GREASE POINTS - FRONT SIDE SHIFT CYLINDERS . . . . . . . . . . . . . . . . . . . .

15

2-3

Figure 8

GREASE POINTS - REAR SIDE SHIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . .

16

2-3

Figure 9

GREASE FITTINGS - IMPACT ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

2-3

Figure 10

GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT . . . . . . . . .

18

2-3

Figure 11

DRIVE AND STEER AXLE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . .

19

2-3

Figure 12

CHAINS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

LIST OF FIGURES

2-Figures Page 1 August 2017

Halvorsen 2-3

Figure 13

ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

2-3

Figure 14

FILL POINT - HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

2-3

Figure 15

FILL POINT - PLANETARY GEAR WHEEL END . . . . . . . . . . . . . . . . . . . . . . . . .

24

Section 4. Maintenance Specifications

Section 5. Maintenance Procedures 2-5

Figure 1

CONVEY MODULE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2-5

Figure 2

WITNESS MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2-5

Figure 3

DRIVE SHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2-5

Figure 4

HELPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

2-5

Figure 5

MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

2-5

Figure 6

HELPER CYLINDER BLEEDER SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

2-5

Figure 7

LOWER ROLLER ON INNER SCISSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

2-5

Figure 8

PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

2-5

Figure 9

LOADER DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

2-5

Figure 10

DECK BUMPER LIMIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

2-5

Figure 11

ROLL CYLINDER HYDRAULICS AND FASTENERS . . . . . . . . . . . . . . . . . . . . . .

27

2-5

Figure 12

REAR VIEW OF FRONT SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . .

29

2-5

Figure 13

SIDE SHIFT BOGY ASSEMBLY CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . .

31

2-5

Figure 14

SIDE SHIFT CYLINDER BOGY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .

32

2-5

Figure 15

FRONT SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . .

33

2-5

Figure 16

ROLL CYLINDER HYDRAULICS AND FASTENERS . . . . . . . . . . . . . . . . . . . . . .

36

2-5

Figure 17

REAR SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

2-5

Figure 18

UPPER SCISSOR ROLLERS AND SCISSOR ROLLER TRACKS . . . . . . . . . . . .

38

2-5

Figure 19

REAR SIDE SHIFT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

2-5

Figure 20

COUPLING HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

2-5

Figure 21

COUPLING ELEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

2-5

Figure 22

ELEMENT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

2-5

Figure 23

JACKING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

2-5

Figure 24

FLUID LEVEL MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

2-5

Figure 25

BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

2-5

Figure 26

RADIATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

2-5

Figure 27

COOLANT SERVICE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

2-5

Figure 28

CLEANING URETHANE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

2-5

Figure 29

REMOVING SKYLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

2-5

Figure 30

CLEANING DIRT FROM PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

2-Figures Page 2 August 2017

MAINTENANCE AND REPAIR

Halvorsen 2-5

Figure 31

CHECK FOR FLATNESS OF CAB SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

2-5

Figure 32

MASKING OFF EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

2-5

Figure 33

APPLYING PRIMER TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

2-5

Figure 34

MASKING EDGE OF “FRIT” SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

2-5

Figure 35

APPLYING PRESSURE TO TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

2-5

Figure 36

PUNCTURING APPLICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

2-5

Figure 37

WET OUT OF TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

2-5

Figure 38

APPLICATION OF PRIMER TO FRIT SURFACE. . . . . . . . . . . . . . . . . . . . . . . . .

66

2-5

Figure 39

APPLICATION OF SEALANT TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . .

67

2-5

Figure 40

INSTALLATION OF NEW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

2-5

Figure 41

MASKING PERIMETER OF GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

2-5

Figure 42

APPLICATION OF SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

2-5

Figure 43

SCRAPING OF EXCESS SEALANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

2-5

Figure 44

FINISHED GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

2-5

Figure 45

REMOVING PROTECTIVE GRATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

2-5

Figure 46

CLEANING URETHANE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

2-5

Figure 47

CLEANING DIRT FROM PINCHWELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

2-5

Figure 48

MASKING OFF EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

2-5

Figure 49

APPLYING PRIMER TO PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

2-5

Figure 50

MASKING EDGE OF “FRIT” SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

2-5

Figure 51

APPLYING PRESSURE TO TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

2-5

Figure 52

PUNCTURING APPLICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

2-5

Figure 53

WET OUT OF TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74

2-5

Figure 54

APPLICATION OF PRIMER TO FRIT SURFACE. . . . . . . . . . . . . . . . . . . . . . . . .

74

2-5

Figure 55

APPLICATION OF SEALANT TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . .

75

2-5

Figure 56

INSTALLATION OF NEW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

2-5

Figure 57

APPLICATION OF SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

2-5

Figure 58

SMOOTHING SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

2-5

Figure 59

FINISHED SKYLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

2-5

Figure 60

HYDRAULIC PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

2-5

Figure 61

CHASSIS MANIFOLD - FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

2-5

Figure 62

CHASSIS MANIFOLD - REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

2-5

Figure 63

LOAD SENSE MARGIN PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . .

83

2-5

Figure 64

PARK BRAKE RELEASE PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .

84

2-5

Figure 65

“P” PORT, THROTTLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

2-5

Figure 66

INNER SCISSORS MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88

2-5

Figure 67

OUTER SCISSORS MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

2-5

Figure 68

REAR PITCH MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

2-5

Figure 69

PALLET STOPS AND CONVEY LIFT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . .

92

LIST OF FIGURES

2-Figures Page 3 August 2017

Halvorsen 2-5

Figure 70

CONVEY MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

2-5

Figure 71

FAN DRIVE MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

2-5

Figure 72

PROXIMITY SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

2-5

Figure 73

VALVE DRIVE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

2-5

Figure 74

LIMIT SWITCH ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

2-5

Figure 75

LIMIT SWITCH 2LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

2-5

Figure 76

LIMIT SWITCH 4LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99

2-5

Figure 77

LIMIT SWITCH 5LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

2-5

Figure 78

LIMIT SWITCH 14LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2-5

Figure 79

LIMIT SWITCH 15LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

2-5

Figure 80

LIMIT SWITCHES 17LS AND 18LS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2-5

Figure 81

LIMIT SWITCH 16LS AND 16LS-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2-5

Figure 82

AIR TRANSPORT PIN AND CLEVIS INSTALLATION . . . . . . . . . . . . . . . . . . . . . 106

2-5

Figure 83

LIMIT SWITCH 3LS-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2-5

Figure 84

TRANSMISSION ACCESSORY BOX IN MAIN PANEL . . . . . . . . . . . . . . . . . . . . 109

2-5

Figure 85

ACCESSORY BOX - PART NO. 623-7300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

2-5

Figure 86

PROXIMITY SWITCHES 4PRS AND 5PRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Section 6. Troubleshooting 2-6

Figure 1

HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2-6

Figure 2

FAULT CODE RETRIEVAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Section 7. System Schematics 2-7

Figure 1

ELECTRICAL SCHEMATIC - 2100SP - 521-3504. . . . . . . . . . . . . . . . . . . . . . . . .

5

2-7

Figure 25

INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 . . . . . . . . . . . . . . . . . . . .

29

2-7

Figure 43

WIRE HARNESS - SP2100 - 625-9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

2-7

Figure 46

HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 . . . . . . . . . . . . . . . . . . . . . .

55

2-Figures Page 4 August 2017

MAINTENANCE AND REPAIR

Halvorsen CHAPTER 2. MAINTENANCE AND REPAIR

Section 1. Safety Precautions 1.

INTRODUCTION

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS. The main purpose of this chapter is to provide all the necessary information for technicians to safely inspect and maintain the Halvorsen, 25 000 lb. Loader for Aircraft. Before operating or maintaining the equipment, all operating instructions should be read and completely understood. Refer to all sections in Chapter 1. Section 1, “Safety Precautions” presents a series of warnings and cautions for the operator and technician to better understand the items that require especial care and attention to avoid personal injury and property damage. Emphasis should always be placed on safety, not only for personnel working with the equipment, but also for persons and property served with this vehicle. Section 2, “System Overview” presents an overall review of the vehicle to allow operators and technicians better understanding on how equipment and most components work. Section 3, “Preventative Maintenance” presents a pre-operational check list, an operator’s daily check and periodic maintenance schedules. Section 4, “Maintenance Specifications” provides information required for performing regular maintenance and procedures. Section 5, “Maintenance Procedures” outlines the necessary procedures for mechanical, hydraulic and electrical adjustments for the vehicle. Section 6, “Troubleshooting” provides useful troubleshooting guidelines for locating and solving general potential problems with the equipment, if they should arise. Section 7, “System Schematics” presents electrical and hydraulic schematics for the vehicle to be used in conjunction with information in Section 6, “Troubleshooting”. It is also important to properly maintain the equipment according to maintenance schedules and manufacturer’s recommendations to avoid potential accidents and costly mechanical breakdowns.

SAFETY PRECAUTIONS

2-1 Page 1 August 2017

Halvorsen 2.

PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT) A.

DESCRIPTION The lock-out and tag-out procedures, also referred to as “out-of-service notification” procedures, must be followed before performing any maintenance on the vehicle to prevent accidental starting of the engine, energizing of the electrical or hydraulic system, closing of any hoods and hatches or any other operation that can injure persons or damage equipment. Energy sources in the vehicle should be isolated and rendered inoperative prior to performing any maintenance. The main energy sources in diesel-powered loaders are the diesel engine and cooling system, electrical batteries, fuel tank and hydraulic system including pressure accumulators. The engine must be switched off and allowed to cool down, prior to starting maintenance work. The vehicle contains many heavy components, hoods and hatches, which also contain energy in a raised position and should be lowered, closed or properly secured when keeping them open or in a raised position. The lock-out and tag-out procedure also prevents accidental return of the vehicle into operation prior to completion of all maintenance work. Refer to NFPA 70E and OSHA 29 CFR 1910.147 and 1910.333 on lock-out and tag-out procedures. Additional procedures and regulations may be applicable at specific locations. The vehicle ignition switch or key should not be used as the sole lock-out device, since in many cases duplicate keys circulate and are not tightly controlled. The battery disconnect switch should also not be used as the sole lock out device, since the switch can be easily re-actuated. Please note that when working with movable scaffolding, cranes or jacks during maintenance work, these also should be locked or tagged out.

WARNING FOLLOW THE REQUIRED PROCEDURES TO PREPARE THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT). B.

2-1 Page 2 August 2017

LOCK-OUT AND TAG-OUT PROCEDURE (1)

Park the vehicle in a clean and level surface. Chock wheels securely and install maintenance supports.

(2)

Ensure deck is fully lowered or if planning to work underneath, ensure the deck is fully supported by the designated maintenance supports to prevent the deck from falling.

(3)

Deplete pressure from hydraulic system. Fully retract and unload all cylinders.

(4)

Turn off ignition switch.

(5)

Ensure winterization systems are disconnected from external power outlets and secure cables to prevent anybody from re-connecting them (if equipped).

(6)

Turn off battery disconnect and remove handle (if equipped).

(7)

Disconnect negative battery cable and secure it to avoid accidental contact with battery posts.

MAINTENANCE AND REPAIR

Halvorsen

Figure 1 ENERGY SOURCES AND DEVICES

SAFETY PRECAUTIONS

2-1 Page 3 August 2017

Halvorsen

C.

(8)

Install an OSHA approved lock-out and tag-out tag or highly visible label on or directly beside the ignition panel. The tag or label should clearly warn against starting, operating or re-energizing the equipment.

(9)

Install guard rails or a fall restraint system when accessing the top of the vehicle for maintenance.

(10)

Allow engine and other components sufficient time to cool down completely before starting maintenance work. Pressure inside the cooling system will be significantly reduced after the cool-down period.

(11)

Deplete all pneumatic pressure in the tires before working on wheels, rims and tires.

(12)

Open hoods and hatches and securely support them before starting any maintenance on the vehicle.

(13)

Secure the power module whenever you need to keep it open, to prevent it from swinging.

(14)

Verify that all energy sources are effectively disabled.

UNLOCKING AND REMOVAL OF TAGS Upon completion of maintenance, repair work and adjustments unlock and un-tag the vehicle following the lock-out and tag-out procedure in reverse order.

3.

MAINTENANCE STANDS

WARNING BEFORE PERFORMING ANY PROCEDURE THAT REQUIRES THE DECK TO BE IN AN ELEVATED POSITION, INSTALL THE MAINTENANCE STANDS AND LOWER THE DECK FULLY AGAINST THE MAINTENANCE STANDS. The Halvorsen comes with maintenance stands (support blocks) to support the platform deck at three different heights. The stands are stowed outside the chassis, one on each side of the vehicle. A.

MAINTENANCE STANDS INSTALLATION AND REMOVAL Refer to Figure 2. (1)

(2)

2-1 Page 4 August 2017

Maintenance Stands Installation (a)

Raise the deck high enough to complete required work.

(b)

Install both maintenance stands into the chassis and install retaining pins.

(c)

Lower deck until the lower scissor rollers come into contact with the maintenance stands.

Maintenance Stands Removal (a)

Raise deck until the lower scissor roller clears the maintenance stands.

(b)

Remove retaining pins.

(c)

Remove both maintenance stands and stow in holders and install retaining pins.

(d)

Lower the deck.

MAINTENANCE AND REPAIR

Halvorsen SUPPORT BLOCK LOCATIONS

MAINTENANCE SUPPORT BLOCKS

Figure 2 MAINTENANCE STANDS 4.

WARNINGS AND CAUTIONS

DANGER ELECTRICAL CURRENT FROM FACILITIES POWER, BATTERY AND LIGHTNING IS HAZARDOUS. TO REDUCE RISK OF ELECTRICAL SHOCK: DO NOT CONNECT OR DISCONNECT ANY ELECTRICAL CABLES DURING AN ELECTRICAL STORM, CONNECT FACILITIES POWER UTILIZING ONLY THE PROPER CONNECTORS PROVIDED, USE ONLY ONE HAND TO CONNECT OR DISCONNECT CABLES AND TURN OFF AND LOCK OUT ALL ELECTRICAL POWER SOURCES BEFORE PERFORMING ANY MAINTENANCE ON THE VEHICLE.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, ENSURE THE VEHICLE IS ON A CLEAN AND LEVEL SURFACE, WHEELS ARE SECURELY CHOCKED, POWER UNIT IS OFF, HYDRAULIC PRESSURE IS DEPLETED AND BATTERIES HAVE BEEN DISCONNECTED. PLACE A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL VEHICLE IS BEING WORKED ON.

SAFETY PRECAUTIONS

2-1 Page 5 August 2017

Halvorsen WARNING VEHICLE MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS.

WARNING LOCK OUT AND TAG OUT THE VEHICLE BEFORE PERFORMING ANY MAINTENANCE, ADJUSTMENTS OR REPAIRS TO THE VEHICLE.

WARNING MAINTENANCE SUPPORT STANDS MUST BE INSTALLED WHILE PERSONNEL ARE WORKING UNDER THE RAISED DECK.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.

WARNING TURN THE BATTERY DISCONNECT SWITCH TO THE “OFF” POSITION TO AVOID ELECTRICAL HAZARDS WHILE WORKING ON THE ELECTRICAL SYSTEM.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, START ENGINE, RAISE DECK TO SUFFICIENT HEIGHT TO INSTALL THE MAINTENANCE STANDS, THEN LOWER THE DECK UNTIL SCISSORS ROLLERS ARE IN CONTACT WITH THE MAINTENANCE STANDS OR BLOCKS. CHOCK WHEELS TO PREVENT MOVEMENT OF THE LOADER IN EITHER DIRECTION, APPLY THE PARK BRAKE AND TURN OFF THE ENGINE.

WARNING BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF THE VEHICLE AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONS.

WARNING IT IS MANDATORY THAT ALL PERSONNEL WEAR A SAFETY HARNESS, WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” WHEN WORKING ON THE DECK IN THE AREA IDENTIFIED AND MARKED AS “HARNESS REQUIRED AREA”. 2-1 Page 6 August 2017

MAINTENANCE AND REPAIR

Halvorsen WARNING USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN PERFORMING VEHICLE MAINTENANCE.

WARNING HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF THE POWER UNIT AND DEPLETE SYSTEM PRESSURE BEFORE INSPECTING OR LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP AWAY FROM HYDRAULIC LEAKS. DO NOT ATTEMPT TO “FEEL” FOR THE SOURCE OF A LEAK. PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER SERIOUS INJURY.

WARNING TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS.

WARNING OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE POISONOUS.

WARNING KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE BURNS.

WARNING COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO RELEASE BEFORE COMPLETELY REMOVING IT.

WARNING INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH MAINTENANCE SCHEDULE.

WARNING AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE EXPLOSIVE HYDROGEN GAS.

SAFETY PRECAUTIONS

2-1 Page 7 August 2017

Halvorsen WARNING USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE VEHICLE (REFER TO JACKING REQUIREMENTS IN SPECIFICATIONS SECTION).

WARNING DO NOT ALLOW ANY PERSONS UNDER THE VEHICLE UNLESS PROPERLY RATED MAINTENANCE STANDS ARE USED FOR SAFE SUPPORT OF THE VEHICLE.

WARNING AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL, LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN IRRITATION.

WARNING DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL SYSTEM.

WARNING REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE VEHICLE AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT. REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS.

CAUTION WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS, CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.

CAUTION WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE OR MOTOR COMPARTMENT.

CAUTION WHEN WASHING OR RINSING THE LOADER, PREVENT WATER FROM INTRUDING THE TRANSMISSION BREATHER VALVE.

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MAINTENANCE AND REPAIR

Halvorsen CAUTION WHEN PERFORMING A BATTERY “JUMP START” ON THE VEHICLE, ENSURE JUMP CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND COMPONENTS.

CAUTION WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND COMPONENTS.

CAUTION DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS, RUBBER HOSES OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS SUCH AS KEROSENE, GASOLINE OR FUEL OIL.

CAUTION DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE ‘MIN’ MARK OR ABOVE THE ‘MAX’ MARK ON THE DIPSTICK.

CAUTION ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT.

CAUTION ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.

CAUTION USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO PREVENT FREEZING AT THE AMBIENT TEMPERATURE.

CAUTION DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE COOLANT SYSTEM OR BATTERIES.

SAFETY PRECAUTIONS

2-1 Page 9 August 2017

Halvorsen CAUTION DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE ALTERNATOR CHARGING SYSTEM.

CAUTION COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS.

CAUTION DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED.

CAUTION USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS.

CAUTION BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES. PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE THE WELDER’S GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO THE WELDING OPERATION AS POSSIBLE.

CAUTION PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED. ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER UNIT.

CAUTION AFTER REPLACING THE PUMP, FILL THE CASE DRAIN PUMP CAVITY WITH NEW HYDRAULIC OIL BEFORE STARTING THE VEHICLE.

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MAINTENANCE AND REPAIR

Halvorsen Section 2. System Overview 1.

GENERAL NOTE:

REFER TO CHAPTER 1, SECTION 1, “DESCRIPTION” AND CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR SPECIFICATIONS AND ADDITIONAL INFORMATION ABOUT THIS VEHICLE.

This section presents an overview of the vehicle and its system components. The Halvorsen, 25 000 lb. Loader for Aircraft, is a self-propelled two-wheel drive vehicle, driven and operated by one person. The vehicle is powered by a diesel engine coupled to an automatic transmission. The hydraulic system is an open center system, powering brakes and steering. The engine provides traction by means of a transmission with a drive shaft coupled to the front drive axle. The parking brake disc is contained within the front axle. The vehicle also includes a no-spin, two-wheel drive and steer axle with hydraulically operated wheel steering, hydraulically operated brakes on the front axle input shaft and on all four rear axle wheels. The electrical system is 24 VDC negative-grounded. 2.

SYSTEM DESCRIPTION Chassis Assemblies and Components •

Power unit (engine, transmission and hydraulic services pump)

•

Radiator (cooling)

•

Fuel tank

•

Main electrical panel

•

Hydraulic tank

•

Hydraulic manifold and components

•

Emergency pump

•

Winterization panel and receptacle

•

Front and rear axles

Platform Deck Assemblies and Components •

Lifting scissors

•

Operator’s cab, including controls and indicators

•

Access ladder (anchored to the chassis)

•

Transfer rollers

•

Walk-deck components and handrails

SYSTEM OVERVIEW

2-2 Page 1 August 2017

Halvorsen A.

CHASSIS Refer to Figure 1 and Figure 2. The chassis assembly is a welded steel frame and provides the base for the mounting of the front drive steer axle, rear axle, power unit and electrical, hydraulic and fuel systems. The scissors lifting system is attached to the chassis. Towing and tie-down points are incorporated in the chassis frame.

MAIN PANEL DRIVE/STEER AXLE

FUEL TANK POWER UNIT RADIATOR HELPER CYLINDER

WINTERIZATION PANEL & RECEPTACLE EMERGENCY PUMP CHASSIS HYDRAULIC MANIFOLD HYDRAULIC RESERVOIR

REAR AXLE ASSEMBLY TOWING/TIE-DOWN POINTS

Figure 1 VEHICLE CHASSIS

2-2 Page 2 August 2017

MAINTENANCE AND REPAIR

Halvorsen TIRE

DRIVE AXLE PARK BRAKE SERVICE BRAKE 2LS LIMIT SWITCH

DRIVE SHAFT MAIN PANEL

WINTERIZATION PANEL & RECEPTACLE

FUEL TANK

EMERGENCY PUMP

TRANSMISSION

CHASSIS MANIFOLD

BATTERIES

HYDRAULIC FILTER (HIGH PRESSURE)

BATTERY DISCONNECT TRANSMISSION FILTER

RETURN FILTER HYDRAULIC OIL

CASE DRAIN FILTER

HYDRAULIC OIL FILLER RADIATOR

HYDRAULIC RESERVOIR BREATHER HYDRAULIC FLUID SIGHT GAUGE

ENGINE REAR AXLE ASSEMBLY

HYDRAULIC PUMP AIR CLEANER

AIRPORTABILITY LATCH

Figure 2 VEHICLE CHASSIS COMPONENTS - TOP VIEW

SYSTEM OVERVIEW

2-2 Page 3 August 2017

Halvorsen B.

POWER UNIT Refer to Figure 3. The power unit consists of a six-cylinder turbocharged diesel engine with an automatic transmission coupled to the flywheel and a variable displacement hydraulic pump coupled to the front end of the crankshaft. The power unit is mounted in the center of the chassis and the transmission is connected to the front drive and steer axle with a drive shaft.

TRANSMISSION

ENGINE

HYDRAULIC PUMP

ALTERNATOR GENERATOR

ENGINE AIR CLEANER

Figure 3 POWER UNIT COMPONENTS

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MAINTENANCE AND REPAIR

Halvorsen The diesel engine provides powers the automatic transmission to propel the loader, the pump to operate the hydraulic systems and the alternator to keep the batteries in a fully charged state. A compressor is powered by an hydraulic motor attached to the compressor that cools the operator’s cab on the loader. C.

COOLING SYSTEM Refer to Figure 4. The engine cooling system for dissipating heat is a closed-loop system consisting of a radiator in a housing and a fan driven by a hydraulic motor.

RADIATOR

HYDRAULIC FAN MOTOR

COOLANT RECOVERY TANK

COOLANT RESERVOIR

Figure 4 COOLING SYSTEM

SYSTEM OVERVIEW

2-2 Page 5 August 2017

Halvorsen The radiator is remotely mounted outside the right-side chassis frame. The fan motor has two speeds and is controlled by sensors in the cooling system. The engine-driven water pump circulates coolant in the system and a thermostat controls engine temperature by regulating the flow of the coolant. A tank mounted, on top of the engine, serves as a reservoir for the fluid volume required to maintain the cooling system temperature within the operating range. The coolant recovery tank, mounted at the rear of the engine, allows coolant recovery to maintain a constant fluid level and prevents the introduction of air in the closed loop system. D.

TRANSMISSION Refer to Figure 5. A four-speed automatic transmission is coupled to the engine flywheel for directional control. The torque converter provides inching capability and smooth acceleration in any range selected.

TRANSMISSION

Figure 5 TRANSMISSION The transmission output shaft is directly connected to the differential pinion shaft with a drive shaft. Range selection is accomplished by an electrically controlled joystick lever with digital readout in the operator’s cab, which actuates a hydraulic cylinder mounted on the transmission, for positioning the transmission control valve. A remote-mounted oil cooler is incorporated in the engine coolant system to remove excessive heat from the transmission fluid and warm the transmission fluid when operating in cold weather conditions. 2-2 Page 6 August 2017

MAINTENANCE AND REPAIR

Halvorsen E.

DRIVE AND STEER FRONT AXLE Refer to Figure 6. The front axle is the loader’s drive and steer axle and is rigidly attached to the chassis frame. Incorporated in the axle are the differential assembly, planetary wheel ends and power steering cylinders. A brake disc is attached to the companion flange on the differential pinion shaft and the front axle service brake and parking brake calipers react on the disc. A differential lock is provided for positive driving of both wheels should one wheel lose traction on slippery surfaces.

SERVICE BRAKE

DIFFERENTIAL

PLANETARY WHEEL END

PARK BRAKE

Figure 6 DRIVE AND STEER FRONT AXLE

SYSTEM OVERVIEW

2-2 Page 7 August 2017

Halvorsen F.

REAR AXLE ASSEMBLY Refer to Figure 7 and Figure 8. The rear axle assembly provides support for the loader chassis at the back end and consists of a framework that has an axle pivot shaft at the front and two attaching lugs at the back end. A bogy assembly, consisting of an arm with two wheel assemblies attached and a telescoping hydraulic cylinder, is assembled on each end of the axle shaft. The helper cylinders are telescoping hydraulic cylinders used to assist the deck main lift cylinders in raising the deck when the deck is at the lowest position and provide additional chassis clearance when driving up and down ramps.

HELPER CYLINDER (TELESCOPING HYDRAULIC CYLINDER) BOGY WHEEL ARM

DISC BRAKE BOGY PIVOT SHAFT

Figure 7 REAR AXLE ASSEMBLY - BOGY WHEELS The bogy assemblies pivot on the axle shaft when traveling over irregular surfaces and each wheel assembly remains on the surface to support the load. Each wheel assembly has an external disc brake assembly incorporated in the wheel hub.

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MAINTENANCE AND REPAIR

Halvorsen The rear axle assembly is underneath the chassis at the back end of the loader and is attached to the chassis with pivot pins. In the normal operating configuration, the chassis rests on the axle shaft. When the loader is to be air transported additional chassis height is required to provide clearance at the crest of the aircraft loading ramp. To obtain the additional clearance, the air portability latch is engaged to physically lock the deck to the chassis at rear of the loader and the DECK RAISE switch is actuated. The helper cylinders, attached to the axle assembly shaft, will extend and force the deck and chassis up to provide the required additional clearance.

HELPER CYLINDER

AIRPORTABILITY LATCH AXLE ASSEMBLY PIVOT

Figure 8 REAR AXLE ASSEMBLY

SYSTEM OVERVIEW

2-2 Page 9 August 2017

Halvorsen 3.

SOLENOID VALVES, MANIFOLDS AND SWITCH LOCATIONS A.

SOLENOID VALVE IDENTIFICATION

TABLE 1 - SOLENOID VALVES DESCRIPTION ENGINE

FUNCTION Fuel Solenoid

1SOL

Hydraulic Dump 1

CHASSIS MANIFOLD

FAN MANIFOLD ON MAIN LIFT CYLINDER

INNER SCISSORS

OUTER SCISSORS

2-2 Page 10 August 2017

SOLENOID VALVE

1SOL-A

Park Brake Release

3SOL

Front Axle Differential Lock

4SOL

Lift Cylinder Lock Valve Up

7SOL

Hydraulic Dump 2

7SOL-A

Deck Raise

8SOL

Deck Lower

9SOL

Helper Cylinder Lower

13SOL

Load Sense Pressure Limiter

47SOL

Fan 1 (low speed)

1SOL-B

Main Lift Cylinder Lock Valve

10SOL

Main Lift Cylinder Lock Valve

11SOL

Front Side Shift Right

14SOL

Front Side Shift Left

16SOL

Front Left Up

21SOL

Front Right Down

23SOL

Front Right Up

25SOL

Front Left Down

27SOL

Rear Side Shift Right

15SOL

Rear Side Shift Left

17SOL

Rear Left Up

22SOL

Rear Right Down

24SOL

Rear Right Up

26SOL

Rear Left Down

28SOL

MAINTENANCE AND REPAIR

Halvorsen TABLE 1 - SOLENOID VALVES DESCRIPTION

REAR PITCH MANIFOLD

DECK

CONVEY MANIFOLD

AIR CONDITIONING

SYSTEM OVERVIEW

FUNCTION

SOLENOID VALVE

Rear Pitch Up

18SOL

Rear Pitch Down

20SOL

Traction Lift Cylinders Retract

29SOL

Front Stop Retract

30SOL

Rear Stop Retract

32SOL

Pilot Traction Rollers

46SOL

Forward 1, 2, 3

33SOL

Forward 4

34SOL

Forward 5, 6

35SOL

Forward 7

36SOL

Forward 8, 9

37SOL

Aft 1, 2, 3

38SOL

Aft 4

39SOL

Aft 5, 6

40SOL

Aft 7

41SOL

Aft 8, 9

42SOL

A/C Compressor Motor

51SOL

2-2 Page 11 August 2017

Halvorsen B.

HYDRAULIC MANIFOLD LOCATIONS

PALLET STOP & CONVEY LIFT MANIFOLD FRONT & REAR CONVEY LIFT MANIFOLD (MOUNTED IN SAME LOCATION ON OPPOSITE SIDE OF DECK)

INNER SCISSORS MANIFOLD (LOCATED BETWEEN SCISSORS)

OUTER SCISSORS MANIFOLD (LOCATED BETWEEN SCISSORS)

REAR PITCH MANIFOLD (LOCATED BETWEEN SCISSORS)

CHASSIS MANIFOLD

Figure 9 HYDRAULIC MANIFOLD LOCATIONS

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MAINTENANCE AND REPAIR

Halvorsen C.

LIMIT SWITCH LOCATIONS

4PRS 5PRS (LOCATED ON OUTSIDE OF SCISSORS) 4LS (CENTERED BETWEEN DECK RAILS)

14 LS 15LS 17LS 18LS (LOCATED BETWEEN SCISSORS)

5LS 16LS 16LS-A (LOCATED ON INSIDE REAR OF DECK) 2LS (LOCATED BETWEEN CHASSIS RAILS) 3LS-A (LOCATED ON INSIDE LEFT CHASSIS RAIL)

Figure 10 LIMIT SWITCH LOCATIONS

SYSTEM OVERVIEW

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THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 3. Preventative Maintenance 1.

INTRODUCTION This section contains instructions for inspecting and maintaining the Halvorsen, 25 000 lb. Loader for Aircraft. A periodic maintenance program is necessary to ensure the maximum performance of your vehicle. Proper maintenance consists of complete lubrication at specified intervals, periodic inspections and replacement of worn parts. As with any equipment, the vehicle may become hazardous if proper service and maintenance are neglected. Therefore, it is essential to perform all described inspections, lubrication and fault isolation on a regularly scheduled basis. Refer to Chapter 1, Section 4, “Specifications” and Chapter 2, Section 4, “Maintenance Specifications” for specified lubricants, reservoir volumes and other information related to lubrication and servicing.

2.

BEFORE COMMISSIONING A UNIT The following equipment pre-operational checklist allows for a comprehensive verification of the unit and its components. It is highly recommended the checklist be followed to be sure everything is in working condition, before putting the unit into service. If you are unsure about how to perform certain checks, refer to Chapter 2, Section 5, “Maintenance Procedures” for mechanical adjustments and hydraulic and electrical adjustments. For technical data and other information such as capacities or fluid amounts, refer to Chapter 1, Section 4, “Specifications” and Chapter 2, Section 4, “Maintenance Specifications” for more information. NOTE:

THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” SHOULD BE UTILIZED WHEN COMMISSIONING NEW EQUIPMENT AND FOR RE-COMMISSIONING AFTER A MAJOR REPAIR, OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THEROAD TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR MORE THAN SIX MONTHS.

NOTE:

REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR GENERAL SPECIFICATIONS AND FLUID CAPACITIES AND CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS” FOR RECOMMENDED LUBRICANTS AND OPERATIONAL, PRESSURE AND ADJUSTMENT SETTINGS.

NOTE:

COPIES OF THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” CAN BE MADE AS PART OF A MAINTENANCE LOG.

NOTE:

BEFORE SERVICING UNDERNEATH THE VEHICLE, BE SURE THE VEHICLE IS SAFELY SUPPORTED ON APPROPRIATE SUPPORTING DEVICES RATED TO HANDLE 150% (1.5 TIMES) THE GROSS VEHICLE WEIGHT.

NOTE:

THE VEHICLE USES BOTH SAE AND METRIC FASTENERS (NUTS, BOLTS AND SCREWS). BE SURE THAT THE CORRECT FASTENERS ARE USED FOR REPAIR AND SERVICE OF THE VEHICLE.

NOTE:

TO AID IN PREVENTING CORROSION, WASH AND RINSE THE LOADER ON A REGULAR BASIS.

PREVENTATIVE MAINTENANCE

2-3 Page 1 August 2017

Halvorsen WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, ENSURE THE VEHICLE IS ON A CLEAN AND LEVEL SURFACE, WHEELS ARE SECURELY CHOCKED, POWER UNIT IS OFF, HYDRAULIC PRESSURE IS DEPLETED AND BATTERIES HAVE BEEN DISCONNECTED. PLACE A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL VEHICLE IS BEING WORKED ON.

WARNING LOCK OUT AND TAG OUT THE VEHICLE BEFORE PERFORMING ANY MAINTENANCE, ADJUSTMENTS OR REPAIRS TO THE VEHICLE. NOTE:

2-3 Page 2 August 2017

REFER TO THE SUBSECTION ‘2. PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT)’ IN CHAPTER 2, SECTION 1, “SAFETY PRECAUTIONS”.

MAINTENANCE AND REPAIR

Halvorsen 3.

EQUIPMENT PRE-OPERATIONAL CHECKLIST

TABLE 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST PROCEDURE

CHECK (√)

Wash and rinse loader upon arrival. Perform walk-around inspection and check for obvious damage, missing parts and fluid leaks. Verify that batteries are secure and terminals are clean. Check level of fluid in hydraulic reservoir (deck lowered). Check fluid level in front axle differential. Check that the dipstick is properly installed. Check fluid level in front axle planetary wheel hubs. Check air pressure in all tires and inflate to specification of 6.9 ± 0.14 bar (100 ± 2 psi). Re-torque all wheel nuts to 271 N·m (200 lbf-ft.) Re-torque driver axle nuts to 271 N·m (200 lbf-ft.) and mark with white line. Check operator’s access ladder for security. Check all handrails, mounting brackets and retaining pins. Check power unit fluid levels, such as engine oil, coolant and transmission fluid. Refer to Figure 1. Check fuel level. Check lights and turn signal operation. Check horn operation. Check windshield and rear door wiper and washer operation. Check emergency pump operation. Start power unit, observe all gauges and indicator lights for indication of proper engine operation during engine warm-up, then MAKE COMPLETE OPERATIONAL CHECK OF THE LOADER: •

Parking Brake

•

Driving, transmission shifting, all ranges

•

Steering

•

Service Brakes

•

Deck Lift

PREVENTATIVE MAINTENANCE

Released, Applied

Left, Right

Up, Down

2-3 Page 3 August 2017

Halvorsen TABLE 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST PROCEDURE

CHECK (√)

•

Deck Pitch

Up, Down

•

Deck Shift

Left, Right

•

Deck Roll

Left, Right

•

Convey (all sections)

•

Deck Pallet Stops (front and rear)

•

Auto Center Level Operation

•

Air Transportability Operation

•

Inspect all hydraulic hoses and fittings for fluid leakage.

•

Inspect all hydraulic motors for fluid leakage.

•

Inspect steering valve for fluid leakage.

•

Inspect all wiring harnesses and wires for security.

Forward, Aft Down, Up

Additional Notes or Comments

EQUIPMENT SERIAL NUMBER:

HOURMETER:

EQUIPMENT CHECK PERFORMED BY:

DATE:

EQUIPMENT CHECK VERIFIED BY:

DATE:

NOTE:

2-3 Page 4 August 2017

COPIES OF THIS TABLE CAN BE MADE AS PART OF A MAINTENANCE LOG.

MAINTENANCE AND REPAIR

Halvorsen COOLANT PRESSURE CAP

ENGINE OIL DIPSTICK

COOLANT RESERVOIR

TRANSMISSION DIPSTICK AND FILLER PIPE ENGINE OIL FILLER CAP COOLANT RECOVERY TANK

Figure 1 ENGINE OIL AND COOLANT FILL POINTS

Figure 2 HYDRAULIC RETURN FILTER GAUGE

PREVENTATIVE MAINTENANCE

2-3 Page 5 August 2017

Halvorsen 4.

BREAK-IN PERIOD AND MAINTENANCE A.

BREAK-IN PERIOD The first 200 hours of operation of the vehicle allows all components and assemblies to adjust for what will become normal operation after the initial break-in period. The vehicle must be thoroughly inspected after the first 200 hours of operation. The 8-hour (daily) and 500-hour (quarterly) schedules should be used as a guide for the 200-hour maintenance inspection.

B.

BREAK-IN MAINTENANCE An initial break-in maintenance is recommended after the first 200 hours of operation (power unit hours). Axles, wheel hubs and transmission lubricants should be changed in accordance with manufacturers’ recommendations. For diesel powered vehicles, there is no need to replace the engine oil as part of the break-in maintenance, if the manufacturer provides the engine with a high-grade lubricant and recommends to change the oil at least every 500 hours of operation or yearly. If any other lubricant is used after the first oil change, more frequent intervals should be observed. NOTE:

ENGINE OIL MUST BE CHANGED AND OIL FILTER CARTRIDGE REPLACED AFTER THE FIRST 50 HOURS OF USE. FAILURE TO PERFORM THIS OPERATION INVALIDATES THE ENGINE MANUFACTURER’S GUARANTEE.

The traction pump and drive train should be inspected for leaks and signs of potential problems, but no oil change is required as part of the break-in maintenance. Refer to Chapter 5, MANUFACTURERS’ APPENDICES for maintenance recommendations for each specific component. 5.

PERIODIC MAINTENANCE Regular maintenance is required to ensure optimum loader performance and long life for machine components. Maintain the vehicle by performing periodic maintenance at the intervals listed in the Maintenance Schedule tables within this section. Specific operating conditions will determine the scope and frequency of maintenance work required. If in doubt about any service intervals or maintenance operations recommended within this manual, please refer to the manufacturer’s recommendations for the specific component. If the vehicle is operated under severe weather conditions such as extreme heat or cold or in sandy, dusty or snowy areas, increase the frequency of periodic maintenance as necessary, but always refer to specific manufacturer’s recommendations. Maintenance records must be kept as evidence of regular and proper maintenance, an essential requirement the manufacturer may request in the event of a warranty claim.

CAUTION COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS.

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MAINTENANCE AND REPAIR

Halvorsen TABLE 2 - MAINTENANCE SCHEDULE PROCEDURE

PERIOD (HOURS) 8

Perform walk-around inspection and check for obvious damage, missing parts and fluid leaks.

◄

Check condition of drive wheel tires.

◄

Check condition of bogy wheel tires.

◄

Check engine oil level (refer to Figure 3).

◄

Check coolant level (refer to Figure 3).

◄

Check fuel level.

◄

Check cab heater fuel level.

◄

Check fluid level in hydraulic reservoir (deck lowered).

◄

Check fluid level in hydraulic reservoir (deck lowered). (Use fluid level marks on aft end of reservoir)

◄

Check spring plunger on impact roller and lubricate.

◄

Check windshield washer fluid level.

◄

Check condition of operator’s access ladder and mounting.

◄

Check condition of all handrails, mounting brackets and lock pins.

◄

Check all casters and rollers on deck for damage.

◄

Check folding wings on front of deck for damage, free movement and lock pin engagement.

◄

Check all lights and turn signal operation.

◄

Check emergency pump operation.

◄

Check horn operation.

◄

Check cab ventilation fan operation.

◄

Check cab heater operation.

◄

Check windshield wiper and rear door wiper for proper operation.

◄

Check cab doors for ease of opening and closing and door latches for proper function. Check top and side skylights for looseness, leaking and adhesive sealant failure.

◄

PREVENTATIVE MAINTENANCE

50

100

OTHER

Lubricate as required.

2-3 Page 7 August 2017

Halvorsen TABLE 2 - MAINTENANCE SCHEDULE PROCEDURE

PERIOD (HOURS) 8

50

Check top and side skylights for looseness, leaking and adhesive sealant failure.

100

OTHER Every 400 hours or 6 months

Check all cab windows for damage and ease of opening and closing.

◄

Check driver’s seat controls for proper operation.

◄

Check cab seat belt for damage and latch operation.

◄

Check and test warning lights on cab dashboard. CAUTION: DO NOT OPERATE WITH DEFECTIVE WARNING LIGHTS.

◄

Start power unit and check indicating lights and gauges for proper engine operation.

◄

Check condition of high pressure filter. NOTE:

CHECK INDICATOR BUTTON ON HIGH PRESSURE FILTER HOUSING. IF INDICATOR BUTTON IS ON THE OUT POSITION, THE FILTER REQUIRES SERVICE.

◄

CAUTION: REPLACE FILTER ELEMENT IF INDICATOR BUTTON IS IN THE OUT POSITION. Check condition of case drain filter. NOTE:

FILTER IS LOCATED ON THE CHASSIS FRAME BEHIND THE HYDRAULIC FLUID RESERVOIR.

CAUTION: REPLACE FILTER ELEMENT IF GAUGE INDICATES 25 PSI OR HIGHER - RED AREA ON GAUGE.

◄

Check condition of hydraulic return filter condition (refer to Figure 2). NOTE:

TO CHECK FILTER CONDITION, PLACE HYDRAULIC PREHEAT SWITCH IN THE ON POSITION AND OBSERVE READING ON GAGE. GUAGE IS LOCATED ON RETURN FILTER HOUSING ON THE TOP OF THE HYDRAULIC RESERVOIR.

◄

CAUTION: REPLACE FILTER ELEMENT IF GAUGE INDICATOR IS IN RED AREA. Drain water from fuel filter. Check air cleaner element Indicator.

2-3 Page 8 August 2017

Every 400 hours. ◄

MAINTENANCE AND REPAIR

Halvorsen TABLE 2 - MAINTENANCE SCHEDULE PROCEDURE

PERIOD (HOURS) 8

Check transmission fluid level at normal operating temperature (refer to Figure 3).

50

OTHER

◄ Every 400 hours or annually.

Verify that batteries are secure and connections are clean. Check condition of engine belt.

100

◄

Check oil level in differential.

Every 400 hours of operation.

Change oil in differential and planetary wheel hubs.

After first 50 hours. Then, every 1000 hours or annually.

◄

Check oil level in planetary wheel hubs. (Front drive axle)

Every 400 hours or annually.

Clean and repack bearings in bogy wheels. Replace seals.

Every 2 years.

Re-torque wheel lug nuts.

◄

Change engine oil.

◄

Replace oil filter cartridge.

◄

Change primary fuel filter.

◄

Check fuel injectors.

After first 50 hours of operation. Then, every 400 hours or annually. Every 400 hours or annually.

Change lubricity fuel filter. Inspect all nine (9) traction rollers for damage and wear. Adjust traction roller chain tension. Replace alternator belt.

Every 1000 hours or annually.

Clean fuel tank. Replace air cleaner filter. Clean radiator externally of debris. Change oil in hydraulic reservoir. Change all four (4) hydraulic oil filter elements: • Return Filters Intake (2) • High Pressure (1)

PREVENTATIVE MAINTENANCE

◄

After first 50 hours of operation. Thereafter, change every 400 hours or annually.

2-3 Page 9 August 2017

Halvorsen TABLE 2 - MAINTENANCE SCHEDULE PROCEDURE

PERIOD (HOURS) 8

50

100

OTHER

Change engine coolant. NOTE:

NOTE:

USE A 50%-50% MIXTURE OF GLYCOL AND DISTILLED WATER FOR STORAGE AND OPERATING TEMPERATURES ABOVE -37 ºC (-34 ºF).

Every 1000 hours or annually.

USE A 60%-40% MIXTURE OF GLYCOL AND DISTILLED WATER FOR STORAGE AND OPERATING TEMPERATURES BELOW -37 ºC (-34 ºF).

Change transmission fluid.

Every 1000 hours or annually.

Change transmission filter.

After first 50 hours of operation. Thereafter, change every 1000 hours or annually.

◄

Rotate tires.

As needed.

Inspect condition of helper cylinder bumpers (refer to Figure 4) and replace if deformed and not holding cylinders in vertical position.

Every 400 hours.

Service the Espar cab heater, per instruction.

Every 1000 hours or annually.

Change all three (3) vapor corrosion inhibitors: • Deck Box (1) • Chassis Box (1) • Winterization Box (1)

Every 1000 hours or annually.

Air conditioner filter free of obstructions. Clean air conditioner filter.

◄

Adjust parking brake.

Every 400 hours or annually.

Check and adjust all limit switches. Refer to Chapter 2, Section 5, “Maintenance Procedures”.

Every 400 hours or annually.

2-3 Page 10 August 2017

MAINTENANCE AND REPAIR

Halvorsen COOLANT PRESSURE CAP

ENGINE OIL DIPSTICK

COOLANT RESERVOIR

TRANSMISSION DIPSTICK AND FILLER PIPE ENGINE OIL FILLER CAP COOLANT RECOVERY TANK

Figure 3 ENGINE OIL, COOLANT AND TRANSMISSION FLUID FILL POINTS

Figure 4 HELPER CYLINDER BUMPERS

PREVENTATIVE MAINTENANCE

2-3 Page 11 August 2017

Halvorsen TABLE 3 - AIR CONDITIONER MAINTENANCE SCHEDULE AIR CONDITIONING COMPONENTS

400 HOURS OR ANNUALLY

COMPRESSOR NOISE

◄

RUN 5 MINUTES

◄

INSPECT SHAFT SEAL

◄

CHECK PRESSURE (RUNNING) (MAINTENANCE PERSONNEL ONLY)

ANNUALLY

◄

CONDENSER CLEANING

◄

CHECK HOSES/MOUNTING BRACKETS

◄

FAN CYCLE

◄

DRYER SIGHT GLASS

◄

INLET AND OUTLET BOTH WARM

◄

EVAPORATOR SWITCHES FUNCTION

◄

FILTER CLEANING

◄

OUTLET TEMPERATURE THERMOSTAT CYCLE CONDENSATE DRAIN THOROUGHLY INSPECT WIRING AND HOSES

2-3 Page 12 August 2017

◄ ◄ ◄

MAINTENANCE AND REPAIR

Halvorsen 6.

MAINTENANCE AND FLUID KITS Maintenance and fluids kits are available from JBT for the recommended maintenance intervals. Refer to Chapter 4, ILLUSTRATED PARTS LIST for details.

7.

HYDRAULIC OIL RECOMMENDATIONS Refer to Chapter 2, Section 4, “Maintenance Specifications” for recommended hydraulic oil.

8.

OPERATIONAL CHECKS SCHEDULE

TABLE 4 - OPERATIONAL CHECKS SCHEDULE PERIOD (HOURS)

PROCEDURE

8

Service Brake

50

100

OTHER

◄

Parking Brake

Release, Applied

◄

Deck

Raise, Lower

◄

Deck

Pitch Up, Down

◄

Deck

Shift Left, Right

◄

Left, Right

◄

Front Pallet

Stop Up, Down

◄

Rear Pallet

Stop Up, Down

◄

Power Steering

Left, Right

◄

Transmission Shifting

All Ranges

◄

Deck Convey Forward

Front, Mid, Aft Sections

◄

Deck Convey Aft

Front, Mid, Aft Sections

◄

Deck Roll

PREVENTATIVE MAINTENANCE

2-3 Page 13 August 2017

Halvorsen 9.

LUBRICATION The vehicle should be lubricated as required in the periodic maintenance charts. Refer to Chapter 2, Section 4 for the fluid specifications required. A.

GREASE POINTS Wipe grease fittings clean and apply grease. Before coating other surfaces with grease, clean surfaces to remove dirt and foreign material. It is important to get the grease in through the greasing nipples to avoid grease hardening and potential plugging of channels. Refer to Figure 5. NOTE:

GREASE MUST BE PUMPED INTO GREASE NIPPLES UNTIL CLEAN GREASE EXITS FROM ALL SIDES AROUND THE CIRCUMFERENCE OF THE BEARING OR PIN.

FRONT SIDE SHIFT CYLINDERS Ref.er to Figure 7

8 7

DRIVE AND STEER AXLE Refer to Figure 9

REAR SIDE SHIFT CYLINDERS Refer to Figure 8

6

4

5 DRIVE SHAFT Refer to Figure 9 HYDRAULIC OIL LEVEL GAUGE

2 Items 1 and 2 refer to Figure 6

3

Figure 5 GREASE POINTS - CHASSIS AND SCISSORS 2-3 Page 14 August 2017

MAINTENANCE AND REPAIR

Halvorsen 1

2

Figure 6 GREASE POINTS - HELPER CYLINDER

11

NOTE:

ITEM 9 - TWO (2) PER BUSHING.

9

9

Figure 7 GREASE POINTS - FRONT SIDE SHIFT CYLINDERS

PREVENTATIVE MAINTENANCE

2-3 Page 15 August 2017

Halvorsen 10

NOTE:

10

ITEM 10 - TWO (2) PER BUSHING.

Figure 8 GREASE POINTS - REAR SIDE SHIFT CYLINDERS

12

Figure 9 GREASE FITTINGS - IMPACT ROLLERS 2-3 Page 16 August 2017

MAINTENANCE AND REPAIR

Halvorsen

GREASE POINTS CHASSIS AND SCISSORS

Refer to Figure 5 through Figure 9.

TABLE 5 - GREASE POINTS - CHASSIS AND SCISSORS ITEM

DESCRIPTION

TOTAL FITTINGS

INTERVAL (HOURS)

1

BUSHING, WALKING BEAM

2

400

2

BUSHING, HELPER CYLINDER

2

400

3

BUSHING, REAR AXLE ASSEMBLY PIVOT

2

400

4

BUSHING, SCISSORS, LOWER, REAR*

2

400

5

BUSHING, SCISSORS, LOWER, FRONT

2

400

6

BUSHING, SCISSORS CENTER SHAFT

2

400

7

BUSHING, SCISSORS PITCH SHAFT

2

400

8

BUSHING, SCISSORS PITCH CYLINDER

4

400

9

BUSHING, SIDE SHIFT CYLINDER ROD, FRONT

4

400

10

BUSHING, SIDE SHIFT CYLINDER ROD, REAR

4

400

11

BEARING, DECK LINK

2

400

12

IMPACT ROLLER*

6

400

NOTE:

*NOT ALL LOADERS HAVE THESE GREASE POINTS.

PREVENTATIVE MAINTENANCE

2-3 Page 17 August 2017

Halvorsen DIFFERENTIAL OIL LEVEL PLUG

DRIVE AND STEER AXLE HUB OIL LEVEL, 2X

DRIVE SHAFT

Figure 10 GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT

2-3 Page 18 August 2017

MAINTENANCE AND REPAIR

Halvorsen SOCKET, STEERING CYLINDER ANCHOR PIN, SLIDERBRAKE PIN SERVICE SERVICECALIPER BRAKE CALIPER DIFFERENTIAL OIL LEVEL PLUG

ANCHOR PIN, SLIDER PIN PARK PARKBRAKE BRAKE CALIPER CALIPER KNUCKLE, UPPER

HUB OIL LEVEL, 2X Ref. Section 2-1, , page

SOCKET, TIE ROD KNUCKLE, LOWER

Figure 11 DRIVE AND STEER AXLE LUBRICATION POINTS

TABLE 6 - FRONT AXLE LUBRICATION POINTS ITEM

DESCRIPTION

TOTAL FITTINGS

1

KNUCKLE, UPPER

2

2

KNUCKLE, LOWER

2

3

SOCKET, STEERING CYLINDER

4

4

SOCKET, TIE ROD

2

5

PIN, SLIDER, SERVICE BRAKE CALIPER

1

6

PIN, SLIDER, PARK BRAKE CALIPER

1

PREVENTATIVE MAINTENANCE

2-3 Page 19 August 2017

Halvorsen

GREASE POINTS DRIVE AND STEER FRONT AXLE AND DRIVE SHAFT

Refer to Figure 10.

TABLE 7 - GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT ITEM

DESCRIPTION

TOTAL FITTINGS

INTERVAL (HOURS)

1

KNUCKLE, UPPER

2

400

2

KNUCKLE, LOWER

2

400

3

SOCKET, STEERING CYLINDER

4

400

4

PIN, ANCHOR, SERVICE BRAKE CALIPER

1

400

5

PIN, ANCHOR, PARKING BRAKE CALIPER

1

400

6

SOCKET, TIE ROD

2

400

7

JOINT, UNIVERSAL, AXLE SHAFT

2

400

8

JOINT, UNIVERSAL, DRIVE SHAFT

3

400

9

SPLINE, DRIVE SHAFT

2

400

2-3 Page 20 August 2017

MAINTENANCE AND REPAIR

Halvorsen B.

LIMITER PIN LUBRICATION Apply any grade motor oil with brush or oil can as appropriate.

C.

CHAINS LUBRICATION Apply any grade motor oil with brush or oil can as appropriate. Refer to Figure 12.

LUBRICATE CHAIN WITH ANY GRADE MOTOR OIL

LIMITER PIN

Figure 12 CHAINS LUBRICATION

PREVENTATIVE MAINTENANCE

2-3 Page 21 August 2017

Halvorsen D.

FILL POINTS Refer to Figure 13, Figure 14 and Figure 15 for locations of fill points for drive wheel planetary hubs and hydraulic oil reservoir. NOTE: (1)

CHECK AT INTERVALS LISTED AND LUBRICATE AS REQUIRED. IN SEVERE WEATHER CONDITIONS, CHECK AT MORE FREQUENT INTERVALS. Engine Fill Point

ENGINE OIL DIPSTICK

COOLANT PRESSURE CAP COOLANT RESERVOIR

TRANSMISSION DIPSTICK AND FILLER PIPE ENGINE OIL FILLER CAP COOLANT RECOVERY TANK

Figure 13 ENGINE OIL AND COOLANT FILL POINTS

2-3 Page 22 August 2017

MAINTENANCE AND REPAIR

Halvorsen (2)

Hydraulic Reservoir Fill Point

FILL POINT - HYDRAULIC RESERVOIR

Figure 14 FILL POINT - HYDRAULIC RESERVOIR

PREVENTATIVE MAINTENANCE

2-3 Page 23 August 2017

Halvorsen (3)

Planetary Gear Wheel End Fill Point

HUB OIL FILL AND SPILL PLUG

HUB OIL DRAIN PLUG HUB ORIENTED SO PLUG IS ON BOTTOM

Figure 15 FILL POINT - PLANETARY GEAR WHEEL END

2-3 Page 24 August 2017

MAINTENANCE AND REPAIR

Halvorsen Section 4. Maintenance Specifications 1.

GENERAL This section includes information on specifications required for performing regular maintenance and adjustment procedures for the Halvorsen, 25 000 lb. Loader for Aircraft. It includes recommendations for hydraulic oil fluids, recommended lubricants, mechanical adjustment settings, pressure settings for hydraulic equipment and components and other settings necessary to tune-up the vehicle for optimal performance. For general vehicle’s specifications and general information, refer to Chapter 1, Section 4, “Specifications”.

2.

HYDRAULIC OIL RECOMMENDATIONS NOTE:

STUDIES HAVE SHOWN THAT NEARLY 90% OF THE FAILURES OF HYDRAULIC COMPONENTS ARE CAUSED BY HYDRAULIC FLUID CONTAMINATION.

The International Standards Organization (ISO) has established a code index system as a guideline for machine builders and end users. This ISO code specifies different levels of oil cleanliness and is based on the type of component used in the machine which is the most sensitive in relation to fluid borne contaminants. According to this, the axial piston pumps and motors used on most JBT equipment require an ISO 4406:1999 code level of 18/16/13. This code level is a means of measuring three sizes of particles contained in 1 milliliter of fluid. The particle sizes are measured in microns, also known as micrometers. The first number, 18 is a measurement of particles equal to or greater than 4 microns. The second number, 16 is for particles equal to or greater than 6 microns, while the last number, 13, is for particles equal to or greater than 14 microns. Whether you are adding, replenishing hydraulic oil to the tank or changing the oil entirely, JBT recommends the new oil should be filtered to meet the ISO 18/16/13 spec. Always add oil to the tank through the in-tank filter installed in the reservoir. The fill ports are color coded, yellow with a blue bar. JBT strongly recommends that owners work with their hydraulic oil suppliers to establish a comprehensive sampling program to check the oil for excessive contaminants on a regular basis. Use appropriate hydraulic oil with the viscosity grade corresponding to the operating temperature range listed below.

TABLE 1 - OIL OPERATING TEMPERATURE RANGE RECOMMENDED HYDRAULIC OIL

MINIMUM START-UP TEMPERATURE (OIL TANK)*

MAXIMUM OPERATING TEMPERATURE (OIL TANK)

ISO VG 15

-40 ºC (-40 ºF)

66 ºC (150 ºF)

ISO VG 32

-29 ºC (-20 ºF)

74 ºC (165 ºF)

ISO VG 46

0 ºC (32 ºF)

82 ºC (180 ºF)**

ISO VG 68

10 ºC (50 ºF)

82 ºC (180 ºF)**

* In cold weather the start-up temperature can be increased by using the optional heater inside the hydraulic tank.

MAINTENANCE SPECIFICATIONS

**Shutdown temperature.

2-4 Page 1 August 2017

Halvorsen 3.

OPERATING TEMPERATURE •

Normal operating oil temperature (tank). . . . . . . . . . . .

+52 ºC to +60 ºC (125 ºF to 140 ºF)

•

Mission ambient temperatures range . . . . . . . . . . . . . .

-40 ºC to +52 ºC (-40 ºF to +125 ºF)

For operating outside the normal weather operating temperature range, take precautions for proper operation, such as avoiding cavitation (extremely cold weather) and overheating (hot weather). NOTE:

4.

REFER TO COMPONENT MANUALS IN CHAPTER 5, APPENDICES FOR SPECIFICATIONS ON FLUIDS AND OPERATING UNDER EXTREME WEATHER CONDITIONS.

MANUFACTURERS’ LUBRICANTS FOR

FLUIDS CAPACITIES •

Engine oil (including filters). . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 L ( 2.5 gal.)

•

Cooling system (engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57.0 L (15.0 gal.)

•

Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 L (32.0 gal.)

•

Transmission including converter and filter . . . . . . . . . . . . . . .

12.3 L ( 3.3 gal.)

•

Transmission Fluid Capacity - Initial fill (new assembly). . . . . . . . . . . . . . . . . . . . . . . . . .

12.3 L (3.25 gal.)

- Refill (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 L ( 2.0 gal.)

•

Air conditioner compressor oil (empty system). . . . . . . . . . . . .

0.12 L ( 4 fl.oz.)

•

Air conditioner refrigerant (freon) . . . . . . . . . . . . . . . . . . . . . . .

1.6 kg (3 lb. 10 oz.)

2-4 Page 2 August 2017

MAINTENANCE AND REPAIR

Halvorsen 5.

RECOMMENDED FLUIDS AND LUBRICANTS

CAUTION DO NOT MIX SYNTETHIC OILS WITH NON-SYNTHETIC OILS! TABLE 2 - ENGINE OIL, TRANSMISSION FLUID AND COOLANT JBT PART NO. 623-5783

ITEM Engine oil

RECOMMENDED OIL AND FLUIDS Mobile Delvac 1, Synthetic 4W-40 If Mobile Delvac not available alternatives are as follows on a temporary basis only with a reduced 200 hour oil change interval: •

API CG-4

•

ACEA-98E2

•

API CF-4

•

ACEA-98B4

•

API CF

•

ACEA-98B3

•

API SH

•

ACEA-98A2

•

CCMC D5-PD2

•

RVI-E2R

•

MB228.1

•

MIL-L2104G

•

MAN271

•

ALLISON CI4

•

VOLVO VDS

•

VM 501/505

•

MACK EO-L

105-0446

Transmission fluid

Dexron or Mobil ATF D/M is recommended for use in application requiring Dexron III H and Allison C-4 and Allison TES-389. Below 0 ºF use TranSynd.

105-1301

Coolant

Use a 50% / 50% mixture of glycol and distilled water for storage and operating temperatures above -37 ºC (-34 ºF). Use a 60% / 40% mixture of glycol and distilled water for storage and operating temperatures below -37 ºC (-34 ºF).

NOTE:

ANTIFREEZE FLUID SHALL MEET ASTM D-3306 REGARDLESS OF MANUFACTURER.

TABLE 3 - ENGINE FUEL ITEM

RECOMMENDED FUEL

Engine Fuel

DF1 - DF2 JP-5 - JP-8 2-DS15

MAINTENANCE SPECIFICATIONS

2-4 Page 3 August 2017

Halvorsen CAUTION BIO-DIESEL BLENDS GREATER THAN 5% CAN REDUCE THE LIFE OF THE ENGINE IF USED. FAILURES ATTRIBUTED TO THE USE OF BIO-DIESEL WILL NOT BE COVERED UNDER THE WARRANTY.

TABLE 4 - BIODIESEL ENGINE FUEL ITEM

FUEL REQUIREMENTS

Bio-diesel

Bio-diesel fuels meeting ASTM D 6751 specification, prior to blending can be mixed up to 20% maximum by volume in petroleum diesel fuel. The resulting mixture must meet the fuel properties listed in Table 5-1 of Detroit Diesel literature 7SE270 and ASTM D-975 specification. Engine failures attributed to the use of bio-diesel fuels will not be covered under the manufacturer warranty. NOTE:

REFER TO MANUFACTURERS’ DATA, SECTION 12 FOR DETROIT DIESEL LITERATURE 7SE270, LUBRICATING OIL, FUEL AND FILTERS.

TABLE 5 - HEATER FUEL ITEM

RECOMMENDED FUEL Diesel fuel DF1 and DF2 Diesel fuel Arctic DF-A

Heater Fuel

Jet fuel JP-5 and JP-8 Kerosene Bio-Diesel blend (5% max)

CAUTION BIO-DIESEL BLENDS CAN REDUCE THE LIFE OF THE HEATER IF LEFT IN THE FUEL SYSTEM FOR EXTENDED PERIODS OF TIME. FAILURES ATTRIBUTED TO THE USE OF BIODIESEL WILL NOT BE COVERED UNDER THE WARRANTY.

2-4 Page 4 August 2017

MAINTENANCE AND REPAIR

Halvorsen TABLE 6 - HYDRAULIC OIL JBT PART NO.

RECOMMENDED HYDRAULIC FLUID

105-1315

MIL-H-83282 NATO STD-H-537

TABLE 7 - LUBRICATING GREASE JBT PART NO.

RECOMMENDED LUBRICATING GREASE

628-0166

Grease, SYN-3001 14 oz. Cartridge

TABLE 8 - ELECTRICAL GREASE JBT PART NO.

RECOMMENDED ELECTRICAL GREASE

620-2858

Dow Corning #4 Insulating Compound MIL Spec 8660

TABLE 9 - AIR CONDITIONER LUBRICANT JBT PART NO.

RECOMMENDED AIR CONDITIOING LUBRICANT

628-0166

Sanden SP-20

TABLE 10 - AIR CONDITIONING SYSTEM REFRIGERANT JBT PART NO.

RECOMMENDED AIR CONDITIONING OIL AND REFRIGERANT

625-4992

R-134a Freon

TABLE 11 - 1000-HOUR (ANNUAL) FLUID 624-8289-1000F ITEM

PART NO.

DESCRIPTION

QTY.

UNIT

1

105-0446

TRANSMISSION FLUID

15

qt.

2

105-0448

GEAR OIL, 75W-140

4

qt.

3

105-1301

ENGINE COOLANT FLUID

8

gal.

MAINTENANCE SPECIFICATIONS

2-4 Page 5 August 2017

Halvorsen 6.

EQUIPMENT ADJUSTMENT SETTINGS The following adjustment settings are recommended for the properly functioning of the vehicle.

TABLE 12 - ADJUSTMENT SETTINGS CHART ADJUSTMENT OPERATION

SETTING

Engine idle speed

850–900 rpm

Engine high speed

1025–1050 rpm 6.9 ± 0.14 bar (100 ± 2 psi)

Tire inflation air pressure Wheel lug nuts torque (front and rear)

271 N·m (200 lbf-ft.)

ADJUSTMENT LOCATION Refer to Chapter 2, Section 5, “Maintenance Procedures”. All tires Follow a crisscross pattern and sequence.

TABLE 13 - FRONT AXLE TORQUE SETTINGS ITEM

DESCRIPTION

N·m

lbf-ft.

1

Drive shaft internal nut

373–441

275–325

2

Center bearing housing

108–122

80–90

3

Drive shaft and axle drive flange

122

90

4

U-joint retainer strap external nut

75–81

55–60

TABLE 14 - BRACE ASSEMBLY TORQUE SPECIFICATIONS ORDER

FASTENERS

TORQUE

First

Bracket connection

41 N·m (30 lbf-ft. / 360 lbf-in.)

Second

Upper bracket

27 N·m (20 lbf-ft. / 240 lbf-in.)

Third

Lower bracket

27 N·m (20 lbf-ft. / 240 lbf-in.)

2-4 Page 6 August 2017

MAINTENANCE AND REPAIR

Halvorsen 7.

8.

HYDRAULIC PRESSURE SETTINGS NOTE:

1 bar = 100 kPa = 0.1 MPa = 14.5 psi.

NOTE:

REFER TO “HYDRAULIC SCHEMATICS” IN CHAPTER 2, SECTION 7 FOR LOCATION POINTS AND CHAPTER 2, SECTION 6, “TROUBLESHOOTING” FOR DP SCREENS AND NAVIGATION.

PERFORMANCE SPECIFICATIONS

TABLE 15 - ENGINE SPECIFICATIONS AND OPERATING RPM ENGINE Detroit Diesel D706LTE

LOW IDLE

HIGH IDLE

RATED POWER FULL LOAD

850 ± 30 rpm

3000–3150 rpm

92.5 kW (124 hp) @ 3000 rpm

Driving Speeds •

Range 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 km/h ( 4.4 mph)

•

range 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4 km/h ( 7.1 mph)

•

range 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.5 km/h (11.5 mph)

•

range d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26.6 km/h (16.5 mph)

•

range r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 km/h ( 3.3 mph)

Deck Lift Speed, Full Extension •

Deck raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 ± 4 seconds

•

Deck lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 seconds

Deck Convey Speed •

Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS

95 fpm (maximum)

2-4 Page 7 August 2017

Halvorsen 9.

BOLT IDENTIFICATION CHART

TABLE 16 - STANDARD AND METRIC STEEL BOLTS AND NUTS SAE HEX NUTS

SAE HEX BOLTS

GRADE 1 OR 2

GRADE 5

GRADE 8

GRADE 1 OR 2

METRIC HEX BOLTS

GRADE 5

GRADE 8

METRIC HEX NUTS

5.8

8.8

9.8

10.9

9

10

CLASS 5.8

CLASS 8.8

CLASS 9.8

CLASS 10.9

CLASS 9

CLASS 10

METRIC HEX BOLTS

SAE HEX BOLTS

2

2 3

1 4 1.

GRADE (BOLT STRENGTH)

2.

THREAD PITCH (THREADS PER INCH)

3.

NOMINAL DIAMETER (INCHES)

4.

BOLT LENGTH (INCHES)

2-4 Page 8 August 2017

3

1 4 1. 2. 3. 4.

GRADE (BOLT STRENGTH) THREAD PITCH (DISTANCE BETWEEN THREADS IN MILLIMETERS) NOMINAL DIAMETER (MILLIMETERS) BOLT LENGTH (MILLIMETERS)

MAINTENANCE AND REPAIR

Halvorsen 10.

BOLT TORQUE SPECIFICATIONS NOTE:

THESE TORQUE VALUES ARE FOR REFERENCE ONLY. USE ONLY IF NOT OTHERWISE GIVEN FOR A SPECIFIC MAINTENANCE PROCEDURE. IF NO TORQUE IS PROVIDED FOR A SPECIFIC BOLT OR SCREW, REFER TO SAE, ISO OR OTHER STANDARD FOR THE CORRESPONDING TORQUE SPECIFICATION.

TABLE 17 - STANDARD STEEL BOLTS TORQUE SPECIFICATIONS Standard Dry Torque in Newton·meters and foot-pounds Bolt Size (in.)

1/4

Coarse Threads per Inch

SAE Grade 5 827 MPa (120 000 psi)

SAE Grade 8 1034 MPa (150 000 psi

Medium Carbon Heat Treated Steel

Medium Carbon Alloy Steel

N·m

lbf-ft.

N·m

lbf-ft.

(0.250)

20

13.6

10

19.0

14

5/16 (0.313)

18

25.8

19

39.3

29

3/8

(0.375)

16

44.7

33

63.7

47

7/16 (0.438)

14

73.2

54

105.8

78

1/2

(0.500)

13

105.8

78

161.3

119

9/16 (0.563)

12

154.6

114

229.1

169

5/8

(0.625)

11

208.8

154

311.8

230

3/4

(0.750)

10

348.4

257

515.2

380

7/8

(0.875)

9

517.9

382

813.5

600

1

(1.000)

8

795.9

587

1220.2

900

1-1/8 (1.125)

7

1076.5

794

1938.8

1430

1-1/4 (1.250)

7

1498.2

1105

2677.7

1975

1-3/8 (1.375)

6

2033.7

1500

3592.9

2650

1-1/2 (1.500)

6

2406.6

1775

4338.6

3200

1-5/8 (1.625)

5.5

3287.9

2425

5965.6

4400

1-3/4 (1.750)

5

4270.8

3150

7660.4

5650

1-7/8 (1.875)

5

5694.4

4200

10 304.2

7600

4.5

6169.0

4550

11 117.7

8200

2

(2.000)

MAINTENANCE SPECIFICATIONS

2-4 Page 9 August 2017

Halvorsen TABLE 18 - METRIC STEEL BOLTS TORQUE SPECIFICATIONS Standard Dry Torque in Newton·meters and foot-pounds Bolt Size (mm)

Coarse Thread Pitch (mm)

Class 8.8 (Old 8G) 785 MPa (113,800 psi)

Class 10.9 (Old 10K) 980 MPa (142,200 psi)

Medium Carbon Steel

Medium Carbon Steel

N·m

lbf-ft.

N·m

lbf-ft.

M6

1.00

8.1

6

10.8

8

M8

1.00

21.7

16

29.8

22

M10

1.25

54.2

40

61.0

45

M12

1.25

73.2

54

94.9

70

M14

1.25

120.7

89

158.6

117

M16

2.00

179.0

132

237.3

175

M18

2.00

246.8

182

320.0

236

M22

2.50

385.1

284

534.2

394

M24

3.00

568.1

419

772.8

570

TABLE 19 - 18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS Standard Dry Torque in Newton·meters and inch-pounds Bolt Size #

#4

#5

#6

#8

#10

2-4 Page 10 August 2017

Threads per Inch

18-8 Stainless Steel

316 Stainless Steel

N·m

lbf-in.

N·m

lbf-in.

40

0.59

5.2

0.62

5.5

48

0.75

6.6

0.78

6.9

40

0.87

7.7

0.92

8.1

44

1.06

9.4

1.11

9.8

32

1.08

9.6

1.14

10.1

40

1.37

12.1

1.43

12.7

32

2.24

19.8

2.34

20.7

36

2.49

22.0

2.60

23.0

24

2.58

22.8

2.69

23.8

32

3.58

31.7

3.74

33.1

MAINTENANCE AND REPAIR

Halvorsen Section 5. Maintenance Procedures 1.

GENERAL

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS. NOTE:

REFER TO CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS”; CHAPTER 1, SECTION 4, “SPECIFICATIONS”; AND CHAPTER 5, MANUFACTURERS’ APPENDICES FOR SETTINGS AND ADJUSTMENT VALUES FOR ALL MAINTENANCE PROCEDURES IN THIS SECTION.

The following procedures outline the necessary steps for adjustment of components for their proper operation. These procedures may be necessary to be performed during regular maintenance and after replacement or repair of components. Refer to Chapter 3, OVERHAUL for component removal and installation. Refer to the “LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL” at the beginning of this volume and to Chapter 2, Section 1, “Safety Precautions”. All warnings and cautions must be read, understood and observed to ensure safety of operation and maintenance personnel. NOTE:

DRIVE SIDE REFERENCES ARE BASED ON U.S. AUTOMOTIVE STANDARDS, WHERE THE DRIVER IS LOCATED ON THE LEFT HAND SIDE OF THE VEHICLE SITTING DIRECTLY BEHIND A STEERING WHEEL FACING FORWARD.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, START ENGINE, RAISE DECK TO SUFFICIENT HEIGHT TO INSTALL THE MAINTENANCE STANDS, THEN LOWER THE DECK UNTIL SCISSORS ROLLERS ARE IN CONTACT WITH THE MAINTENANCE STANDS OR BLOCKS. CHOCK WHEELS TO PREVENT MOVEMENT OF THE LOADER IN EITHER DIRECTION, APPLY THE PARK BRAKE AND TURN OFF THE ENGINE.

WARNING APPLY THE PARKING BRAKE AND TURN OFF THE IGNITION SWITCH BEFORE LEAVING THE VEHICLE UNATTENDED.

CAUTION WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS, CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.

MAINTENANCE PROCEDURES

2-5 Page 1 August 2017

Halvorsen 2.

SPROCKETS AND ROLLER CHAINS INSPECTION AND ADJUSTMENT A.

SPROCKETS INSPECTION (1)

Inspect sprockets for broken teeth.

(2)

Inspect sprocket alignment and check for secure attachment to shafts.

CAUTION WHEN REPLACING A SPROCKET, ALWAYS REPLACE THE CHAIN. USING AN OLD CHAIN ON NEW SPROCKETS WILL CAUSE PREMATURE WEAR OF THE SPROCKETS. B.

ROLLER CHAINS INSPECTION

C.

(1)

Inspect chains for elongation by comparing with a new chain. If elongation is 3% or more (3 links in 100 or about 1/2 link in 17), replace the chain.

(2)

Inspect chain for discoloration. Brown or red color on chain or in the oil, indicates presence of rust. Remove chain and inspect rollers, pins and links. If evidence of galling, excessive wear or corrosion exists, replace chain.

(3)

Inspect chain drives on convey rollers for proper adjustment.

ROLLER CHAINS ADJUSTMENT Frequent adjustment of roller chains on the convey modules should not be required; however, a check of the chain tension should be made periodically.

D.

CONVEY MODULE CHAINS ADJUSTMENT

CAUTION OVER-TIGHTENING THE CHAIN CAN CAUSE RAPID CHAIN AND SPROCKET WEAR, CHAIN BREAKAGE, HYDRAULIC MOTOR FAILURE OR BEARING FAILURE ON THE ROLLER SHAFT. Refer to Figure 1. (1)

2-5 Page 2 August 2017

Loosen the two bolts securing the hydraulic motor just enough to allow the motor to slide when adjusting chain tension.

MAINTENANCE AND REPAIR

Halvorsen

JACKING SCREW JACKING SCREW

Figure 1 CONVEY MODULE CHAIN ADJUSTMENT (2)

Loosen the outer lock nut on the motor jacking screw adjuster three or four turns.

(3)

Tighten the inner nut on the motor jacking screw to move the hydraulic motor to tighten the chain.

NOTE:

3.

UPON COMPLETION OF ADJUSTMENT, CHAIN SHOULD HAVE 12.7 MM (1/2 IN.) DEFLECTION WHEN LIGHT THUMB PRESSURE IS APPLIED AT MID-SPAN OF THE CHAIN.

(4)

Tighten the two bolts to secure the motor and the jacking screw lock nut.

(5)

Recheck the chain tension for proper deflection.

(6)

Always lubricate chain with motor oil after making a chain tension adjustment.

FRONT AXLE REMOVAL AND INSTALLATION

CAUTION WHEN HYDRAULIC JACKS ARE USED TO RAISE THE CHASSIS, THEY MUST BE PLACED DIRECTLY UNDER THE AXLE MOUNTING PADS. NOTE:

BEFORE THE REMOVAL OF THE DRIVE AND STEER AXLE FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

MAINTENANCE PROCEDURES

2-5 Page 3 August 2017

Halvorsen A.

DRIVE AND STEER FRONT AXLE REMOVAL (1)

Turn the battery disconnect switch on the battery box to the OFF position.

(2)

Using a suitable lifting device or hydraulic jacks (10-ton capacity), raise the front of the chassis until the drive wheels can be removed.

(3)

Place shoring under chassis frame on both sides, then remove the hydraulic jacks or lifting device. Drive wheels must be clear of the surface when the chassis frame is on the shoring.

(4)

Remove both drive wheels.

(5)

Remove hydraulic hoses to the steering cylinders and differential lock cylinder. Mark all hoses for location when removing. Install caps and plugs on hoses and fittings to prevent contamination of the hydraulic system and components.

(6)

Back off parking brake adjustment, without disconnecting hydraulic hoses, remove the 4 cap screws and nuts and remove parking brake assembly and lay on frame.

(7)

Without removing hydraulic lines, remove 4 cap screws and remove service brake assembly and lay on frame.

(8)

Remove the drive shaft.

(9)

Attach lifting straps (5-ton rating) around the axle housing on each side of the gear carrier and remove all slack in the straps with a portable hoist.

(10)

Remove the eight cap screws and nuts that secure the axle housing to the chassis frame, then lower the axle to ground level.

NOTE:

AN ALTERNATIVE METHOD TO REMOVE THE AXLE FROM UNDER THE CHASSIS FRAME IS WITH A FORKLIFT. AXLE ASSEMBLY MUST BE SECURED TO THE FORKLIFT TINES TO PREVENT MOVEMENT WHEN THE AXLE IS LOWERED AND BEING MOVED.

B.

DRIVE AND STEER FRONT AXLE INSTALLATION

CAUTION AXLE HOUSING MOUNTING PAD AND FRAME PAD SURFACES MUST BE SMOOTH WITH NO NICKS AND CLEAN OF ALL DEBRIS AND LUBRICANTS.

2-5 Page 4 August 2017

(1)

Position the axle assembly directly under the chassis mounting pads and lift axle in position.

(2)

Install the eight axle mounting bolts, washers and nuts. Tighten the nuts just enough to hold the axle in place. After all eight nuts are tightened, remove the lifting equipment and slings. Tighten the mounting hardware, in a cross pattern, to 447 N·m (330 lbf-ft.).

(3)

Check the connection between the drive shaft tubes from the transmission and drive axle for alignment of “witness marks” (impression-stamped codes), then install drive shaft and torque attaching hardware. Refer to Figure 2.

MAINTENANCE AND REPAIR

Halvorsen NOTE:

ALIGNMENT OF “WITNESS MARKS” MUST BE ACCURATE. ALIGNMENT OF DRIVE SHAFT YOKES IS REQUIRED TO MAINTAIN DRIVE SHAFT BALANCE.

NOTE:

APPLY THREAD LOCKING COMPOUND (LOCTITE) ON ALL SCREW THREADS.

DRIVE SHAFT SLIP YOKE

DRIVE SHAFT TUBE

WITNESS MARKS - TWO PLACES AXLE SIDE AND TRANSMISSION SIDE

Figure 2 WITNESS MARKS (4)

Connect all hydraulic hoses to the fittings.

(5)

Check oil level in differential and wheel ends.

(6)

Install service brake with 4 cap screws and nuts.

(7)

Install parking brake assembly with 4 cap screws and nuts and adjust as outlined in Chapter 3.

(8)

Lubricate all points of the axle. Refer to Chapter 2, Section 3, “Preventative Maintenance”.

(9)

Install drive wheels and torque wheel nuts to 271 N·m (200 lbf-ft.).

(10)

Raise chassis, remove shoring and lower the chassis to ground level.

(11)

Turn battery disconnect switch on the battery box to the ON position.

(12)

With the help of an assistant, bleed the air from the park brake, service brake and differential lock cylinder.

(13)

Remove the maintenance stands and lower the deck fully. Remove the wheel chocks.

(14)

Road check the loader for performance and inspect the axle assembly for oil leaks.

MAINTENANCE PROCEDURES

2-5 Page 5 August 2017

Halvorsen

3

DIFFERENTIAL SHAFT

2

4

1

TRANSMISSION SHAFT

Figure 3 DRIVE SHAFT ALIGNMENT

2-5 Page 6 August 2017

MAINTENANCE AND REPAIR

Halvorsen 4.

MAIN LIFT CYLINDERS REMOVAL AND INSTALLATION NOTE: A.

BEFORE THE REMOVAL OF THE MAIN LIFT CYLINDER FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

MAIN LIFT CYLINDERS REMOVAL

CAUTION DUST CAP MUST BE REMOVED BY HAND. THE USE OF A STRAP WRENCH IS PERMITTED, IF REQUIRED, TO INITIALLY LOOSEN THE DUST CAP.

CAUTION PIVOT SHAFT CAP SCREWS MUST BE REMOVED OR DAMAGE TO THE CAP SCREWS OR THE PIVOT SHAFT WILL OCCUR.

CAUTION DO NOT PUSH PIVOT SHAFT PAST THE WELDMENT. THE SCISSORS ALSO PIVOT ON THIS SHAFT. (1)

Turn the battery disconnect switch, on the battery box, to the OFF position.

(2)

Disconnect the drive shaft at the transmission companion flange.

(3)

Remove the four cap screws and nuts securing the drive shaft to the transmission companion flange.

(4)

Remove the two cap screws, nuts and washers, that secures the mid-ship bearing to the chassis.

(5)

At the differential end of the drive shaft assembly, remove the dust seal cover from the slip yoke by turning it counterclockwise.

(6)

Verify that the drive shaft and the slip yoke have impression stamped “witness marks” for alignment and balance. Refer to Figure 2.

(7)

Slide the splined end of the drive shaft out of the slip yoke and remove the drive shaft as a complete assembly from the chassis.

(8)

Remove the cap screws located on the left and right outside surfaces of the chassis frame, that secure the lower pivot shafts (2, one per side) in the chassis.

NOTE:

HYDRAULIC TUBES ROUTED ALONG CHASSIS FRAME WILL REQUIRE REMOVING TO ACCESS THE RETAINING SCREWS AND FOR REMOVING THE PIVOT PIN. INSTALL CAPS AND PLUGS ON ALL LINES AND FITTINGS THAT ARE REMOVED.

(9)

On the left side of the scissors, remove the cap screw that retains the main lift cylinder upper pivot shaft.

(10)

Disconnect hydraulic lines on the cylinder to be removed. Install caps and plugs on lines and fittings to prevent oil leakage and contamination.

MAINTENANCE PROCEDURES

2-5 Page 7 August 2017

Halvorsen (11)

Disconnect electrical wiring on hydraulic cylinder valves.

(12)

Open bleeder screws on both hydraulic cylinders to remove residual pressure.

(13)

To remove the right side main lift cylinder, use a dummy shaft that is slightly smaller than the pivot shaft. Drive the upper pivot shaft towards the left side until it is clear of the bearing in the cylinder upper clevis.

NOTE:

DUMMY SHAFT MUST HAVE A SMALLER DIAMETER THAN THE CYLINDER PIVOT SHAFT. SUGGESTED SHAFT SIZE: 66.7 mm x 1067 mm (2.625 in. x 42 in.).

NOTE:

DO NOT REMOVE THE DUMMY SHAFT AT THIS TIME.

(14) NOTE:

To remove the left side main lift cylinder, use a dummy shaft and drive the upper pivot shaft completely out of the scissors. DO NOT REMOVE THE DUMMY SHAFT AT THIS TIME.

(15)

Position forklift, with side shift capability, at the side of the loader and with the tines above the top of the cylinder barrel.

(16)

Using a nylon-lifting strap around the cylinder barrel, secure the cylinder to the fork lift tine.

(17)

Place a hydraulic power ram between the end of the lower pivot shafts, with the ram base towards the cylinder that will not be removed and apply pressure to push on the pivot shaft of the cylinder that is to be removed.

NOTE:

THE BASE OF THE HYDRAULIC RAM WILL PUSH THE SHAFT ON THE CYLINDER NOT BEING REMOVED BACK UNTIL IT IS FLUSH WITH THE WELDMENT. THE RAM WILL THEN EXERT PRESSURE ON THE SHAFT FOR THE CYLINDER TO BE REMOVED.

(18)

Place a floor jack under lower end of the cylinder and support the cylinder. Remove the hydraulic ram.

(19)

Push on the lower pivot shaft until it is just past the eye and spacers on the lower end of the cylinder.

(20)

Lift the cylinder with the forklift until it is above the chassis. This will force the cylinder to collapse as the oil is forced out through the bleeder screws. Close the bleeder screws when the cylinder is above the chassis.

(21)

Using a nylon cargo strap around the cylinder rod, secure the top end of the cylinder to the deck.

(22)

Slide the dummy shaft, at the top of the cylinders, out of the scissors until the cylinder is free.

(23)

Remove the cylinder from the chassis.

2-5 Page 8 August 2017

MAINTENANCE AND REPAIR

Halvorsen B.

MAIN LIFT CYLINDERS INSTALLATION AND BLEEDING

CAUTION INSTALLING MAIN LIFT CYLINDERS MAY BE POTENTIALLY HAZARDOUS DUE TO THE SIZE, WEIGHT AND POSITION OF THE CYLINDERS. USE EXTREME CAUTION WHEN PERFORMING THESE PROCEDURES. (1) NOTE:

Attach a nylon lifting strap around the cylinder barrel, near the top end. CYLINDER ROD MUST BE FULLY RETRACTED WHEN INSTALLING CYLINDER IN THE CHASSIS.

(2)

Lift the cylinder into place with a forklift and lower the bottom end into the mounting bracket on the chassis.

(3)

Drive the lower pivot shaft into the spherical bearing in the eye on the bottom of the cylinder.

NOTE:

INSTALL THE SPACERS ON EACH SIDE OF THE SPHERICAL BEARING ON THE PIVOT SHAFT AS THE SHAFT IS INSTALLED.

(4)

Install and tighten the pivot shaft retaining cap screws on both sides.

(5)

Reconnect the hydraulic tubes that were removed on the chassis to access the lower cylinder pivot shafts.

(6)

Connect the hydraulic hoses and wiring to the valve on the cylinder barrel.

(7)

Turn the battery disconnect switch to the ON position.

(8)

Turn the ignition switch to the ON position.

NOTE:

DO NOT START THE ENGINE.

(9)

Hold the EMERGENCY PUMP switch in the ON position.

(10)

Extend cylinder rod by actuating the LIFT switch.

NOTE:

POSITION CYLINDER WITH THE FORKLIFT AS THE CYLINDER IS EXTENDED TO ALIGN THE UPPER BEARING WITH THE SCISSORS PIVOT SHAFT. DO NOT EXTEND CYLINDER PAST THE SHAFT. IF CYLINDER ROD IS EXTENDED TOO FAR, OPEN BLEEDER SCREW TO PUSH ROD BACK INTO CYLINDER FOR ALIGNMENT WITH THE SHAFT.

(11)

Drive upper pivot shaft through the spherical bearing and secure with the retaining screw.

(12)

Install drive shaft in chassis, making sure that witness marks are aligned.

(13)

Lubricate spherical bearings.

(14)

Bleed air from cylinders.

CAUTION DO NOT START ENGINE, USE THE EMERGENCY PUMP TO PROVIDE HYDRAULIC FLUID WHEN BLEEDING AIR FROM THE MAIN LIFT CYLINDERS.

MAINTENANCE PROCEDURES

2-5 Page 9 August 2017

Halvorsen NOTE: (15)

Actuate the emergency pump.

(16)

Open only one (1) bleeder screw on one main lift cylinder at a time.

NOTE:

EACH MAIN LIFT CYLINDER HAS THREE (3) BLEEDER SCREWS.

NOTE:

THERE IS NO SEQUENCE TO OPENING THE BLEEDER SCREWS.

(17)

When fluid being released from bleeder screw is clear and free of air bubbles, close bleeder screw.

(18)

Open the other bleeder screws, one at a time, on the same cylinder and when fluid being released is clear and free of air bubbles, close bleeder screw.

(19)

Bleed air from remaining main lift cylinder using procedure in steps 1 through 4.

(20)

Actuate the emergency pump and raise the deck just high enough to remove the Maintenance Stands, then lower the deck fully.

(21)

Actuate the emergency pump and raise the deck to maximum height.

NOTE:

5.

BLEED AIR FROM BOTH MAIN LIFT CYLINDERS AFTER REPLACING A CYLINDER.

CYLINDER MUST BE FULLY EXTENDED.

(22)

Install Maintenance Stands in the #3 position.

(23)

Leave cylinders in the fully extended position for a minimum of 20 minutes.

(24)

Actuate the emergency pump and lower the deck until scissor rollers are in contact with the Maintenance Stands.

(25)

Bleed air from both main lift cylinders again using steps 1 through 5.

(26)

Start engine and raise deck to remove Maintenance Stands.

(27)

Lower the deck fully.

(28)

Bleeding of cylinders is now complete.

HELPER CYLINDERS REMOVAL AND INSTALLATION NOTE: A.

BEFORE THE REMOVAL OF THE HELPER CYLINDER FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

HELPER CYLINDERS REMOVAL Refer to Figure 4.

2-5 Page 10 August 2017

(1)

Remove the nut on the bolt that retains the collar assembly on the rear axle shaft.

(2)

Remove the collar assembly retaining bolt by driving it out of the axle shaft with a brass drift punch or a punch of other soft material, to prevent damage to the retaining bolt.

(3)

Remove the hydraulic hose attached to the helper cylinder and install caps and plugs on the hose and fitting to prevent the entrance of dirt or other foreign material, that would contaminate the hydraulic system.

(4)

Place a lifting sling around the top of the cylinder rod and attach it to a portable engine lifting hoist to support the cylinder when removing it from the axle shaft.

MAINTENANCE AND REPAIR

Halvorsen NOTE:

IF AN ENGINE HOIST IS NOT AVAILABLE, PLACE A PIECE OF PLYWOOD OR OTHER SOFT MATERIAL, UNDER CYLINDER TO PROTECT THE CYLINDER FROM DAMAGE WHEN IT IS BEING REMOVED.

CAUTION USE EXTREME CARE WHEN REMOVING CYLINDER WHEN PORTABLE ENGINE HOIST IS NOT AVAILABLE. PERSONAL INJURY CAN OCCUR IF CYLINDER IS DROPPED. (5) NOTE:

B.

Remove the collar assembly, outer thrust washer and hydraulic cylinder. ROCK THE CYLINDER FORE AND AFT, WHILE PULLING OUTWARD, TO REMOVE THE CYLINDER FROM THE AXLE SHAFT. IF NECESSARY, APPLY PRESSURE WITH A PRY BAR TO THE BACK SIDE OF THE CYLINDER TO FORCE THE CYLINDER OUTWARD AS IT IS BEING ROCKED FORE AND AFT WHEN BEING REMOVED.

HELPER CYLINDERS INSTALLATION Refer to Figure 4. (1)

Ensure that axle shaft is clean of all dirt and there are no nicks or other damage on the bearing surfaces for the cylinder bushings.

(2)

Install bushings in the housing on the bottom of the helper cylinder.

(3)

Coat the bushings and shaft with grease to ease assembly.

(4)

Lift cylinder with a portable engine hoist and install cylinder on the axle shaft.

NOTE: (5) NOTE:

ENSURE THE INNER BRASS SPACER WASHER IS ON THE SHAFT AND AGAINST THE BOGY WHEEL ASSEMBLY BEFORE INSTALLING THE CYLINDER. Install the outer collar assembly on the shaft and install the retaining bolt and nut. CHECK THE CONDITION OF THE TWO SPRINGS IN THE COLLAR ASSEMBLY AND REPLACE IF DAMAGED OR DEFORMED.

(6)

Remove the lifting equipment.

(7)

Remove the caps and plugs from the hydraulic fittings and connect the hydraulic hose.

(8)

Bleed the air from the helper cylinder. Refer to ‘C. HELPER CYLINDERS BLEEDING’.

(9)

Start engine and raise the deck. Remove the scissors Maintenance Stands and lower the deck.

(10)

Shut down the engine.

MAINTENANCE PROCEDURES

2-5 Page 11 August 2017

Halvorsen

RETAINING BOLT

NUT

COLLAR ASSEMBLY THRUST WASHER

GREASE FITTING

Figure 4 HELPER CYLINDER

2-5 Page 12 August 2017

MAINTENANCE AND REPAIR

Halvorsen C.

HELPER CYLINDERS BLEEDING (1)

Disconnect the wires on 7SOL valve. Refer to Chapter 2, Section 2, “System Overview” for solenoid valves locations.

(2)

To extend the cylinder in order to bleed air from the cylinder, actuate and hold the EMERGENCY PUMP switch in the ON position and the AUX. DECK RAISE AND LOWER switch in the UP position. Refer to Figure 5.

AUXILIARY DECK RAISE/LOWER WORK LIGHTS

EMERGENCY PUMP SWITCH

IGNITION/START SWITCH (MAINTENANCE USE ONLY)

EMERGENCY STOP SWITCH

SHUTDOWN OVERRIDE SWITCH

Figure 5 MAIN PANEL

MAINTENANCE PROCEDURES

2-5 Page 13 August 2017

Halvorsen (3)

Loosen bleeder screw to bleed the air in the cylinder and tighten bleed screw securely. Refer to Figure 6.

BLEEDER SCREW

Figure 6 HELPER CYLINDER BLEEDER SCREW

2-5 Page 14 August 2017

(4)

Reconnect wires to 7 SOL.

(5)

Start the engine and raise the deck.

(6)

Remove the scissors Maintenance Stands and lower the deck.

(7)

Shut down the engine.

(8)

Check the fluid level in the hydraulic reservoir and refill as required.

MAINTENANCE AND REPAIR

Halvorsen 6.

SCISSORS LOWER ROLLERS REMOVAL AND INSTALLATION

WARNING THIS IS A MANDATORY SAFETY PRECAUTION. THE NORMAL SCISSORS MAINTENANCE STANDS CANNOT BE INSTALLED WHEN REMOVING AND REPLACING ROLLERS. ENSURE TO PROPERLY SUPPORT THE DECK AND SCISSORS. Refer to Figure 7. A.

REMOVE LOWER ROLLERS ON INNER SCISSORS (1)

Chock wheels to prevent movement of the loader.

(2)

Start engine, raise deck to align the center of the roller shaft horizontally with the hole in the chassis frame. Turn off the engine.

(3)

Attach a lift chain or sling to the front end of the deck and apply tension to the chain with an overhead hoist.

(4)

Remove the roller shaft retention cap screw in the scissors cross tube.

(5)

Place a hydraulic jack under the scissors cross tube and raise the scissors until the roller shaft is centered vertically with the hole in the chassis frame.

NOTE:

B.

HYDRAULIC JACK MUST BE RATED AT 10-TON OR GREATER CAPACITY.

(6)

Thread a slide hammer in the end of the roller shaft and remove the shaft from the scissors cross tube, thrust washer and roller.

(7)

Roll the scissors lower roller forward on the chassis track to clear the scissors to remove for repair or replacement.

INSTALL LOWER ROLLER ON INNER SCISSORS (1) NOTE: (2) NOTE:

Lift roller into chassis frame forward of the scissors, then roll the roller towards the rear and align the bore of the assembly with the hole in the chassis frame. THE CHASSIS ROLLER TRACK MUST BE SMOOTH, CLEAN AND FREE OF ANY LUBRICANT. Insert the pivot shaft through the opening in the chassis frame, through the roller and thrust washer and into the scissors cross tube. Install the shaft retention bolt. THE HOLE IN THE SHAFT MUST BE INDEXED WITH THE HOLE IN THE CROSS TUBE FOR THE RETENTION BOLT.

(3)

Lower the scissors onto the chassis frame and remove the hydraulic jack.

(4)

Lubricate roller.

(5)

Remove the hoist and lifting chain or strap, then have the assistant start the engine and lower the deck.

MAINTENANCE PROCEDURES

2-5 Page 15 August 2017

Halvorsen SHAFT RETENTION CAP SCREW

ROLLER

Figure 7 LOWER ROLLER ON INNER SCISSORS

2-5 Page 16 August 2017

MAINTENANCE AND REPAIR

Halvorsen 7.

BRAKES ADJUSTMENTS NOTE: A.

REFER TO CHAPTER 3, SECTION 2, FOR PARK BRAKE OVERHAUL PROCEDURE.

PARK BRAKE ADJUSTMENT Refer to Figure 8. NOTE:

THE PARK BRAKE IS SPRING APPLIED AND HYDRAULICALLY RELEASED. THE LOADER MUST BE RUNNING TO ADJUST THE PARKING BRAKE.

(1)

Start the loader. Keep the transmission selector in the neutral position. Ensure the parking brake is disengaged (parking brake switch in the OFF position).

(2)

Loosen lock nut (1) and adjusting screw (2) on brake caliper.

Figure 8 PARK BRAKE ADJUSTMENT (3)

Place a 0.30 mm (0.012 in.) thick shim between the disc and one of the linings (loader must be running with the parking brake disengaged).

(4)

Tighten the adjusting screw (2) until it is just possible to remove the shim.

(5)

Torque lock nut (1) at 27–37 N·m (22–27 lbf-ft.) while holding the adjusting screw (2) with a wrench. Remove the shim and release the hydraulic pressure by positioning the park brake switch in the ON position (applies the brake).

(6)

Raise deck off Maintenance Stands, remove Maintenance Stands and ready loader for operation.

MAINTENANCE PROCEDURES

2-5 Page 17 August 2017

Halvorsen B.

PARKING BRAKE FORWARD MOVEMENT FUNCTION CHECK NOTE:

C.

FORWARD MOVEMENT FUNCTION CHECK TO BE PERFORMED IN THE CAB.

(1)

Start the loader.

(2)

Place foot pressure on the service brake foot pedal and release parking brake.

(3)

Shift transmission to drive.

(4)

Apply parking brake.

(5)

Release foot brake.

(6)

Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm). Ensure loader does not move.

PARKING BRAKE REVERSE MOVEMENT FUNCTION CHECK NOTE:

PLACE CHOCKS APPROXIMATELY 50 MM (2 IN.) FROM THE FRONT AND REAR OF A TIRE TO PREVENT EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD OR REVERSE DIRECTION SHOULD THE PARKING BRAKE FAIL.

NOTE:

FORWARD MOVEMENT FUNCTION CHECK TO BE PERFORMED IN THE CAB.

D.

(1)

Start the loader.

(2)

Place foot pressure on the service brake foot pedal and release parking brake.

(3)

Shift transmission to reverse.

(4)

Apply parking brake.

(5)

Release foot brake.

(6)

Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm). Ensure loader does not move.

FRONT SERVICE BRAKE ADJUSTMENT NOTE:

REFER TO CHAPTER 3, SECTION 2, FOR FRONT SERVICE BRAKE OVERHAUL PROCEDURE.

NOTE:

REFER TO CHAPTER 5, SECTION 2, “MANUFACTURERS’ DATA” FOR REAR SERVICE BRAKE INFORMATION.

E.

2-5 Page 18 August 2017

(1)

Service brake on drive axle. Drive shaft disc brake assembly does not require adjusting.

(2)

Service brakes on bogy wheels. Bogy wheel disc brake assemblies do not require adjusting.

FRONT SERVICE BRAKE BLEEDING (1)

Start engine and have assistant hold service brake.

(2)

Attach a clear plastic tube from the bleeder to a suitable container.

(3)

Loosen bleeder and observe flow of fluid.

(4)

When all air is expelled close bleeder and release service brake.

(5)

Bleed all remaining calipers.

MAINTENANCE AND REPAIR

Halvorsen 8.

ENGINE REMOVAL AND INSTALLATION NOTE:

BEFORE THE REMOVAL OF THE ENGINE FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

NOTE:

WHEN IT IS NECESSARY TO REMOVE THE ENGINE FROM THE CHASSIS, THE ENGINE AND TRANSMISSION ARE REMOVED TOGETHER AS AN ASSEMBLY.

CAUTION TO PREVENT ENGINE DAMAGE AND POSSIBLE COMPLETE DESTRUCTION OF THE TURBOCHARGER, ALWAYS COVER TURBOCHARGER INLET AND EXHAUST OPENINGS TO PREVENT THE ENTRANCE OF ANY FOREIGN OBJECT. A.

ENGINE REMOVAL (1)

Turn battery disconnect switch on the battery box to the OFF position and disconnect battery cables.

(2)

Place drain pan under transmission, remove transmission oil pan drain plug and drain transmission fluid. Replace drain plug in transmission oil pan.

(3)

Disconnect all hydraulic hoses connected to transmission and install caps and plugs on hoses and fittings to prevent the entrance of foreign material that would contaminate the system. Mark each hose as it is removed so that it will be installed on the correct fitting upon re-installation of engine/transmission assembly.

(4)

Remove external components and wiring on transmission.

(5)

Tie all cables and hoses to the chassis frame for clearance and to prevent damage when engine/transmission assembly is removed.

(6)

Disconnect drive shaft at the transmission flange.

(7)

Place drain pan under engine, remove oil pan drain plug and drain engine oil. Replace drain plug in engine oil pan.

(8)

Place drain pans under the engine and coolant radiator and drain coolant system. Remove surge tank cap to vent cooling system during draining.

(9)

Disconnect fuel lines and install caps and plugs to prevent leakage and the entrance of foreign material that could possibly contaminate the fuel system.

(10)

Disconnect all electrical wiring and temporally tie back to chassis frame to prevent damage to the harnesses and conductors.

(11)

Disconnect and remove coolant pipes and hoses on engine.

(12)

Remove air inlet pipe and hose from inlet on the turbocharger air pump.

(13)

Remove exhaust pipe from the outlet on the turbocharger.

(14)

Remove the bolt on generator belt tension adjuster and remove belts from generator sheave. Pull generator outward to access the socket head cap screws that hold the main hydraulic pump mounting bracket to the engine block on the right side.

(15)

Place shoring under the pump mounting bracket for the pump to rest on when it is removed.

MAINTENANCE PROCEDURES

2-5 Page 19 August 2017

Halvorsen

B.

(16)

Remove clamps and tie-wrap restraints on all hydraulic hoses that are attached to the main pump. DO NOT disconnect any hydraulic hoses on the pump.

(17)

Remove the socket head screws on each side of the engine that attach the pump mounting bracket to the engine block.

(18)

Carefully pull the pump assembly away from the engine. When clear, lower the assembly onto the shoring.

(19)

Install a lifting chain to the lifting brackets on the engine and, with an engine hoist, remove all slack in the lifting chain. Lifting chain must be positioned to lift the engine/transmission assembly as level as possible.

(20)

Remove the eight hex head nuts and cap screws that secure the four engine and transmission motor mounts to the chassis cross members.

(21)

Lift the engine and transmission high enough to clear all fixed chassis components and remove the assembly from the chassis.

ENGINE INSTALLATION NOTE: (1)

Install an engine lifting chain on the two engine lifting brackets on the engine.

(2)

Position the lifting chain on the engine hoist to pick up the engine/transmission assembly as level as possible before moving the assembly into the chassis.

(3)

Carefully lower the engine and transmission assembly and align the motor mounts with the holes in the chassis cross-members.

(4)

Install the eight cap screws and hex head nuts in the motor mounts (two in each motor mount) and tighten the hex head nuts to specifications.

NOTE:

INSTALLATION OF THE PUMP ASSEMBLY MAY REQUIRE ROTATING THE PUMP COUPLING TO INDEX WITH THE MATING HALF OF THE COUPLING ATTACHED TO THE ENGINE CRANKSHAFT.

(5)

Install hydraulic pump assembly on front of engine. When mounting bracket is aligned with the threaded holes in the engine block, insert all four of the socket head screws and tighten to specifications.

(6)

Install generator drive belts on generator sheave and move generator out to tension the belts to specifications. When the belt is tensioned, tighten cap screw securely on the slotted tension bracket.

NOTE:

2-5 Page 20 August 2017

ENGINE AND TRANSMISSION MUST BE INSTALLED IN THE LOADER AS A COMPLETE ASSEMBLY.

FLANGES MUST BE CLEAN AND SMOOTH.

(7)

Connect drive shaft to the transmission flange and tighten the four nuts on the cap screws to specifications.

(8)

Remove caps and plugs from hydraulic lines and fittings and reconnect to transmission.

(9)

Install external components on transmission that were removed in order to remove the engine and transmission from the chassis.

(10)

Remove protective covers from the turbocharger inlet and exhaust openings and connect the exhaust pipe and inlet hose.

MAINTENANCE AND REPAIR

Halvorsen (11)

Install the engine coolant hoses and pipes.

(12)

Install the electrical harnesses and wiring. Secure the harnesses and wiring with tie wraps to prevent chafing or mechanical damage.

(13)

Refill the transmission with transmission fluid.

(14)

Fill engine with lubricating oil.

(15)

Remove caps and plugs on fuel lines and connect the hoses to the engine.

(16)

Bleed air from the fuel system. Loosen the bleed screw on top of the secondary fuel filter. Turn on the IGNITION switch, when a continuous flow of fuel is vented from the bleeder screw, tighten the bleeder screw and turn off the IGNITION switch.

NOTE:

IF THE STROKE OF THE LEVER ON THE FUEL PUMP APPEARS TO BE SHORT, ROTATE THE ENGINE ONE-HALF REVOLUTION SO THAT THE FUEL PUMP LEVER IS ON THE LOW PART OF THE CAM ON THE CAMSHAFT.

(17)

Fill cooling system with coolant. Use coolant with the correct ratio of glycol and water.

(18)

Connect battery cables to the batteries and turn the battery disconnect switch on the battery box to the ON position.

NOTE: (19)

9.

ALWAYS CONNECT THE NEGATIVE BATTERY CABLE LAST. Start engine and allow engine to warm up at the idle position.

NOTE:

IMMEDIATELY CHECK INSTRUMENT GAUGES FOR ENGINE OIL PRESSURE AND OBSERVE GAUGES DURING THE WARM-UP PERIOD FOR NORMAL OPERATION.

(20)

During the warm-up period, monitor the engine for oil leaks and the coolant level. Shut down the engine immediately if oil pressure is low or there is any abnormal noise.

(21)

Once the engine has warmed up, shut the engine down and recheck all fluid levels.

TRANSMISSION REMOVAL AND INSTALLATION NOTE: A.

BEFORE THE REMOVAL OF THE TRANSMISSION FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

TRANSMISSION REMOVAL (1)

Turn battery disconnect switch on the battery box to the OFF position and disconnect battery cables.

(2)

Place drain pan under transmission, remove transmission oil pan drain plug and drain transmission fluid. Replace drain plug in transmission oil pan.

(3)

Disconnect all hydraulic hoses connected to transmission and install caps and plugs on hoses and fittings to prevent the entrance of foreign material that can contaminate the system. Mark each hose as it is removed so that it will be installed on the correct fitting upon re-installation of transmission.

(4)

Remove external components, oil level dipstick tube and wiring on transmission.

(5)

Tie all cables and hoses to the chassis frame for clearance and to prevent damage when transmission is removed.

MAINTENANCE PROCEDURES

2-5 Page 21 August 2017

Halvorsen (6)

Disconnect drive shaft at the transmission flange.

(7)

Remove access cover on bottom of engine flywheel housing and remove the six bolts that attach the torque converter to the drive plate.

NOTE:

ROTATE THE TORQUE CONVERTER FOR ACCESS TO EACH MOUNTING BOLT BY PRYING ON THE TEETH OF THE RING GEAR THROUGH THE ACCESS HOLE.

(8)

Lift engine and transmission slightly by attaching a portable engine hoist to the transmission.

(9)

Remove the two 5/8 in. cap screws on each side of the transmission that secure the chassis mounting brackets to the transmission case.

(10)

Place shoring under the engine flywheel housing to support the engine and transmission.

(11)

Remove the chassis cross member under the transmission.

(12)

Lower the engine and transmission onto the shoring.

NOTE:

SHORING SHOULD SUPPORT THE ENGINE AND TRANSMISSION APPROXIMATELY THE SAME HEIGHT AS THE CROSS MEMBER.

AT

(13)

Remove the twelve cap screws that attach the transmission to the engine flywheel housing.

(14)

Carefully separate the transmission from the engine.

CAUTION DO NOT ALLOW THE FRONT OF THE TRANSMISSION TO BE LOWER THAN LEVEL TO PREVENT THE TORQUE CONVERTER FROM SLIDING FORWARD AND OUT OF THE TRANSMISSION.

B.

(15)

Immediately attach a restraint strap on the converter to secure the converter on the transmission before continuing to remove the assembly from the chassis.

(16)

Remove the transmission assembly from the chassis.

TRANSMISSION INSTALLATION

CAUTION IF A CONDITION OCCURS THAT INTRODUCES DEBRIS INTO THE TRANSMISSION HYDRAULIC SYSTEM, A COMPLETE CLEANUP OF THE OIL COOLER AND HYDRAULIC LINES IS REQUIRED BEFORE REPLACEMENT TRANSMISSION IS INSTALLED.

2-5 Page 22 August 2017

(1)

Install lifting chain to the pads on top of the transmission case.

(2)

With an engine hoist, pick up the transmission and move it into position at the back of the engine. Transmission must be level, end to end, when it is being installed.

(3)

Remove the torque converter retaining device, then rotate the converter to align the driving lugs with the drive plate on the engine.

MAINTENANCE AND REPAIR

Halvorsen (4)

Carefully move the transmission forward to the engine flywheel housing and ensure that the torque converter pilot enters the engine drive plate. Transmission must mate to the engine housing surface without any force and the torque converter should be able to be rotated easily by hand through the access hole.

(5)

Install the twelve cap screws to secure the transmission to the engine housing.

(6)

Install the six torque converter drive cap screws in the drive plate only finger-tight until they are all in place. Tighten the cap screws to specifications. Install the cover over the access hole.

(7)

Lift the engine and transmission slightly and remove the shoring from under the engine housing.

(8)

Install the transmission cross member and bolt the support brackets to the transmission case with the 5/8-in. bolts.

(9)

Install the bolts through the frame and cross member and tighten securely.

(10)

Remove lifting equipment and lifting chain.

(11)

Connect drive shaft to transmission drive flange.

NOTE:

FLANGES MUST BE CLEAN AND SMOOTH.

(12)

Install external components, oil dipstick tube and electrical wiring.

(13)

Reconnect all hydraulic hoses.

(14)

Remove and replace auxiliary filter element.

(15)

Refill the transmission with fluid.

CAUTION CONTAINERS OR FILLERS THAT HAVE BEEN USED TO HANDLE ANTIFREEZE OR ENGINE COOLANT SOLUTION MUST NEVER BE USED FOR TRANSMISSION FLUID. ANTIFREEZE AND COOLANT SOLUTIONS CONTAIN ETHYLENE GLYCOL WHICH, IF INTRODUCED INTO THE TRANSMISSION, CAN CAUSE THE CLUTCH PLATES TO FAIL. (16)

Start engine and allow sufficient time for warm-up of transmission fluid. Perform HOT oil level check.

(17)

Service cooling system as outlined in ‘22. COOLANT SYSTEM LEVEL AND REFILLING’.

(18)

Drive the loader and check for proper shifting and fluid leaks.

(19)

Recheck the transmission fluid level after driving.

MAINTENANCE PROCEDURES

2-5 Page 23 August 2017

Halvorsen 10.

FORWARD DECK SHIFT AND ROLL CYLINDERS REPLACEMENT

CAUTION DO NOT REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY UNTIL ALL REPLACEMENT SERVICE PARTS ARE ON HAND AND READY TO BE INSTALLED. THE FRONT SIDE SHIFT BOGY ASSEMBLY IS A MAJOR STRUCTURAL ITEM. TO AVOID DAMAGE, THE LOADER MUST NOT BE LEFT IN THIS DISASSEMBLED STATE FOR A LONG PERIOD OF TIME. NOTE:

THE LEFT AND RIGHT ROLL CYLINDERS ARE ATTACHED TO THE DECK SIDE SHIFT CYLINDER ROD. TO REPLACE EITHER ROLL CYLINDER, THE SIDE SHIFT CYLINDER BOGY ASSEMBLY MUST BE REMOVED.

NOTE:

HEAVY-LIFTING EQUIPMENT IS REQUIRED. A 6800 KG (15 000 LB.) CAPACITY FORKLIFT WITH FORK SIDE SHIFT CAPABILITIES OR AN OVERHEAD CRANE OF THE SAME CAPACITY MUST BE USED TO SAFELY SUPPORT THE FRONT OF THE DECK DURING THIS PROCEDURE.

NOTE:

ONCE THE DECK AND SCISSORS ARE DISCONNECTED, THE DECK WILL NEED TO BE LIFTED AND MOVED FORWARD APPROXIMATELY 0.60 M (2 FT.) TO GAIN CLEARANCE TO SAFELY REMOVE THE FRONT SIDE SHIFT CYLINDER BOGY ASSEMBLY. HEAVY-DUTY LIFTING SLINGS OR CHAINS WITH A MINIMUM TOTAL CAPACITY OF 6800 KG (15 000 LB.) IS REQUIRED.

NOTE:

THE LOADER MUST BE PARKED IN A LEVEL LOCATION THAT HAS SUFFICIENT SPACE SUROUNDING THE LOADER TO ALLOW THE FORKLIFT TO SAFELY APPROACH THE LOADER FROM ALL SIDES.

A.

LOADER DECK PREPARATION If using a forklift to support the deck, the folding walk-deck and handrails on the non-cab side of the loader must be configured for shipping. If using an overhead crane, proceed to step (5).

2-5 Page 24 August 2017

(1)

Remove the forward two (2) folding walk-deck and handrail sections adjacent to front deck lifting rings. Refer to Figure 9.

(2)

Remove the retaining pins on each of the folding walk-deck and handrail sections on the non-cab side of the loader.

(3)

Lift up and fold the walk-deck and handrail section on top of the deck. Refer to Figure 9.

(4)

Install all of the retaining pins to secure the folding walk-deck and handrail sections.

MAINTENANCE AND REPAIR

Halvorsen DECK LIFT RINGS

FOLD WALKDECK/HANDRAIL

REMOVE TWO HANDRAILS

HEADLIGHT, MARKER LIGHT, AMBER LIGHT

DECK TIE DOWN LUGS (BOTH SIDES)

Figure 9 LOADER DECK PREPARATION

B.

(5)

Start the engine. Raise the deck to a height so the inner scissor lower rollers are between the first and second maintenance stand position.

(6)

Install both maintenance stands in the FIRST maintenance stand position. DO NOT LOWER THE DECK FROM THIS POSITION UNTIL INSTRUCTED TO DO SO.

CENTER AND LEVEL THE DECK (1)

From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch on the cab dash panel until the pitch, roll and shift indicator lights on the dash panel are not illuminated.

(2)

From outside of the cab, visually verify the deck platform is centered and level.

(3)

Shut down the engine.

MAINTENANCE PROCEDURES

2-5 Page 25 August 2017

Halvorsen C.

REMOVE MISCELLANEOUS ITEMS (1)

At the rear of the loader, unplug and remove the three (3) limit switches located on the inside of the deck bumper. Save hardware for re-use. Refer to Figure 10.

(2)

At the front of the deck, remove the two (2) tie down lugs and backing plates located on the deck I-beams. Discard all hardware. Refer to Figure 9.

(3)

At the front of the deck, unplug the Cab side marker light, head light and amber light from the deck electrical harness. Refer to Figure 9.

(4)

Remove the headlight housing with attached lights. Save hardware for re-use.

LIMIT SWITCHES

Figure 10 DECK BUMPER LIMIT SWITCHES D.

2-5 Page 26 August 2017

DISCONNECT THE ROLL CYLINDER HYDRAULICS (1)

Label each of the extend and retract hydraulic hoses connected to the front roll cylinders. These ports should be labeled on the bottom of the roll cylinders. The ports labeled “E” are the extend ports and the ports labeled “R” are the retract ports.

(2)

Disconnect the four (4) hydraulic hoses from the two front roll cylinders hydraulic ports. Use a drain pan to collect hydraulic fluid. Install hydraulic plugs on the four (4) hydraulic hoses to prevent contamination. Refer to Figure 11.

MAINTENANCE AND REPAIR

Halvorsen UPPER FASTENERS

LOWER FASTENERS ROLL CYLINDER HYDRAULICS

Figure 11 ROLL CYLINDER HYDRAULICS AND FASTENERS E.

SECURE LIFTING PROVISIONS TO THE DECK

WARNING HEAVY-DUTY LIFTING PROVISIONS SUCH AS SLINGS OR CHAINS USED TO SUPPORT THE DECK PLATFORM SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.). (1)

Secure heavy-duty lifting sling or chains to the two (2) forward deck lifting rings. Refer to Figure 9. Be sure the lifting provisions have a the minimum total capacity required.

(2)

Secure the lifting provisions to an overhead crane or a set of forklift tines. Be sure the selected lifting equipment has the minimum lifting capacity required. Leave enough slack in the lifting provisions to allow the loader’s deck to fully side shift to each side. Deck side shift is necessary to remove the top roll cylinder mounting fasteners.

MAINTENANCE PROCEDURES

2-5 Page 27 August 2017

Halvorsen WARNING HEAVY-LIFTING EQUIPMENT USED TO SUPPORT THE DECK PLATFORMS SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.) AND BE CAPABLE OF MOVING THE DECK PLATFORM FORWARD APPROXIMATELY 0.60 M (2 FT.) ONCE THE DECK AND SCISSORS ARE DISCONNECTED. F.

REMOVE UPPER FASTENERS Follow the instruction below to remove the upper fasteners that secure the roll cylinders to the scissor structure.

G.

(1)

Start the engine.

(2)

From within the cab, actuate and hold the SHIFT toggle switch until the deck is fully shifted to the non-cab side.

(3)

Remove and discard the upper two (2) fasteners that secure the non-cab side roll cylinder to the scissors. Do not remove the bottom two (2) fasteners until instructed to do so. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the roll cylinder fasteners. Refer to Figure 11.

(4)

From within the cab, actuate and hold the SHIFT toggle switch until the deck is fully shifted to the Cab side.

(5)

Remove and discard the top two (2) fasteners that secure the Cab side roll cylinder to the scissors. Do not remove the bottom two (2) fasteners until instructed to do so. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the roll cylinder fasteners. Refer to Figure 11.

(6)

From within the cab, actuate and hold the AUTO CENTER/LEVEL switch until the shift indicator lights on the dash panel are not illuminated. The deck should be centered.

(7)

From outside of the cab, visually verify the deck platform is centered and level.

(8)

Shut down the engine and turn the battery disconnect OFF.

DISCONNECT ELECTRICAL COMPONENTS (1)

NOTE:

(2)

2-5 Page 28 August 2017

Toward the front of the scissors, unplug and remove the two (2) side shift limit switches 17LS and 18LS from their respective mounting brackets on the scissors. These limit switches should be attached to a lanyard that is also attached to the deck I-beams. Save hardware for re-use. Refer to Figure 12 for limit switch locations. THE LANYARDS ATTACHED BETWEEN THE DECK AND SIDE SHIFT CYLINDER LIMIT SWITCHES SHOULD REMAIN ATTACHED TO THESE ITEMS. TIE WRAP THE LIMIT SWITCHES TO THE DECK TO AVOID DAMAGING THESE ITEMS. Unplug the two twelve pin electrical connectors near the Cab side roll cylinder. This electrical connections are located directly behind the front side shift cylinder. Some loader functions will not operate while this electrical connection is disconnected.

MAINTENANCE AND REPAIR

Halvorsen H.

DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS (1)

Label the cab side and non-cab side hydraulic hoses connected on the front side shift cylinder. Refer to Figure 12.

DISCONNECT ELECTRICAL CONNECTIONS

LIMIT SWITCHES 17LS AND 18LS

SIDE SHIFT CYLINDER HYDRAULIC PORTS

Figure 12 REAR VIEW OF FRONT SIDE SHIFT BOGY ASSEMBLY (2)

Disconnect the two (2) hydraulic hoses from the front side shift cylinder. Use a drain pan to collect hydraulic fluid. Install hydraulic plugs on the two (2) hydraulic hoses.

WARNING THE DECK LINKAGE MUST BE PROPERLY SUPPORTED WHILE REMOVING THE FRONT PIN TO AVOID PERSONAL INJURY. (3)

Remove the forward pin attaching the deck linkage to the deck. Support the deck linkage throughout this process to prevent serious injury to personnel. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the pin. The rear pin in the deck linkage does not need to be removed. Refer to Figure 13.

MAINTENANCE PROCEDURES

2-5 Page 29 August 2017

Halvorsen I.

REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY Refer to Figure 13. (1)

Adjust the tension in the lift provisions so the front portion of the deck is completely supported.

(2)

Remove and discard the four (4) remaining fasteners that secure the front roll cylinders to the scissors.

(3)

Lift the deck high enough using the heavy lifting equipment so the bottom of the side shift cylinder is above the deck linkage attached to the front of the scissors.

(4)

Move the deck forward until the side shift cylinder is in front of the deck linkage.

(5)

Install two sets of wooden blocks between the scissors and the deck.

(6)

Lower the deck until it is completely resting on the wooden blocks. The deck and scissors should not be contacting each other.

(7)

Position fork lift tines (using optional extensions as needed) under the center of the side shift bogy assembly so it is completely and safely supporting the assembly. Refer to Figure 13 for support location.

(8)

Remove the two (2) pins that attach the side shift cylinder bogy assembly to the deck structure. Save hardware for reuse.

(9)

Lift the side shift cylinder bogy assembly high enough to clear the deck link and move it forward approximately one foot. The side shift cylinder bogy assembly should be completely and safely supported by the forklift.

(10)

Rotate the side shift cylinder bogy assembly so it can be lowered out from under the deck.

CAUTION DO NOT OPERATE THE LOADER WHILE THE FRONT SIDE SHIFT BOGY IS REMOVED TO PREVENT DAMAGING THE LOADER. THE HEAVY LIFTING EQUIPMENT SHOULD REMAIN.

2-5 Page 30 August 2017

MAINTENANCE AND REPAIR

Halvorsen

PIVOT PIN (BOTH SIDES)

FORK LIFT TINE/PALLET SUPPORT LOCATION

REMOVE DECK LINKAGE FRONT PIN

LEAVE DECK LINKAGE REAR PIN

WOODEN SUPPORT BLOCKS

Figure 13 SIDE SHIFT BOGY ASSEMBLY CYLINDER REMOVAL 11.

FORWARD DECK SHIFT AND ROLL CYLINDERS INSTALLATION A.

INSTALL THE FRONT SIDE SHIFT BOGY ASSEMBLY Refer to Figure 13. (1)

Place the side shift cylinder bogy assembly on the ends of fork lift tines so the assembly is at a 45 degree bias to the fork lift tines. Secure the assembly to prevent it from rolling.

(2)

Lift the side shift cylinder bogy assembly into the deck frame. Rotate the side shift cylinder bogy assembly so the pivot arm assemblies, on the ends of the side shift cylinder, fit within the deck frame I-beams.

(3)

Position the side shift cylinder assembly so the two (2) pivot arm pins can be installed to secure the side shift cylinder assembly to the deck.

(4)

Secure the pivot arm pins to the deck using fasteners with thread locker applied to the leading threads.

(5)

Lift the deck high enough using the heavy lifting equipment so the bottom of the side shift cylinder is above the deck linkage attached to the front of the scissors.

(6)

Remove the wooden Maintenance Stands that are between the scissor and deck.

MAINTENANCE PROCEDURES

2-5 Page 31 August 2017

Halvorsen (7)

Move the deck backwards until the roll cylinders are aligned with the scissors. Slowly lower the deck until the roll cylinders are within the supporting plates on the scissors. Install the two (2) lower fasteners that secure both roll cylinders to the scissors. Do not completely tighten the fasteners. Refer to Figure 14.

DECK LINKAGE

UPPER FASTENERS (BOTH SIDES)

LOWER FASTENERS (BOTH SIDES)

ROLL CYLINDER HYDRAULICS

Figure 14 SIDE SHIFT CYLINDER BOGY INSTALLATION

WARNING THE DECK LINKAGE MUST BE PROPERLY SUPPORTED WHILE REMOVING THE FRONT PIN TO AVOID PERSONAL INJURY.

2-5 Page 32 August 2017

MAINTENANCE AND REPAIR

Halvorsen (8)

B.

Attach the front deck linkage to the deck. Manually support the deck linkage throughout this process to prevent serious injury to personnel. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the pin. Refer to Figure 14.

CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS (1)

Install new hydraulic fittings with O-ring seals in the hydraulic side shift cylinder ports. Refer to Figure 15.

(2)

Connect the two (2) hydraulic hoses to the front side shift cylinder. Refer to markings on the hydraulic hoses for correct installation locations.

(3)

Tighten hydraulic connections.

SIDE SHIFT CYLINDER HYDRAULICS

Figure 15 FRONT SIDE SHIFT CYLINDER HYDRAULICS C.

CONNECT THE ROLL CYLINDER HYDRAULICS (1)

Install new hydraulic 45 degree hydraulic fittings with O-ring seals in the hydraulic roll cylinder ports. Refer to Figure 14.

(2)

Connect the four hydraulic hoses to the roll cylinders. Refer to markings on the hydraulic hoses and roll cylinder for correct installation locations.

MAINTENANCE PROCEDURES

2-5 Page 33 August 2017

Halvorsen (3) D.

E.

Tighten hydraulic connections.

CONNECT ELECTRICAL COMPONENTS (1)

Install the side shift cylinder limit switches 17LS and 18LS to their respective brackets on the scissors. The limit switches should be adjusted to ensure the deck auto center and level system functions correctly after these procedures are completed. Refer to Figure 12 for limit switch locations.

(2)

Connect the two twelve pin electrical connectors on the scissor electrical harness to the deck electrical harness. These electrical connectors are located directly behind the front side shift cylinder. Refer to Figure 12.

INSTALL UPPER FASTENERS TO SECURE ROLL CYLINDERS Installation of upper fasteners that secure the roll cylinders to the scissor structure.

2-5 Page 34 August 2017

(1)

Start the engine.

(2)

From within the cab, actuate and hold the SHIFT toggle switch until the deck is fully shifted to the non-cab side.

(3)

Install the upper two (2) fasteners that secure the non-cab side roll cylinder to the scissors. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the roll cylinder fasteners. Refer to Figure 14.

(4)

From within the cab, actuate and hold the SHIFT toggle switch until the deck is fully shifted to the Cab side.

(5)

Install the top two (2) fasteners that secure the Cab side roll cylinder to the scissors. The lifting provisions may need to be temporarily adjusted during this process to remove the load on the roll cylinder fasteners. Refer to Figure 14.

(6)

From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch until the shift indicator lights on the dash panel are not illuminated. The deck should be centered.

(7)

Fully tighten all eight fasteners attaching the roll cylinders to the scissor plates.

(8)

Shut down the engine and turn the battery disconnect OFF.

(9)

Operate the deck shift and roll functions to verify no hydraulic fluid leaks exist. Be sure the deck is center and level before proceeding.

(10)

Remove the lifting provisions from the deck.

MAINTENANCE AND REPAIR

Halvorsen F.

12.

INSTALL MISCELLANEOUS ITEMS (1)

At the rear of the loader, reinstall the three (3) limit switches located on the inside of the deck bumper. Reconnect the limit switches to the deck electrical harness. Refer to Figure 10.

(2)

At the front of the deck, reinstall the two (2) tie down lugs and backing plates located on the deck I-beams. Tighten fasteners to 542 N·m (400 lbf-ft.). Refer to Figure 9.

(3)

Remove the headlight housing with attached lights. Connect all lights to the deck electrical harness. Refer to Figure 9.

(4)

Start the engine. Remove the maintenance stands and stow them in the maintenance stand stowing locations on the chassis.

(5)

Lower the deck until it is completely resting on the chassis frame.

(6)

Configure the loader for normal operation.

REAR DECK SHIFT AND ROLL CYLINDERS REMOVAL NOTE:

A.

B.

THE LOADER MUST BE PARKED IN A LEVEL LOCATION THAT HAS SUFFICIENT SPACE BEHIND THE LOADER TO ALLOW A FORKLIFT TO SAFELY APPROACH THE LOADER FROM THE REAR.

CENTER AND LEVEL THE DECK (1)

Install both maintenance stands in the FIRST position.

(2)

From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch on the cab dash panel until the pitch, roll and shift indicator lights on the dash panel are not illuminated.

(3)

From outside of the cab, visually verify the deck platform is centered and level.

(4)

Shut down the engine and turn the battery disconnect OFF.

DISCONNECT THE REAR ROLL CYLINDER HYDRAULICS (1)

Label each of the extend and retract hydraulic hoses connected to the rear roll cylinders. These ports should be labeled on the bottom of the roll cylinders. The ports labeled “E” are the extend ports and the ports labeled “R” are the retract ports.

(2)

Disconnect the four (4) hydraulic hoses from the two rear roll cylinders. Use a drain pan to collect hydraulic fluid. Install hydraulic plugs on the four (4) hydraulic hoses to prevent contamination. Refer to Figure 16.

(3)

If the roll cylinders are being replaced, remove and discard the four (4) 45º hydraulic fittings with O-rings on the bottom of the roll cylinders.

MAINTENANCE PROCEDURES

2-5 Page 35 August 2017

Halvorsen

FASTENERS

FASTENERS

ROLL CYLINDER HYDRAULICS

Figure 16 ROLL CYLINDER HYDRAULICS AND FASTENERS C.

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DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS (1)

Label the cab side and non-cab side hydraulic hoses connected on the rear side shift cylinder. Refer to Figure 17.

(2)

Disconnect the two (2) hydraulic hoses from the rear side shift cylinder. Use a drain pan to collect hydraulic fluid. Install hydraulic plugs on the two (2) hydraulic hoses.

(3)

If the side shift cylinder is being replaced, remove and discard the hydraulic fittings with O-ring seals attached to the cylinder.

MAINTENANCE AND REPAIR

Halvorsen

SIDE SHIFT CYLINDER HYDRAULICS

Figure 17 REAR SIDE SHIFT CYLINDER HYDRAULICS (4)

Start the engine. Raise the deck high enough so the upper scissor rollers on the ends of the rear side shift cylinder are in front of the rear scissor roller tracks attached to the deck. Refer to Figure 18.

(5)

Shut down the engine, turn the battery disconnect OFF and install both maintenance stands in the SECOND maintenance stand position.

MAINTENANCE PROCEDURES

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Halvorsen

FORWARD

OUTER SCISSORS UPPER SCISSORS

REAR SCISSORS ROLLER TRACKS

INSIDE VIEW

Figure 18 UPPER SCISSOR ROLLERS AND SCISSOR ROLLER TRACKS D.

2-5 Page 38 August 2017

REMOVE REAR SCISSOR ROLLER TRACKS FROM THE DECK (1)

At the rear of the deck, remove and discard the ten (10) fasteners that secure each of the scissor roller tracks to the deck. Refer to Figure 18.

(2)

Remove the scissor roller tracks and backing plates.

(3)

Remove the maintenance stands and stow them in the maintenance stand stowing locations on the chassis.

(4)

Start the engine. Slowly lower the deck until the deck saddles contact the helper cylinders. Continue to slowly lower the deck until the rear side shift assembly rolls out from the rear of the deck and is exposed. Refer to Figure 19.

MAINTENANCE AND REPAIR

Halvorsen DECK SADDLES

REAR SIDE SHIFT BOGY ASSEMBLY SUPPORT LOCATION

Figure 19 REAR SIDE SHIFT CYLINDER REMOVAL

13.

(5)

Position fork lift tines under the center of the side shift bogy assembly so they are completely and safely supporting the assembly. Refer to Figure 19.

(6)

Remove and discard the four (4) fasteners that attach each rear roll cylinder to the scissors. Refer to Figure 16. The forklift may need to be temporarily adjusted during this process to remove the load on the roll cylinder hardware.

(7)

Remove the rear roll cylinder bogy assembly.

REAR DECK SHIFT AND ROLL CYLINDERS INSTALLATION A.

INSTALL REAR SIDE SHIFT BOGY ASSEMBLY (1)

Place the side shift cylinder bogy assembly on the ends of fork lift tines and secure the assembly to prevent it from rolling.

(2)

Slowly position the side shift cylinder bogy assembly until the roll cylinders are within the supporting plates on the scissors.

(3)

Install the eight (8) fasteners that secure both roll cylinders to the scissors.

(4)

Tighten the fasteners to standard specifications.

(5)

Start the engine. Slowly raise the deck until the outer scissor upper rollers pass through the openings in the deck and contact the upper scissor roller tracks.

(6)

Continue to raise the deck past the first support block position and install both maintenance stands in the FIRST maintenance stand position. Lower the deck until the scissor rollers are resting on both maintenance stands.

(7)

Shut down the engine and turn the battery disconnect OFF.

MAINTENANCE PROCEDURES

2-5 Page 39 August 2017

Halvorsen B.

C.

D.

2-5 Page 40 August 2017

CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS (1)

Install new hydraulic fittings with O-ring seals in the hydraulic side shift cylinder ports. Refer to Figure 17.

(2)

Connect the two (2) hydraulic hoses to the front side shift cylinder. Refer to markings on the hydraulic hoses for correct installation locations.

(3)

Tighten hydraulic connections.

CONNECT THE ROLL CYLINDER HYDRAULICS (1)

Install new hydraulic 45 degree hydraulic fittings with O-ring seals in the hydraulic roll cylinder ports. Refer Figure 16.

(2)

Connect the four hydraulic hoses to the roll cylinders. Refer to markings on the hydraulic hoses and roll cylinder for correct installation locations.

(3)

Tighten hydraulic connections.

(4)

Operate the deck shift and roll functions to verify no hydraulic fluid leaks exist. Be sure the deck is center and level before proceeding.

(5)

Start the engine. Raise the deck high enough so the outer scissor upper rollers on the ends of the rear side shift cylinder are in front of the rear scissor roller tracks attached to the deck. Refer to Figure 18.

(6)

Shut down the engine, turn the battery disconnect OFF and install both maintenance stands in the SECOND maintenance stand position. Do not lower the deck until instructed to do so.

INSTALL REAR SCISSOR ROLLER TRACKS ON THE DECK (1)

At the rear of the deck, install the rear scissor tracks and backing plate Refer to Figure 18.

(2)

Torque all fasteners to 61 N·m (45 lbf-ft.) and then torque all fasteners to 88 N·m (65 lbf-ft.) to avoid distorting the roller track.

(3)

Start the engine. Remove the maintenance stands and stow them in the maintenance stand stowing locations on the chassis.

(4)

Lower the deck until it is completely resting on the chassis frame.

MAINTENANCE AND REPAIR

Halvorsen 14.

REPLACE FAN BELTS NOTE: (1)

Disconnect turbo-charger air induction hose from the air cleaner.

(2)

Remove the hardware that secures the air cleaner assembly to the support bracket and remove the air cleaner as a complete assembly.

(3)

Remove the cap screw and washer, on the generator belt tension adjuster.

(4)

Remove the belts from the generator sheave and then pull the generator outward to access the socket head screws that secure the main hydraulic pump-mounting bracket to the engine block.

(5)

Support the pump assembly with an engine hoist or a floor jack, then remove the four (4) socket head screws that secure the pump bracket to the engine block.

NOTE: (6) NOTE: (7) NOTE:

15.

APPLY THREAD LOCKING COMPOUND (LOCTITE) ON ALL SCREW THREADS.

DO NOT REMOVE ANY HYDRAULIC LINES. Carefully pull the pump and mounting bracket, as an assembly away from the engine until there is sufficient clearance in the coupling to remove the belts. IT MAY BE NECESSARY TO USE A SMALL PRY BAR TO SEPARATE THE COUPLING. USE CARE TO PREVENT DAMAGE TO THE ELEMENT. Remove the old belts and install the new belts. Position the belts around the crankshaft pulley and water pump sheave. ALWAYS INSTALL A MATCHED SET OF BELTS WHEN REPLACING BELTS.

(8)

Move the pump assembly back into position. Coupling drive pins must be aligned to enter the coupling element without force.

(9)

Install the four (4) socket head screws to secure the pump assembly to the motor block. Tighten the cap screws securely.

(10)

After the socket head screws are tightened, remove the engine hoist or floor jack.

(11)

Move the generator back into place and install the belts on the sheave.

(12)

Install the cap screw and washer in the belt tension adjuster and generator and tighten after the belts have been tensioned.

(13)

Install the air cleaner assembly and reconnect the induction hose for the turbo-charger.

HYDRAULIC PUMP REMOVAL AND INSTALLATION NOTE: A.

BEFORE THE REMOVAL OF THE HYDRAULIC PUMP FOR REPLACEMENT, CONTACT JBT FOR INSTRUCTIONS.

HYDRAULIC PUMP REMOVAL FROM CHASSIS (1)

Disconnect the turbo-charger air induction hose from the air cleaner.

(2)

Remove the hardware that secures the air cleaner assembly to the support bracket and remove the air cleaner as a complete assembly.

(3)

Remove the cap screw and washer, on the generator belt tension adjuster.

MAINTENANCE PROCEDURES

2-5 Page 41 August 2017

Halvorsen (4)

Remove the belts from the generator sheave and then pull the generator outward to access the socket head screws that secure the main hydraulic pump mounting bracket to the engine block.

(5)

On the rear of the hydraulic reservoir remove the plug on top of the elbow for the oil supply line to the hydraulic pump. This will allow air to enter the elbow to prevent the siphon of oil when the suction hose is removed from pump.

(6)

Remove the hydraulic lines on the pump.

NOTE:

THERE WILL BE A LOSS OF SOME HYDRAULIC FLUID AND THE USE OF DRAIN PANS WILL BE REQUIRED WHEN THE FLUID HOSES ARE REMOVED.

(7)

Cap or plug, all open hydraulic lines to prevent contamination of the fluid system when the pump is removed.

(8)

Support the pump assembly with an engine hoist or a floor jack, then remove the four (4) socket head screws that secure the pump bracket to the engine block.

(9)

Carefully pull the pump and mounting bracket, as an assembly away from the engine and out of the chassis.

NOTE:

IT MAY BE NECESSARY TO USE A SMALL PRY BAR TO SEPARATE THE COUPLING. USE CARE TO PREVENT DAMAGE TO THE ELEMENT.

(10)

Remove the three (3) radial socket head cap screws that hold the drive element on the coupling hub on the pump shaft and remove the element.

(11)

Loosen the two socket head set screws in the coupling hub and remove the hub from the pump shaft.

(12)

Remove the two cap screws that secure the pump to the pump bracket weldment.

B.

HYDRAULIC PUMP INSTALLATION

CAUTION FAILURE TO POSITION AND ORIENT THE COUPLING CORRECTLY COULD CAUSE DAMAGE TO THE COUPLING AND PUMP. NOTE:

ALWAYS REPLACE HYDRAULIC FILTER ELEMENTS WHEN INSTALLING A NEW PUMP.

NOTE:

MOUNTING SURFACES MUST BE SMOOTH AND CLEAN ON THE PUMP BRACKET.

2-5 Page 42 August 2017

(1)

Attach the pump to the pump bracket weldment with the two (2) cap screws and nuts.

(2)

Slide coupling hub onto the pump shaft, noting the orientation of the internal splines. The spline portion of the hub must be installed over the splines of the pump shaft. Refer to Figure 20.

MAINTENANCE AND REPAIR

Halvorsen

DEPTH OF SHAFT FACE TO HUB FACE TO BE APPROX. .93 INCHES.

ORIENT HUB SO THAT NONSPLINED PORTION IS FACING OUT, AWAY FROM PUMP.

Figure 20 COUPLING HUB (3)

The distance from the front of the hub to the face of the pump shaft should be approximately 23 mm (0.93 in.). Refer to Figure 20.

(4)

When the coupling hub has been properly positioned, torque the two (2) set screws in the hub to 122 N·m (90 lbf-ft.).

(5)

Install the coupling element on the pump hub with the side with the extended radial lugs facing towards the coupling hub on the engine. Refer to Figure 21.

MAINTENANCE PROCEDURES

2-5 Page 43 August 2017

Halvorsen ALIGN HOLES FOR BOLT INSTALLATION

CUT OUT FOR BELTS

EXTENDED SHORTER SIDE

Figure 21 COUPLING ELEMENT INSTALLATION (6) NOTE:

2-5 Page 44 August 2017

Apply a small amount of grease to the underside of the heads on the three (3) special socket head cap screws and insert in the element and thread into the hub. THREADS ON THE RADIAL AND AXIAL CAP SCREWS ARE COATED WITH MICRO-ENCAPSULATED ADHESIVE. DO NOT USE ANAEROBIC ADHESIVES (SUCH AS LOCTITE). AS THEY HAVE A DETRIMENTAL EFFECT ON THE BOND BETWEEN THE RUBBER AND THE INSERT. RECOMMENDED ADHESIVES ARE 3M MICROTITE. SCREWS THAT ARE PROVIDED WITH THIS ADHESIVE MAY BE USED UP TO THREE (3) TIMES.

(7)

With a torque wrench, tighten the three (3) radial cap screws to 203 N·m (150 lbf-ft.).

(8)

Element must not be twisted when tightening the cap screws. After tightening the radial cap screws, inspect the element for not being twisted. Refer to Figure 22.

MAINTENANCE AND REPAIR

Halvorsen

Figure 22 ELEMENT ALIGNMENT (9)

Install the pump and bracket assembly on the engine.

NOTE:

THIS REQUIRES THE USE OF A PORTABLE ENGINE HOIST OR A FLOOR JACK, FOR THE SUPPORT OF THE PUMP ASSEMBLY DURING THE INSTALLATION PROCESS.

(10)

Move the pump assembly into position with the fan belts in the pump bracket cut out. Rotate the pump coupling to align the drive pins on the engine flange to match the mating holes in the element. Refer to Figure 22.

(11)

Install the four (4) socket head screws to secure the pump assembly to the motor block and tighten the cap screws.

NOTE:

APPLY THREAD LOCKING COMPOUND (LOCTITE) ON THE SCREW THREADS.

(12)

Move the generator back in place and install the belts on the sheave.

(13)

Install the cap screw and washer in the belt tension adjuster and generator. Tighten after the belts have been tensioned.

(14)

Remove the plugs and caps and reconnect the hydraulic hoses to the pump.

NOTE:

USE NEW O-RINGS ON THE HOSE FLANGE FITTINGS.

NOTE:

PUMP CAN BE DAMAGED IF IT IS NOT PRIMED.

(15)

Fill pump suction hose with hydraulic fluid to prime the pump, then install the plug and tighten securely.

NOTE:

FILL THE SUCTION HOSE THROUGH THE FITTING ON THE TOP OF THE ELBOW ON THE BACK OF THE HYDRAULIC RESERVOIR.

(16)

Install the air cleaner assembly and reconnect the induction hose for the turbo-charger.

(17)

Start the engine and allow engine to run a minimum of 10 minutes at idle speed.

(18)

Check reservoir for correct hydraulic fluid level.

MAINTENANCE PROCEDURES

2-5 Page 45 August 2017

Halvorsen 16.

CHANGING WHEELS ON FRONT AXLE

CAUTION DO NOT PLACE HYDRAULIC JACK UNDER THE BOWL IN THE CENTER OF THE AXLE HOUSING.

CAUTION USE A WHEEL CHANGING JACK OR TWO PERSONS, TO REMOVE AND INSTALL THE WHEEL ASSEMBLY.

CAUTION TO PREVENT FATIGUE AND FRACTURING OF THE WHEEL BOLTS WHEN USING IMPACT TOOLS, DO NOT ALLOW THE IMPACT TOOLS TO “HAMMER” AFTER THE NUT IS SEATED. A.

FRONT AXLE WHEEL REMOVAL

B.

(1)

Turn the battery disconnect switch on the battery box to the OFF position.

(2)

Loosen lug nuts on wheel to be removed, 1/4–1/2 turn.

(3)

Position a hydraulic jack (10-ton minimum capacity) directly under the axle mounting pad and raise the chassis until the tire is off the ground.

(4)

Place a fixed stand or shoring under the frame for safety, before removing the wheel assembly.

(5)

Remove all the lug nuts on the wheel assembly and then remove the wheel assembly from the planetary hub.

FRONT AXLE WHEEL INSTALLATION (1)

Inspect the threads on the wheel bolts and nuts for damage. Replace all damaged hardware before mounting the wheel assembly.

(2)

Check all mounting surfaces for being smooth and clear.

NOTE: (3)

Carefully lift the wheel assembly and install on the planetary wheel hub. Slide the assembly into position over the wheel bolts, taking care not to damage the bolt threads.

(4)

Install the wheel nuts loosely, by hand, to ensure that they are not cross threaded and turn freely on the threads.

(5)

Tighten the wheel nuts in a cross pattern to approximately 136–205 N·m (100–150 lbf-ft.) of torque.

NOTE:

2-5 Page 46 August 2017

NO LUBRICANTS ARE PERMITTED ON MOUNTING SURFACES OR ON THE THREADS OF THE WHEEL BOLTS AND WHEEL NUTS.

MAKE SURE THAT WHEEL NUTS CENTER IN THE HOLES TO ALIGN THE WHEEL ON THE WHEEL BOLTS.

MAINTENANCE AND REPAIR

Halvorsen 17.

(6)

Raise chassis slightly with the hydraulic jack and remove the safety stand or shoring.

(7)

Lower the loader to ground level and remove the hydraulic jack or other lifting device.

(8)

Using an accurate torque wrench, torque all wheel nuts in a cross pattern to 271 N·m (200 lbf-ft.).

CHANGING WHEELS ON REAR AXLE (BOGY WHEELS)

WARNING CHOCK THE BOGY WHEELS ON THE OPPOSITE SIDE OF THE LOADER, TO PREVENT MOVEMENT IN EITHER DIRECTION, APPLY THE PARKING BRAKE AND TURN OFF THE ENGINE.

CAUTION USE A WHEEL CHANGING JACK OR TWO PERSONS, TO REMOVE AND INSTALL THE WHEEL ASSEMBLY.

CAUTION TO PREVENT FATIGUE AND FRACTURING OF THE WHEEL BOLTS WHEN USING IMPACT TOOLS, DO NOT ALLOW THE IMPACT TOOLS TO “HAMMER” AFTER THE NUT IS SEATED. A.

REAR AXLE WHEEL REMOVAL (BOGY WHEELS) (1)

Raise the deck and install the maintenance safety blocks in the first position and lower the deck until the scissors rollers are against the blocks.

(2)

Measure the height from the bottom of the frame side rail to the ground surface just forward of the bogy axle pivot shaft (jacking point) and the height of the hydraulic jack that will be used to change the wheel assembly. Refer to Figure 23.

NOTE: (3)

NOTE:

HYDRAULIC JACK MUST HAVE A MINIMUM RATED CAPACITY OF 10 TONS. If there is insufficient clearance to place a jack under the frame side rail, due to the condition of the tire and tread wear, it is permissible to drive the loader onto blocking (shoring) to obtain an increase in frame height. DO NOT DRIVE THE DEFLATED TIRE ONTO BLOCKING.

(4)

Wrap a chain or cargo straps around the bogy pivot shaft and the chassis cross members, to secure the bogy axle pivot shaft to the chassis. Refer to Figure 23.

(5)

Loosen lug nuts on wheel to be removed, 1/4–1/2 turn.

(6)

Position a hydraulic jack (10-ton capacity, min.) directly under and in the center of the chassis frame. Raise the chassis until the tires are off the ground. Refer to Figure 23.

(7)

For safety place a fixed stand or shoring under the chassis at the rear. Refer to Figure 23.

(8)

Remove all the lug nuts on the wheel assembly and then remove the wheel assembly from the wheel hub.

MAINTENANCE PROCEDURES

2-5 Page 47 August 2017

Halvorsen SAFETY STAND / SHORING

JACKING POINT SECURE PIVOT SHAFT TO CHASSIS WITH CHAIN

Figure 23 JACKING POINT B.

REAR AXLE WHEEL INSTALLATION (BOGY WHEELS) (1)

Inspect the threads on the wheel bolts and nuts for damage. Replace all damaged hardware before mounting the wheel assembly.

(2)

Check all mounting surfaces for being smooth and clear.

NOTE: (3)

Carefully lift the wheel assembly and install on the planetary wheel hub. Slide the assembly into position over the wheel bolts, taking care not to damage the bolt threads.

(4)

Install the wheel nuts loosely, by hand, to ensure that they are not cross threaded and turn freely on the threads.

(5)

Tighten the wheel nuts in a cross pattern to approximately 136–203 N·m (100–150 lbf-ft.) of torque.

NOTE: (6)

2-5 Page 48 August 2017

NO LUBRICANTS ARE PERMITTED ON MOUNTING SURFACES OR ON THE THREADS OF THE WHEEL BOLTS AND WHEEL NUTS.

MAKE SURE THAT WHEEL NUTS CENTER IN THE HOLES TO ALIGN THE WHEEL ON THE WHEEL BOLTS. Raise chassis slightly with the hydraulic jack and remove the safety stand or shoring.

MAINTENANCE AND REPAIR

Halvorsen

18.

(7)

Lower the loader to ground level and remove the hydraulic jack.

(8)

Using an accurate torque wrench, torque all wheel nuts in a cross pattern to 271 N·m (200 lbf-ft.).

(9)

Remove the chain or strap that is wrapped around the bogy pivot axle and chassis.

(10)

Start engine and lower the deck.

HYDRAULIC FLUID LEVEL AND REFILLING There are two sets of fluid level marks on the hydraulic reservoir. The marks on the aft end of the reservoir are used to check the fluid level when the loader deck is in the fully lowered position. The fluid level marks on the side of the tank are used to observe the fluid level when the reservoir is being filled and the deck is elevated with the lower scissors rollers resting against the maintenance blocks that have been placed in the first maintenance position.

CAUTION DO NOT OVERFILL THE HYDRAULIC RESERVOIR. RESERVOIR CAN BE DAMAGED IF THE OIL LEVEL IS ABOVE THE “FULL” MARK, ON THE AFT END OF THE RESERVOIR, WHEN THE DECK IS FULLY LOWERED. NOTE:

A.

MAINTAIN FLUID LEVEL IN THE HYDRAULIC RESERVOIR BETWEEN THE HIGH AND LOW MARKS ON THE AFT END OF THE HYDRAULIC RESERVOIR WITH DECK FULLY LOWERED.

CHECKING FLUID LEVEL (1)

Check fluid level in the hydraulic fluid reservoir daily by observing the fluid level in the sight gauge and the marks on the aft end of the reservoir when the deck is fully lowered. Refer to Figure 24.

(2)

Maintain oil level between the HIGH and LOW marks.

NOTE:

DO NOT OPERATE LOADER WHEN THE FLUID LEVEL IN THE SIGHT GLASS IS BELOW THE “LOW” LEVEL MARK.

MAINTENANCE PROCEDURES

2-5 Page 49 August 2017

Halvorsen

Figure 24 FLUID LEVEL MARKS B.

REFILLING HYDRAULIC RESERVOIR NOTE:

2-5 Page 50 August 2017

HYDRAULIC FLUID MUST BE FILTERED TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM WHEN ADDING FLUID OR REFILLING THE RESERVOIR.

(1)

Start the engine and raise the deck. Insert the maintenance blocks in the first maintenance position and then lower the deck until the scissor rollers are against the maintenance blocks. Shut the engine down.

(2)

Clean the FILL POINT cap and fitting on the suction filter located on the top of the hydraulic fluid reservoir. Refer to Figure 24).

(3)

Remove the cap on the fill point fitting.

(4)

Connect the hose from the filter on the service vehicle or fluid storage tank, to the FILL POINT fitting on the reservoir.

MAINTENANCE AND REPAIR

Halvorsen (5)

19.

Add fluid to the reservoir until the fluid level in the sight glass is between the HIGH and LOW marks on the side of the reservoir (refer to Figure 24).

NOTE:

MARKS ARE IDENTIFIED AS “FIRST MX STAND”.

NOTE:

DO NOT USE MARKS ON AFT END OF RESERVOIR.

(6)

Remove hose from the FILL POINT fitting and install the protective cap.

(7)

After adding fluid or refilling the reservoir, start the engine, remove the maintenance blocks and lower the deck fully.

(8)

Recheck fluid level when the deck is fully down. Observe the fluid level in the sight glass and the fluid level marks on the aft end of the reservoir.

BATTERY MAINTENANCE CHARGING AND STORAGE The battery box is located on the right side of the loader. The batteries used in the loader are sealed and maintenance free. The cells do not have vent caps and no provision is made for adding electrolyte or checking electrolyte level. Ensuring that the battery restraints are secure and that there is no corrosion forming on the cable terminals is all that is required for service.

WARNING STORAGE OF BATTERIES GENERATE HYDROGEN GAS THAT IS EXPLOSIVE. KEEP ALL OPEN FLAMES AND SPARKS AWAY FROM BATTERIES.

WARNING A COMPLETELY DISCHARGED OR FROZEN BATTERY CAN EXPLODE IF POWER IS APPLIED. FROZEN BATTERIES MUST BE ALLOWED TO WARM GRADUALLY TO NORMAL ROOM TEMPERATURE BEFORE USING.

WARNING WHEN REMOVING A BATTERY, ALWAYS DISCONNECT THE CABLES ON THE GROUND TERMINALS FIRST TO PREVENT A SPARK. ALWAYS CONNECT THE GROUND CABLE LAST WHEN CONNECTING CABLES.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE. A.

BATTERIES CHARGING To ensure proper charging of your battery, Deltran Corporation and Hawker Energy Products Inc have developed a special charge algorithm that is designed to rapidly and safely charge these batteries. They are available in 6 A, 10 A, 15 A and 20 A versions. Since these are automatic chargers no manual intervention is necessary. We suggest the following Deltran chargers to get

MAINTENANCE PROCEDURES

2-5 Page 51 August 2017

Halvorsen peak performance from your battery (charger rating 20 A charger, recommended model use on PC 1700 or smaller battery). As an alternative small portable automotive chargers may also be used to charge your battery. B.

CHARGER OUTPUT VOLTAGE Determining the charger output voltage is the most important step in the charger qualification process. NOTE:

C.

IF THE VOLTAGE OUTPUT FROM THE CHARGER IS LESS THAN 14.2 V OR MORE THAN 15 V FOR A 12 VDC BATTERY DO NOT USE THE CHARGER.

CHARGER TYPE - AUTOMATIC OR MANUAL The two broad types of small portable charger available today are classified as either automatic or manual. Automatic charger can be further classified as those that charge the battery up to a certain voltage and then shut off and those that charge the battery up to a certain voltage and then switch to a lower float (trickle) voltage. The trickle charger type of automatic charger is preferred.

D.

SELECTING BATTERY TYPE ON YOUR CHARGER OUTPUT In general, do not use either the gel cell or maintenance free setting. If provided on your charger. Choose the deep cycle option, should there de one on your charger. For maximum life from your battery we recommend that you switch your charger to the 2 A trickle charger position and leave the battery connected to the charger for a further six to eight hours. If the battery is only partially discharged, the charge times should be appropriately reduced. The battery should however be placed on trickle charge (2 A setting) regardless of its initial state of charge (SOC).

E.

BATTERIES STORAGE NOTE:

20.

THE BATTERY MUST BE CHARGED BEFORE STORAGE. YOUR BATTERY CAN BE STORED AT A TEMPERATURE OF 25 ºC (77 ºF) FOR UP TO TWO YEARS. THE LOWER THE TEMPERATURE THE LONGER THE STORAGE TIME FOR YOUR BATTERY. IF THE TEMPERATURE RISES TO ABOUT 35 ºC (95 ºF) THE BATTERY MAY BE STORED FOR ONLY ONE YEAR BEFORE IT NEEDS TO BE RECHARGED.

BATTERY REMOVAL AND REPLACEMENT

WARNING ENGINE MUST BE SHUT DOWN AND THE EXTERNAL POWER CORD MUST BE DISCONNECTED WHEN REMOVING AND REPLACING BATTERIES. A.

2-5 Page 52 August 2017

REMOVE BATTERY (1)

Turn battery disconnect switch on the battery box to the OFF position. Refer to Figure 25.

(2)

Remove cover from battery box.

(3)

Disconnect the ground cable from the negative (-) battery terminal first.

(4)

Disconnect the cable from the positive (+) battery terminal.

MAINTENANCE AND REPAIR

Halvorsen

Figure 25 BATTERY DISCONNECT SWITCH (5)

Remove the battery hold-down restraint from the battery to be removed.

(6)

Remove the battery from the box.

MAINTENANCE PROCEDURES

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Halvorsen B.

21.

INSTALL BATTERY (1)

Place the battery in the battery box and note that the negative (-) terminal post is oriented in the correct position.

(2)

Install the battery hold-down restraint and tighten the bolts to prevent any movement. Over-tightening of the restraining bolts can cause distortion and damage to the battery.

(3)

Coat the battery terminal posts with anti-corrosion compound.

(4)

Install and tighten the cable on the positive (+) battery terminal first.

(5)

Install and tighten the ground cables on the negative (-) battery terminal last.

(6)

Replace the battery box cover.

RADIATOR REMOVAL AND INSTALLATION

WARNING COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO RELEASE BEFORE COMPLETELY REMOVING IT.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE. A.

RADIATOR REMOVAL Refer to Figure 26).

2-5 Page 54 August 2017

(1)

Drain coolant into an approved container.

(2)

Remove top vent hoses and fittings (item 5)

(3)

Mark, remove and cap transmission cooler lines.

(4)

Remove fasteners from fuel filter (item 7) and set aside.

(5)

Loosen upper and lower radiator hose clamps

(6)

Loosen isolator bolts (items 2 and 3) and isolator nuts (item 4) and remove grill assembly (item 6) from the front of the radiator.

(7)

Remove isolator bolts (items 2 and 3) and isolator nuts (item 4), remove isolators (item 1) and gaskets.

(8)

Slowly slide radiator out from bracket assembly, at the same time carefully removing upper and lower radiator hoses.

MAINTENANCE AND REPAIR

Halvorsen 5 6 7 1 4 EACH

2 3 8 EACH

4 4 EACH

Figure 26 RADIATOR COMPONENTS B.

RADIATOR INSTALLATION

CAUTION WHENEVER THE COOLING SYSTEM HAS BEEN DRAINED, YOU MUST BLEED ALL AIR FROM THE COOLING SYSTEM TO AVOID SERIOUS ENGINE DAMAGE. Refer to Figure 26. (1)

Ensure all surfaces are clean and free of debris. Inspect isolators for any damage (cracks or deformations to rubber), replace as necessary.

(2)

Apply new sealer to fan shroud surface.

(3)

Slide radiator into place, insuring upper and lower radiator hoses are placed over outlets.

(4)

Install isolators (item 1) new gaskets and nuts (item 4), leave nuts loose.

(5)

Install nuts and bolts (items 2 and 3), leave loose.

(6)

Install grill assembly (item 6), by sliding into place under the isolators and torque nut and bolts (items 2 and 3) to 47.5 N·m (35 lbf-ft.).

(7)

Torque nuts (item 4) to 47.5 N·m (35 lbf-ft.).

(8)

Install fuel filter (item 7).

MAINTENANCE PROCEDURES

2-5 Page 55 August 2017

Halvorsen 22.

(9)

Install transmission oil cooler lines.

(10)

Install vent hoses and fittings, tighten upper and lower radiator hose clamps.

(11)

Refill and bleed cooling system as outlined in ‘B. REFILL AND BLEED AIR FROM COOLING SYSTEM’.

COOLANT SYSTEM LEVEL AND REFILLING

WARNING COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO RELEASE BEFORE COMPLETELY REMOVING IT.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.

CAUTION WHENEVER THE COOLING SYSTEM HAS BEEN DRAINED, YOU MUST BLEED ALL AIR FROM THE COOLING SYSTEM TO AVOID SERIOUS ENGINE DAMAGE. NOTE: A.

THE COOLANT RESERVOIR HAS A SIGHT GLASS TO OBSERVE IF THERE IS AIR IN THE SYSTEM.

COOLANT LEVEL (1)

Coolant level must be checked daily in the coolant recovery tank.

(2)

Check coolant level in the coolant recovery tank and adjust fluid level as required. Refer to Figure 27.

(3)

The coolant level must be at the COLD mark when the engine is cold.

(4)

If the coolant level is below the COLD mark, add fluid to bring the level to the COLD mark.

NOTE:

2-5 Page 56 August 2017

NEVER ADD WATER TO THE COOLANT SYSTEM. USE COOLANT OF THE PROPER MIXTURE TO PROTECT THE ENGINE FROM FREEZING. USE A HYDROMETER TO CHECK THE COOLANT RATIO.

MAINTENANCE AND REPAIR

Halvorsen

Figure 27 COOLANT SERVICE AREA B.

C.

REFILL AND BLEED AIR FROM COOLING SYSTEM (1)

Ensure drain is closed on the bottom of the radiator and all hoses are properly connected.

(2)

Open petcock on the top of the radiator.

(3)

Refill then system slowly with the proper mixture of coolant (50%-50% mix; 60%-40% for arctic conditions).

(4)

Allow the system to settle from time to time as it is being filled.

(5)

Close the petcock when a steady stream of coolant is observed flowing from the top of the radiator.

(6)

Start the loader and allow the engine to reach normal operating temperature.

(7)

With the engine running at 1500 rpm slightly open the petcock on the top of the radiator to ensure all trapped air has been expelled.

(8)

Fill surge tank and reinstall cap, fill the coolant recovery tank to the hot level.

COLD WEATHER OPERATIONS NOTE:

COLD WEATHER OPERATION IS DEFINED AS SUSTAINED OPERATIONS AT OR BELOW -18 ºC (0 ºF).

Before loader is placed in a known cold weather area, perform the following steps.

MAINTENANCE PROCEDURES

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Halvorsen

23.

(1)

Change Anti-freeze level of protection to a 60%-40% mix of glycol and distilled water.

(2)

Drain and refill transmission with synthetic transmission fluid. (Recommend Allison Transmission fluid ATF TranSynd JBT part number 624-7415).

(3)

Replace engine drive belts with cold weather belts JBT part number 623-9550.

NOTE:

IF THE LOADER IS PARKED DURING COLD WEATHER CONDITIONS, THE WINTERIZATION SYSTEM SHOULD BE PLUGGED IN AND ACTIVATED AS OUTLINED IN CHAPTER 1, SECTION 2.

NOTE:

IF THE LOADER IS COLD SOAKED FOR A PERIOD OF MORE THAN 24 HOURS, THE WINTERIZATION SYSTEM WILL NEED TO OPERATE FOR MINIMUM OF 6 HOURS, BEFORE STARTING THE LOADER.

NOTE:

WINTERIZATION CABLE FOR COLD WEATHER PART NUMBER 624-7414.

AIR CONDITIONER INSPECTION AND MAINTENANCE (WITHOUT GAUGES) Inspect system for loose components, worn components, refrigerant leaks and other signs of malfunctioning components. Follow guidelines below during system inspection and maintenance procedures. NOTE: A.

FOR MAINTENANCE, SERVICE AND INSPECTION ENSURE THE MANUFACTURER’S MANUAL IS USED FOR ALL SPECIFICATIONS, REFERENCES AND PROCEDURES.

CONSIDERATIONS BEFORE MAINTENANCE Answer the following three questions while inspecting the air conditioning system: •

Has vehicle just come from operation and was A/C system used?

•

Did the operator or work order explain or describe air conditioning system problems?

•

If recent maintenance was performed on system, what was repaired?

Visual Inspection - System Off With air conditioning system off, inspect the following: (1)

Inspect all system parts for obvious signs of failure.

(2)

Check all hoses and fittings for indication of refrigerant leakage. Oily deposits on air conditioning system hoses and fittings may indicate a leak.

(3)

Check remaining components for signs of refrigerant leaks.

NOTE:

B.

FOR TROUBLESHOOTING THE A/C SYSTEM USING THE MANIFOLD GAUGES. REFER TO THE VISIONAIRE INC. MANUFACTURER’S MANUAL FOR HEAVY DUTY EQUIPMENT.

COMPONENTS INSPECTION The following components must be inspected during system maintenance and inspection: (1)

2-5 Page 58 August 2017

Condenser - Coils must be free of all obstructions such as dirt, mud, bugs, feathers and leaves to maintain proper air flow and heat transfer. Clean with soap and water or use an air hose with brush.

MAINTENANCE AND REPAIR

Halvorsen (2)

Compressor - Ensure the compressor mounting bolts are tight. Check for refrigerant and oil leaks. Ensure all connections are tight. The compressor must be free of dirt and obstructions that may hamper performance.

(3)

Evaporator - Ensure all drain hoses and check valves are intact and secure. Drain hoses must be free of obstruction to ensure proper disposal of condensation from system.

(4)

Air filter must be clean an intact and free of obstructions.

(5)

Ensure control switches are secure and operating properly.

(6)

Check all Hoses and Fittings - Inspect all hoses and fittings for leaks.

(7)

Any indication of refrigerant leaks or other malfunctions must be reported to the maintenance section as soon as possible.

NOTE:

24.

IT IS THE OPERATOR’S RESPONSIBILITY TO ENSURE ALL PROBLEMS FOUND DURING SYSTEM OPERATION, INSPECTION AND MAINTENANCE, ARE REPORTED TO MAINTENANCE PERSONNEL AS SOON AS POSSIBLE.

AIR CONDITIONING COMPONENT REPAIR OR REPLACEMENT Service and repair procedures are similar to other vehicle service work. However, many of the A/C system parts are made of soft metals such as copper, aluminum and brass. Caution must be taken when removing and installing soft metal parts to avoid damage that may degrade A/C system operation or cause premature A/C system failure.

CAUTION ALL OF THE SERVICE PROCEDURES DESCRIBED ARE ONLY PERFORMED AFTER AIR CONDITIONER SYSTEM REFRIGERANT HAS BEEN RECOVERED. NEVER USE REGULAR SHOP OIL OR JOINT COMPOUND TO LUBRICATE OR SEAL ANY A/C CONNECTIONS. ENSURE THE MANUFACTURER’S MANUAL IS PRESENT FOR REFERENCE. NOTE:

TO HELP PREVENT AIR, MOISTURE OR DEBRIS FROM ENTERING AN OPEN SYSTEM, CAP OR PLUG OPEN LINES, FITTINGS OR COMPONENTS AS SOON AS THEY ARE DISCONNECTED. IT’S IMPORTANT TO KEEP ALL CONNECTIONS, CAPS AND PLUGS CLEAN TO AVOID A/C SYSTEM CONTAMINATION. DEBRIS THAT MIGHT ENTER SYSTEM CAN CAUSE SERIOUS SYSTEM DAMAGE.

NOTE:

AS A GENERAL RULE IN A/C SERVICE, ALL REMOVED GASKETS AND O-RINGS MUST BE REPLACED DURING MAINTENANCE. NEVER REUSE GASKETS AND O-RINGS TO PREVENT LEAKS AND FAILURE. USE FRESH REFIGERANT OIL TO LUBRICATE CONNECTIONS, GASKETS AND O-RINGS DURING INSTALLATION.

The following components and parts should be inspected during scheduled and operator maintenance. •

Hoses and fittings

•

Lines

•

Expansion valves

•

Receiver-dryer and accumulator

•

Compressor

MAINTENANCE PROCEDURES

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Halvorsen A.

HOSES AND FITTINGS When replacing hoses be sure to use the same type and ID hose as that removed. When hoses or fittings are shielded or clamped to prevent vibration damage, ensure that these are in the proper position and secured as necessary. On R-134a systems make sure replacement hoses and O-rings used during reassembly are designed for use with R-134a. Use reusable fittings on the nylon-lined hose.

B.

AIR CONDITIONING LINES Always use two wrenches when connecting or disconnecting A/C fittings attached to metal lines. Copper and aluminum tubing used in A/C systems can kink or break easily. Tube O-ring type fittings require only 18 foot pounds of torque for correct sealing. Ensure all grommets or clamps used to prevent line vibration, are properly placed and secured during reassembly.

C.

AIR CONDITIONING EXPANSION VALVE To remove expansion valve from the system, remove the insulation, clean the area and disconnect the line receiver to drier. Remove the expansion valve from the evaporator inlet. Replace expansion valve if expansion valve failure was indicated by system operation or if debris is detected in the valve.

D.

RECEIVER-DRYER AND ACCUMULATOR The receiver-dryer and accumulator cannot be serviced or repaired. They should be replaced whenever the A/C system is opened for service. If the receiver-dryer or accumulator has a pressure switch to control the compressor, remove and save for installation on new unit.

E.

COMPRESSOR The compressor can fail due to shaft seal leaks, defective valve plates, bad bearings or problems associated with high pressure heat or lack of lubrication. Excessive heat, contaminated oil or back pressure in the case drain line can cause compressor failure. NOTE:

AIR CONDITIONING SYSTEM AND COMPRESSOR REQUIRE ADEQUATE REFRIGERANT OIL FOR LUBRICATION AND SAFE OPERATION. WHEN THE SYSTEM IS OPENED FOR SERVICE, CHECK THE COMPRESSOR OIL LEVEL AND ADD CLEAN REFRIGERATION OIL AS REQUIRED IN ACCORDANCE WITH MANUFACTURER SPECIFICATIONS. ROTARY COMPRESSORS THAT HAVE NO OIL SUMP ARE ESPECIALLY SUSCEPTIBLE TO FAILURE CAUSED BY INADEQUATE REFRIGERANT OIL. ENSURE THAT THE OIL RETURN SYSTEM IS CLEAN AND OPERATIONAL WHEN REPLACING A COMPRESSOR. WHEN ADDING OIL, USE ONLY SANDEN SP-20. ADD OIL INTO DISCHARGE LINE OR OIL SEPARATOR. NEVER ADD OIL TO THE SUCTION SIDE OF THE COMPRESSOR.

CAUTION EVEN WHEN TOLD OF AIR CONDITIONING SYSTEM DEFECT, ALWAYS PERFORM A VISUAL INSPECTION PRIOR TO CONNECTING THE MANIFOLD GAUGE SET. NEVER ATTEMPT TO ADD REFRIGERANT TO A SYSTEM UNTIL YOU HAVE MADE A COMPLETE VISUAL AND PERFORMANCE INSPECTION OF ALL OF THE COMPONENTS.

2-5 Page 60 August 2017

MAINTENANCE AND REPAIR

Halvorsen With system operating, inspect system components for cycling and cab temperature levels. Refer to the Manufacturer’s Manual for the following inspections:

25.

•

Check the Sight Glass.

•

Electrical System Inspection.

•

Troubleshooting and Service Procedures of the A/C System.

•

Troubleshooting by Manifold Gauge Set Readings.

•

Review Frequent Problem Areas.

•

Performance Inspection - Engine Running.

LEFT SIDE SKYLIGHT REMOVAL AND INSTALLATION A.

LEFT SIDE SKYLIGHT REMOVAL (1)

Use gasket scraper or other available tool to clean urethane sealant from between the edge of the side skylight and the cab pinch-weld of the cab. Refer to Figure 28.

Figure 28 CLEANING URETHANE SEALANT (2)

Use available tools to free the side skylight from the cab pinch-weld. Refer to Figure 28.

CAUTION BE CAREFUL NOT TO BEND PINCH-WELD WHEN REMOVING THE GLASS FROM THE ADHESIVE. (3)

Carefully remove the side skylight glass from the cab. Refer to Figure 29.

MAINTENANCE PROCEDURES

2-5 Page 61 August 2017

Halvorsen

Figure 29 REMOVING SKYLIGHT B.

LEFT SIDE SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION (1)

Clean dirt and debris from around the pinch-weld of cab. Using available tools, remove any remaining sealant to achieve a flat bonding surface. Refer to Figure 30.

Figure 30 CLEANING DIRT FROM PINCHWELD (2)

2-5 Page 62 August 2017

Clean remaining sealant from old skylight glass and reinsert into pinch-weld to check for flatness of cab surface. Grind and/or adjust surface as needed. If old glass is not available, a straight edge may be used to check for flatness. Refer to Figure 31.

MAINTENANCE AND REPAIR

Halvorsen

Figure 31 CHECK FOR FLATNESS OF CAB SURFACE (3)

Mask off edge around the pinch-weld area of cab to avoid any overspill of primer and sealant. Refer to Figure 32.

Figure 32 MASKING OFF EDGES C.

APPLY CAB PRIMER (1)

Read all manufacturing instructions on primers and sealants prior to the start of remaining steps.

(2)

Open K-SKYLIGHT SEALANT AND PRIMERS, part no. 627-2118. Shake can of DOW 5404 PINCHWELD PRIMER, part no. 627-2066, for a minimum of one minute.

(3)

Apply primer to side of pinch-weld surface of the cab using a clean dauber, part no. 627-2166. Refer to Figure 33.

(4)

Allow to dry for a minimum of six minutes.

MAINTENANCE PROCEDURES

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Halvorsen

Figure 33 APPLYING PRIMER TO PINCH-WELD D.

PREPARE LEFT SKYLIGHT GLASS FOR INSTALLATION (1)

Wearing clean gloves, lay WINDOW, LEFT SIDE SKYLIGHT, part no. 624-2980-002, on a clean surface with the “frit” side of glass facing up (dark band around perimeter facing up).

(2)

Clean the “frit” surface and the edge of the skylight glass with acetone or alcohol using a lint-free cloth. Wipe clean and dry with a clean lint-free cloth.

(3)

Mask off the inside edge of the “frit” area on the skylight glass. This is to avoid over spill of primer onto the glass. Mask should be placed at the “frit” edge or slightly overlapping less than 1/16 inch. Refer to Figure 34.

Figure 34 MASKING EDGE OF “FRIT” SURFACE E.

APPLY GLASS PRIMER TO LEFT SKYLIGHT GLASS NOTE: (1)

2-5 Page 64 August 2017

READ ALL MANUFACTURING INSTRUCTIONS ON PRIMERS AND SEALANTS PRIOR TO THE START OF REMAINING STEPS. Shake applicator stick of DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068, for a minimum of one minute.

MAINTENANCE AND REPAIR

Halvorsen (2)

While gently holding applicator stick with applicator sponge pointing up, apply pressure with thumb and forefinger to the color band at the top of the tube. Refer to Figure 35.

Figure 35 APPLYING PRESSURE TO TUBE (3)

Screw the applicator cap down to puncture the seal on the applicator stick. Refer to Figure 36.

Figure 36 PUNCTURING APPLICATOR (4) NOTE:

Hold applicator stick on the skylight glass over the “fritted” surface (black band around the perimeter of the glass). Press down until the tip “wets out.” EXCESSIVE SQUEEZING WILL NOT SPEED “WET OUT” AND CAN LEAD TO LEAKAGE AROUND THE TUBE. REFER TO FIGURE 37.

MAINTENANCE PROCEDURES

2-5 Page 65 August 2017

Halvorsen “WET OUT” OF TIP

Figure 37 WET OUT OF TIP (5)

Apply DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068, to the frit surface and glass edge of the side skylight glass. Allow to dry for a minimum of 6 minutes. Refer to Figure 38.

Figure 38 APPLICATION OF PRIMER TO FRIT SURFACE (6)

2-5 Page 66 August 2017

Remove tap from frit side of the glass.

MAINTENANCE AND REPAIR

Halvorsen F.

LEFT SIDE SKYLIGHT INSTALLATION (1)

Apply 1/4 inch bead of DOW U-400 HV SEALANT, part no. 627-2067, around pinch-weld, placing a bead on the center of the pinch-weld surface area. Refer to Figure 39.

Figure 39 APPLICATION OF SEALANT TO PINCH-WELD (2)

Place glass into pinch-weld area of the cab. Press down until glass is within 1/16 inch of flush to cab surface in order to distribute sealant between the bonding surfaces. Center glass within the pinch-weld area so that there is an even space around the glass perimeter. Refer to Figure 40.

Figure 40 INSTALLATION OF NEW GLASS (3)

Allow sealant to set for 10 minutes before proceeding.

(4)

Mask off the top surface of glass around its perimeter with tape. This is to avoid overspill of sealant onto glass. Refer to Figure 41.

MAINTENANCE PROCEDURES

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Halvorsen

Figure 41 MASKING PERIMETER OF GLASS (5)

Fill gap between pinch-weld and glass with DOW U-400 HV SEALANT, part no. 627-2067. Refer to Figure 42.

Figure 42 APPLICATION OF SEALANT (6)

Smooth sealant around perimeter of glass using a scraper or other available tool. Refer to Figure 43.

Figure 43 SCRAPING OF EXCESS SEALANT (7)

2-5 Page 68 August 2017

Allow to dry for 10 minutes then remove tape. Refer to Figure 44.

MAINTENANCE AND REPAIR

Halvorsen

Figure 44 FINISHED GLASS (8)

Allow sealant to dry. Sealant dry time depends on temperature and humidity. Use the following table to calculate relative dry time.

TABLE 1 - SEALANT DRYING TIMES (HOURS) Ambient Temperature ºC (ºF)

Relative Humidity %

4–10 (40–50)

10–16 (50–60)

16–21 (60–70)

21–27 (70–80)

27–32 (80–90)

32–38 (90–100)

38–43 (100–110)

43 + (110 +)

>90

7

5

4

3

2

2

2

2

70–90

8

6

5

3

2

2

2

2

50–70

8

7

5

4

3

2

2

2

30–50

24

12

7

5

3

3

3

2

10–30

24

24

12

7

6

5

5

4

MAINTENANCE PROCEDURES

2-5 Page 69 August 2017

Halvorsen 26.

TOP SKYLIGHT REMOVAL AND INSTALLATION A.

TOP SKYLIGHT REMOVAL (1)

Remove the six bolts securing the top skylight glass protective grate to the cab. Set grate and bolts aside, exposing the top skylight glass. Refer to Figure 45.

Figure 45 REMOVING PROTECTIVE GRATE (2)

Use gasket scraper or other available tools to clean all old urethane sealant from around the edge of the top skylight. Refer to Figure 46.

Figure 46 CLEANING URETHANE SEALANT (3)

2-5 Page 70 August 2017

Carefully remove skylight glass from cab.

MAINTENANCE AND REPAIR

Halvorsen B.

TOP SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION (1)

Clean any dirt and debris from around surface of cab. Using available tools, remove any remaining sealant to achieve a flat bonding surface. Refer to Figure 47.

Figure 47 CLEANING DIRT FROM PINCHWELD (2)

Mask off area around skylight opening of cab, approximately 3/4 inch from the edge, in order to avoid any overspill of primer and sealant. Refer to Figure 48.

Figure 48 MASKING OFF EDGES C.

APPLY PRIMER TO TOP SKYLIGHT PINCHWELD NOTE:

READ ALL MANUFACTURING INSTRUCTIONS ON PRIMERS AND SEALANTS PRIOR TO THE START OF REMAINING STEPS.

(1)

Open K-SKYLIGHT SEALANT AND PRIMERS, part no. 627-2118. Shake can of DOW 5404 PINCHWELD PRIMER, part no. 627-2066, for a minimum of one minute.

(2)

Apply primer to the top pinch-weld surface area of the cab using a clean dauber, part no. 627-2166. Refer to Figure 49.

MAINTENANCE PROCEDURES

2-5 Page 71 August 2017

Halvorsen

Figure 49 APPLYING PRIMER TO PINCHWELD (3) D.

Allow to dry for a minimum of six minutes.

PREPARE TOP SKYLIGHT GLASS FOR INSTALLATION (1)

Wearing clean gloves, lay WINDOW, SKYLIGHT, part no. 624-2980-004, on a clean surface with the frit side of the glass facing up (dark band around perimeter facing up).

(2)

Clean the frit surface and the edge of the skylight glass with acetone or alcohol using a lint-free cloth. Wipe clean and dry with a clean lint-free cloth.

(3)

Mask off the inside edge of the frit area on the skylight. This is to avoid overspill of primer onto the glass. Mask should be placed at frit edge or slightly overlapping less than 1/16 inch. Refer to Figure 50.

Figure 50 MASKING EDGE OF “FRIT” SURFACE E.

APPLY GLASS PRIMER TO TOP SKYLIGHT GLASS NOTE: (1)

2-5 Page 72 August 2017

READ ALL MANUFACTURING INSTRUCTIONS ON PRIMERS AND SEALANTS PRIOR TO THE START OF REMAINING STEPS. Shake applicator stick of DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068.

MAINTENANCE AND REPAIR

Halvorsen (2)

While gently holding applicator stick with applicator sponge pointing up, apply pressure with thumb and forefinger to the color band at the top of the tube. Refer to Figure 51.

Figure 51 APPLYING PRESSURE TO TUBE (3)

Screw the applicator cap down to puncture the seal on the applicator stick. Refer to Figure 52.

Figure 52 PUNCTURING APPLICATOR (4)

Hold applicator stick on the skylight glass over the fritted surface (black band around the perimeter of the glass). Press down until the tip “wets out”.

MAINTENANCE PROCEDURES

2-5 Page 73 August 2017

Halvorsen NOTE:

EXCESSIVE SQUEEZING WILL NOT SPEED “WET OUT” AND CAN LEAD TO LEAKAGE AROUND THE TUBE. REFER TO FIGURE 53.

“WET OUT” OF TIP

Figure 53 WET OUT OF TIP (5)

Apply DOW 5500 SA GLASS/FRIT PRIMER to the frit surface and glass edge of the top skylight glass. Allow to dry for a minimum of six minutes. Refer to Figure 54.

Figure 54 APPLICATION OF PRIMER TO FRIT SURFACE (6)

2-5 Page 74 August 2017

Remove tape from frit side of the glass.

MAINTENANCE AND REPAIR

Halvorsen F.

TOP SKYLIGHT GLASS INSTALLATION (1)

Apply 1/4 inch bead of DOW U-400 HV SEALANT, part no. 627-2067, to the cab around opening for top skylight glass, centering the bead within the primer area. Refer to Figure 55.

Figure 55 APPLICATION OF SEALANT TO PINCH-WELD (2)

Place glass centered over the opening in the cab. Press down until glass is within 1/8 inch of the cab surface in order to distribute sealant between the bonding surfaces. Refer to Figure 56.

Figure 56 INSTALLATION OF NEW GLASS (3)

Allow sealant to set for 10 minutes. Remove tape from around the skylight opening in the cab before proceeding.

(4)

Fill gap between the surface of the cab and the glass with DOW U-400 HV SEALANT, part no. 627-2067. Refer to Figure 57.

MAINTENANCE PROCEDURES

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Halvorsen

Figure 57 APPLICATION OF SEALANT (5)

Smooth sealant around perimeter of glass. Refer to Figure 58.

Figure 58 SMOOTHING SEALANT (6)

Allow to dry for 10 minutes, then replace top protective grate. Refer to Figure 59.

Figure 59 FINISHED SKYLIGHT

2-5 Page 76 August 2017

MAINTENANCE AND REPAIR

Halvorsen (7)

Allow sealant to dry. Sealant dry time depends on temperature and humidity. Use the following table to calculate relative dry time.

TABLE 2 - SEALANT DRYING TIMES (HOURS) Ambient Temperature ºC (ºF)

Relative Humidity %

4–10 (40–50)

10–16 (50–60)

16–21 (60–70)

21–27 (70–80)

27–32 (80–90)

32–38 (90–100)

38–43 (100–110)

43 + (110 +)

>90

7

5

4

3

2

2

2

2

70–90

8

6

5

3

2

2

2

2

50–70

8

7

5

4

3

2

2

2

30–50

24

12

7

5

3

3

3

2

10–30

24

24

12

7

6

5

5

4

(8)

Clean up all remaining tape and tape residue. Discard old skylight glass and any remaining sealant and primers per site regulations.

MAINTENANCE PROCEDURES

2-5 Page 77 August 2017

Halvorsen 27.

HYDRAULIC SYSTEM ADJUSTMENTS

WARNING HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF THE POWER UNIT AND DEPLETE SYSTEM PRESSURE BEFORE INSPECTING OR LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP AWAY FROM HYDRAULIC LEAKS. DO NOT ATTEMPT TO “FEEL” FOR THE SOURCE OF A LEAK. PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER SERIOUS INJURY.

WARNING DO NOT REMOVE GAUGE PORT PLUGS AND GAUGES OR LOOSEN HYDRAULIC CONNECTIONS WITH THE POWER UNIT RUNNING. HYDRAULIC PRESSURE IN THE SYSTEMS COULD CAUSE HYDRAULIC OIL TO SPRAY ON PERSONNEL.

CAUTION WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS, CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.

28.

NOTE:

THE HYDRAULIC OIL MUST BE AT NORMAL OPERATING TEMPERATURE WHEN MAKING PERFORMANCE CHECKS, HYDRAULIC SYSTEM PRESSURE CHECKS OR HYDRAULIC SYSTEM ADJUSTMENTS. REFER TO CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS” FOR HYDRAULIC OIL INFORMATION.

NOTE:

IN MOST CASES ‘SPECIFIED PRESSURE’ + ‘STAND-BY PRESSURE’ = ‘INDICATED PRESSURE’.

NOTE:

AN ASSISTANT IS REQUIRED TO PERFORM MOST ADJUSTMENT PROCEDURES.

NOTE:

OVER-TIGHTENING THE JAM NUT WILL BREAK THE ADJUSTING SCREW.

CHASSIS MANIFOLD ADJUSTMENTS A.

LOAD SENSE MARGIN PRESSURE (1) NOTE:

2-5 Page 78 August 2017

Install a differential pressure gauge on chassis manifold. A DIFFERENTIAL PRESSURE GAUGE RATED TO 5000 PSI MAXIMUM LINE PRESSURE AND MAGNETICALLY COUPLED TO PREVENT DAMAGE TO THE GAUGE IS REQUIRED WHEN MAKING THIS ADJUSTMENT (ORANGE RESEARCH INC. PART NO. 1303PG-1C-3.5B-0-350 PSID).

(2)

Remove the 5000 psi gauge that is installed on the chassis manifold. Refer to Figure 60.

(3)

Connect the port marked “HI” on the differential pressure gauge to the port from which the 5000 psi gauge was removed.

MAINTENANCE AND REPAIR

Halvorsen (4)

Connect the port marked “LO” on the differential pressure gauge to the port marked “TP1” on the chassis manifold. Refer to Figure 62.

5000 PSI PRESSURE GAUGE

REMOVE 5000 PSI GAUGE

Figure 60 HYDRAULIC PRESSURE GAUGE (5)

Start the engine and then raise the deck.

(6)

Observe the differential pressure gauge when the deck is rising and record the indicated pressure: Indicated pressure should be 290–305 psid.

(7)

Stop the deck.

(8)

Adjust load sense margin pressure by loosening the lock nut and turning the “A” load sense adjusting screw clockwise to increase pressure and counterclockwise to decrease pressure. Refer to Figure 63.

NOTE:

B.

TURNING CLOCKWISE WILL INCREASE PRESSURE 90 PSID PER TURN. TURNING COUNTERCLOCKWISE WILL DECREASE PRESSURE 90 PSID PER TURN.

(9)

Recheck pressure by repeating steps (5) through (8).

(10)

Shut down engine, remove differential gauge and re-install the 5000 psi gauge that was removed.

MAIN RELIEF VALVE AND PUMP COMPENSATOR PRESSURE Refer to Figure 61, Figure 62 and Figure 63. (1)

Locate the main relief valve and pressure gauge on the chassis manifold.

(2)

Loosen the lock nut on the “B” pressure compensator adjusting screw and turn the adjusting screw 3 to 4 turns counterclockwise.

MAINTENANCE PROCEDURES

2-5 Page 79 August 2017

Halvorsen (3)

Loosen the lock nut on the main relief valve pressure adjustment screw and turn the adjusting screw clockwise all the way in.

(4)

Remove the wires from the coil on 7 SOL valve on chassis manifold.

(5)

Start engine.

(6)

Move and hold the deck lift switch in the UP position.

(7)

Turn the pressure compensator adjusting screw slowly clockwise until a pressure of 241 bar (3500 psi) is indicated on the gauge.

NOTE:

2-5 Page 80 August 2017

THE FOLLOWING STEPS (8) AND (9), MUST BE MADE RAPIDLY BECAUSE THE HYDRAULIC PUMP WILL BE DELIVERING ITS MAXIMUM FLOW AT HIGH PRESSURE AND THE ENGINE HORSEPOWER IS BEING CONVERTED TO HEAT IN THE HYDRAULIC OIL THAT FLOWS OVER THE RELIEF VALVE.

(8)

Main relief valve pressure setting - Turn the pressure adjusting screw on the main relief valve counterclockwise to lower the pressure to 241 bar (3500 psi) and tighten the adjusting screw lock nut. You will hear the engine “load” as the relief valve opens to bypass the excess flow from the pump to the reservoir.

(9)

Pressure compensator setting - Immediately after adjusting the main relief valve, turn the pressure compensator adjusting screw slowly counterclockwise to an indicated pressure of 220 bar (3200 psi) on the gauge and tighten the lock nut on the adjusting screw.

(10)

Release the lift switch.

(11)

Reinstall the wires on 7 SOL.

(12)

Remove the maintenance stands.

(13)

Lower deck and shut down engine.

MAINTENANCE AND REPAIR

Halvorsen PARKING BRAKE RELEASE PRESSURE ADJUSTMENT (Ref. Page 10)

13 SOL 5000 PSI PRESSURE GAUGE

MAIN RELIEF

7 SOL A

47 SOL 4 SOL

3 SOL

7 SOL

1 SOL A

VALVE IN THIS PORT NON-ADJUSTABLE

TP 3 (PORT) DECK SUPPLY CUTOFF

THROTTLE PRESSURE REDUCING VALVE ADJUSTMENT

FRONT VIEW Figure 61 CHASSIS MANIFOLD - FRONT VIEW

MAINTENANCE PROCEDURES

2-5 Page 81 August 2017

Halvorsen HELPER CYLINDER PRESSURE ADJUSTMENT

7 SOL A

(Ref. Page 10)

MAIN RELIEF 13 SOL TP1 (PORT) GAUGE PORT

TP2 (PORT)

1 SOL A 8 SOL

9 SOL 3 SOL SECONDARY SERVICE PRESSURE ADJUSTMENT (Ref. Page 11)

47 SOL 4 SOL

REAR VIEW Figure 62 CHASSIS MANIFOLD - REAR VIEW 2-5 Page 82 August 2017

MAINTENANCE AND REPAIR

Halvorsen

Figure 63 LOAD SENSE MARGIN PRESSURE ADJUSTMENT

MAINTENANCE PROCEDURES

2-5 Page 83 August 2017

Halvorsen C.

HELPER CYLINDER PRESSURE ADJUSTMENT Refer to Figure 61 and Figure 62.

D.

(1)

With engine shut down, connect a 5000 psi pressure gauge to port TP2 located on the back side of the chassis manifold (remove the plug from the port to connect the gauge).

(2)

Disconnect valve 7 SOL on chassis manifold (remove wires from coil).

(3)

Actuate 13 SOL with manual override on valve.

(4)

Raise deck by moving the lift switch to the UP position.

(5)

Adjust the helper cylinder pressure to 172 bar (2500 psi) after the cylinder is fully extended.

(6)

Loosen lock nut on the HELPER CYLINDER adjustment screw and turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is complete.

(7)

Return manual override to the normal position on 13 SOL.

(8)

Shut down engine, remove the gauge and reinstall the plug in the manifold.

(9)

Reinstall the wires on 7 SOL that were removed in step (2).

PARK BRAKE RELEASE PRESSURE Refer to Figure 61 and Figure 64.

1500 PSI

PRESSURE GAUGE INSTALLED FOR CHECKING PARKING BRAKE RELEASE PRESSURE

Figure 64 PARK BRAKE RELEASE PRESSURE ADJUSTMENT 2-5 Page 84 August 2017

MAINTENANCE AND REPAIR

Halvorsen

E.

F.

(1)

With engine shut down, remove hydraulic line from park brake cylinder and install pressure gauge on end of line.

(2)

Start the engine and place the park brake switch in the OFF position.

(3)

Adjust the pressure to indicate 103 bar (1500 psi). Turn the adjusting screw clockwise to increase pressure and counterclockwise to decrease pressure.

(4)

Shut down engine, remove the gauge and reconnect hydraulic line to the brake cylinder.

SECONDARY SERVICE PRESSURE (1)

With engine shut down, connect a 200 bar (3000 psi) pressure gauge to port TP3 located on the left side of the chassis manifold. Remove the plug from the port in the manifold to connect the gauge. Refer to Figure 61.

(2)

Actuate 47 SOL with manual override on valve.

(3)

Loosen lock nut on the SECONDARY SERVICE adjusting screw and turn clockwise to increase pressure to 172 bar (2500 psi) or counterclockwise to decrease the pressure. Tighten lock nut when adjustment is completed.

(4)

Return manual override to the normal position on 47 SOL.

(5)

Shut down engine, remove the gauge and reinstall the plug in the manifold after making the adjustment.

THROTTLE PRESSURE REDUCING VALVE (1)

With engine shut down, disconnect the hydraulic pressure hose from the fitting on the throttle actuator in the port marked “P” and place a cap on the fitting. Refer to Figure 65.

(2)

Install a 40 bar (600 psi) pressure gauge on the end of the hydraulic hose that was removed.

(3)

Start engine and observe the pressure reading on the gauge.

(4)

Loosen lock nut on adjusting screw and turn adjusting screw clockwise to increase pressure and counterclockwise to decrease the pressure. Set pressure at 24 bar (350 psi) then tighten lock nut on the adjusting screw. Refer to Figure 61, front view.

(5)

Shut down engine, remove the gauge and reconnect hydraulic line to the fitting that was capped in step (1).

MAINTENANCE PROCEDURES

2-5 Page 85 August 2017

Halvorsen 29.

INNER AND OUTER SCISSORS MANIFOLD ADJUSTMENTS NOTE:

THESE PROCEDURES APPLY TO SIDE SHIFT CYLINDER FLOW CONTROL VALVES, FRONT AND REAR.

NOTE:

THE ADJUSTMENTS ON THE INNER SCISSORS MANIFOLD CONTROL THE SPEED THAT THE FRONT END OF THE DECK WILL SHIFT. THE ADJUSTMENTS ON THE OUTER SCISSORS MANIFOLD CONTROL THE SPEED THAT THE REAR END OF THE DECK WILL SHIFT. ADJUSTING THE SIDE SHIFT CYLINDER FLOW CONTROL VALVES IS A TWO-PART PROCEDURE BECAUSE THE DECK MUST SHIFT EVENLY AT THE FRONT AND REAR IN BOTH DIRECTIONS, LEFT AND RIGHT. IF AN ADJUSTMENT IS REQUIRED, ADJUST THE FLOW CONTROL REQUIRED TO SHIFT THE DECK FULLY IN THE SELECTED DIRECTION IN 5 TO 6 SECONDS AS DESCRIBED IN PARAGRAPHS A. AND B. BELOW.

A.

SHIFT LEFT SPEED ADJUSTMENT Refer to Figure 66 and Figure 67. (1)

Shift deck fully to the right.

(2)

With a stopwatch, check the time required to side shift the deck fully to the left. Nominal time for full shift from one side is 5 to 6 seconds.

(3)

Loosen lock nut on the SHIFT LEFT speed adjustment screw and turn clockwise to slow the speed and counterclockwise to increase the speed.

NOTE:

(4) B.

USE THE ADJUSTING SCREW ON THE INNER SCISSORS MANIFOLD FOR THE FRONT END OF THE DECK USE THE ADJUSTING SCREW ON THE OUTER SCISSORS MANIFOLD FOR THE REAR OF THE DECK. Tighten lock nut upon completion of adjustment.

SHIFT RIGHT SPEED ADJUSTMENT Refer to Figure 66 and Figure 67. (1)

NOTE:

Shift deck fully to the left. (a)

With a stopwatch, check the time required to side shift the deck fully to the right. Nominal time for full shift from one side is 5 to 6 seconds.

(b)

Loosen lock nut on the SHIFT RIGHT speed adjustment screw and turn clockwise to slow the speed and counterclockwise to increase the speed.

USE THE ADJUSTING SCREW ON THE INNER SCISSORS MANIFOLD FOR THE FRONT END OF THE DECK. USE THE ADJUSTING SCREW ON THE OUTER SCISSORS MANIFOLD FOR THE REAR OF THE DECK. (c)

2-5 Page 86 August 2017

Tighten lock nut upon completion of adjustment.

MAINTENANCE AND REPAIR

Halvorsen

Figure 65 “P” PORT, THROTTLE ACTUATOR

MAINTENANCE PROCEDURES

2-5 Page 87 August 2017

Halvorsen FRONT DECK SHIFT RIGHT SPEED ADJUSTMENT (Ref. Page 13)

ROLL CYLINDER FLOW CONTROL PRESET @ 1/2 GPM FLOW

FRONT DECK SHIFT LEFT SPEED ADJUSTMENT (Ref. Page 12)

25 SOL 23 SOL

16 SOL

14 SOL

21 SOL 27 SOL

CROSSOVER RELIEF VALVES (6) PRESET @ 3000 PSI (207 BAR) (SEALED)

Figure 66 INNER SCISSORS MANIFOLD

2-5 Page 88 August 2017

MAINTENANCE AND REPAIR

Halvorsen REAR DECK SHIFT RIGHT SPEED ADJUSTMENT (Ref. Page 13)

REAR DECK SHIFT LEFT SPEED ADJUSTMENT

ROLL CYLINDER FLOW CONTROL PRESET @ 1/2 GPM FLOW

(Ref. Page 12)

24 SOL 26 SOL

17 SOL

15 SOL

22 SOL 28 SOL

CROSSOVER RELIEF VALVES (6) PRESET @ 3000 PSI (207 BAR) (SEALED)

Figure 67 OUTER SCISSORS MANIFOLD

MAINTENANCE PROCEDURES

2-5 Page 89 August 2017

Halvorsen 30.

REAR PITCH MANIFOLD A.

REAR PITCH CYLINDERS Refer to Figure 68.

B.

(1)

With engine shut down, remove hydraulic line from fitting in port marked PL2 on REAR PITCH manifold and install a tee fitting.

(2)

Connect a pressure gauge to the tee fitting and reconnect the hydraulic line to the fitting.

(3)

Start engine.

(4)

Move and hold, the pitch switch in the DOWN position (rear of deck raised).

(5)

Adjust the pressure to indicate 103 bar (1500 psi).

(6)

Loosen lock nut on the PITCH PRESSURE adjusting screw and turn clockwise to increase pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is complete.

(7)

Shut down engine, remove the gauge and tee fitting. Reconnect the hydraulic line to the manifold.

REAR PITCH SPEED, PITCH DOWN Refer to Figure 68.

C.

(1)

Start engine.

(2)

move and hold the deck pitch switch in the UP position until the rear of deck is fully lowered (hydraulic cylinders retracted).

(3)

Using a stopwatch, check the time required to extend the cylinder rod fully. Nominal time to extend the cylinder fully is 17 seconds.

(4)

Move and hold the pitch switch in the DOWN position until the rear of the deck is fully raised (hydraulic cylinders extended).

(5)

Loosen lock nut on the pitch down adjusting screw and turn clockwise to decrease speed and counterclockwise to increase speed. Tighten lock nut when adjustment is complete.

(6)

Verify the time after each adjustment has been made and the adjustment screw lock nut has been tightened.

REAR PITCH SPEED, PITCH UP Refer to Figure 68.

2-5 Page 90 August 2017

(1)

Start engine.

(2)

Move and hold the pitch switch in the DOWN position until the rear of deck is fully raised (hydraulic cylinders extended).

(3)

Using a stopwatch, check the time required to retract the cylinder rod fully. Nominal time to retract the cylinder fully is 22 seconds.

(4)

Move and hold the pitch switch in the UP position until the rear of the deck is fully lowered (hydraulic cylinders retracted).

(5)

Loosen lock nut on the PITCH UP adjusting screw and turn clockwise to decrease speed and counterclockwise to increase speed. Tighten lock nut when adjustment is complete.

MAINTENANCE AND REPAIR

Halvorsen (6)

Verify the time after each adjustment has been made and the adjustment screw lock nut has been tightened.

18 SOL PITCH DOWN SPEED ADJUSTMENT

PITCH UP SPEED ADJUSTMENT

PL2

20 SOL

PITCH PRESSURE

COUNTERBALANCE VALVE (PRESET)

Figure 68 REAR PITCH MANIFOLD 31.

PALLET STOPS AND CONVEY LIFT MANIFOLD A.

PALLET STOPS Refer to Figure 69. (1)

With engine shut down, remove hydraulic line from fitting in port marked A2 on PALLET STOPS AND CONVEY LIFT manifold and install a tee fitting.

(2)

Connect a pressure gauge to the tee fitting and reconnect the hydraulic line to the fitting.

(3)

Start the engine.

(4)

Adjust the pressure to indicate 103 bar (1500 psi).

(5)

Loosen lock nut on the PALLET STOPS adjusting screw and turn clockwise to increase pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is complete.

(6)

Shut down engine, remove the gauge and tee fitting; reconnect the hydraulic line to the manifold.

MAINTENANCE PROCEDURES

2-5 Page 91 August 2017

Halvorsen TRACTION ROLLER LIFT CYLINDER ADJUSTMENT 46 SOL

(Ref. Page 19)

PALLET STOPS ADJUSTMENT (Ref. Page 18)

A4 A3 A2

29 SOL GAUGE PORT 32 SOL 30 SOL

Figure 69 PALLET STOPS AND CONVEY LIFT MANIFOLD B.

TRACTION ROLLER LIFT CYLINDERS Refer to Figure 69.

2-5 Page 92 August 2017

(1)

With engine shut down, remove hydraulic line from fitting in port marked A4 on PALLET STOPS AND CONVEY LIFT manifold and install a tee fitting.

(2)

Connect a pressure gauge to the tee fitting and reconnect the hydraulic line to the fitting.

(3)

Start the engine.

(4)

Actuate valve 47 SOL on the chassis manifold () using the manual override. Refer to Figure 61.

MAINTENANCE AND REPAIR

Halvorsen

32.

(5)

Adjust the pressure to indicate 55 bar (800 psi).

(6)

Loosen lock nut on the TRACTION ROLLER LIFT CYLINDER adjusting screw and turn clockwise to increase pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is complete.

(7)

Reset the manual override on 47 SOL to the normal position.

(8)

Shut down engine, remove the gauge and tee fitting; reconnect the hydraulic line to the manifold.

CONVEY MANIFOLD

37 SOL

36 SOL

33 SOL

34 SOL

35 SOL

GA

42 SOL

41 SOL 38 SOL

39 SOL 40 SOL

CROSSOVER RELIEF VALVE 10 PLACES

Figure 70 CONVEY MANIFOLD NOTE:

CROSSOVER RELIEF VALVES ARE FACTORY PRESET AND NOT ADJUSTABLE IN THE FIELD.

MAINTENANCE PROCEDURES

2-5 Page 93 August 2017

Halvorsen 33.

ENGINE COOLANT FAN MANIFOLD NOTE:

RELIEF VALVE ADJUSTMENT IS MADE WITH ENGINE SHUT DOWN.

NOTE:

FAN MOTOR PRESSURE ADJUSTMENT MAY BE PRE-SET AND SEALED.

A.

FAN MOTOR PRESSURE ADJUSTMENT Refer to Figure 71. (1)

Loosen lock nut on relief valve adjusting screw.

(2)

Rotate adjusting screw fully clockwise (minimum setting).

(3)

Tighten lock nut.

FAN MOTOR PRESSURE ADJUSTMENT

1 SOL-B

Figure 71 FAN DRIVE MANIFOLD

2-5 Page 94 August 2017

MAINTENANCE AND REPAIR

Halvorsen 34.

PROXIMITY SWITCH ADJUSTMENT PROCEDURE

WARNING THE ENGINE MUST BE TURNED OFF WHEN MAKING ANY SWITCH ADJUSTMENT TO PREVENT AN UNCONTROLLED MOVEMENT OF THE LOADER. A.

PROXIMITY SWITCH ADJUSTMENT Inductive Proximity Switch. Refer to Figure 72. “Proximity switch” is a generic term that refers to a device capable of acting as an electronic switch when in the presence or close proximity of a metallic object. The important distinction that differentiates a proximity switch from a mechanical switch is that a proximity switch does not require physical contact with anything else to operate.

Figure 72 PROXIMITY SWITCH ADJUSTMENT B.

PROXIMITY SWITCH LOCATIONS Proximity sensors are located throughout the vehicle for different purposes. Refer to Chapter 2, Section 4, “Maintenance Specifications” for specific locations of proximity switches.

MAINTENANCE PROCEDURES

2-5 Page 95 August 2017

Halvorsen 35.

ELECTRICAL SYSTEM ADJUSTMENTS A.

POTENTIOMETERS NOTE:

POTENTIOMETERS ARE FACTORY ADJUSTED AND SEALED. DO NOT BREAK SEALS.

(1)

Deck lift, 1VC

(2)

Fan controller, 2VC

(3)

Throttle controller, 3VC

(4)

Convey controller, 4VC

Figure 73 VALVE DRIVE BOARD B.

LIMIT SWITCH ARM ADJUSTMENTS NOTE:

REFER TO CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS” FOR SPECIFIC LOCATIONS OF PROXIMITY SWITCHES.

Limit switches are located throughout the vehicle for different purposes.

2-5 Page 96 August 2017

(1)

Adjust the limit switch arm so the end of the arm is aligned flush with the base as shown. Refer to Figure 74.

(2)

Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

MAINTENANCE AND REPAIR

Halvorsen

SET SCREW

89 mm 3-1/2” (3.5 in.)

Align Edge Figure 74 LIMIT SWITCH ARM C.

DECK FULLY DOWN (2LS) ADJUSTMENT (1)

Raise the deck to the FIRST maintenance stands position and install both maintenance stands.

(2)

Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arm so the center of the roller is 54 mm (2-1/8 in.) above the limit switch body as shown. Refer to Figure 75.

(5)

Apply Loctite 242 to the switch set screw on the 2LS limit switch arm and tighten 4 N·m (35 lbf-in.). Refer to Figure 74.

(6)

Remove the maintenance stands and completely lower the deck until it is resting on the chassis frame.

MAINTENANCE PROCEDURES

2-5 Page 97 August 2017

Halvorsen (7)

(8)

(9)

Verify the following loader functions: (a)

The deck does not shift when the SHIFT toggle switch is activated to the left or right.

(b)

The engine RPM changes when the throttle pedal is actuated.

(c)

The transmission can be shifted in all gears.

Lift the deck 25–50 mm (1–2 in.) off the chassis frame and verify the following functions. (a)

The deck shifts when the SHIFT toggle switch is activated to the left or right.

(b)

The engine rpm does not change when the throttle pedal is actuated, except for first and reverse gear.

(c)

The transmission is limited to first and reverse.

This adjustment is precise and may take several small adjustments to obtain the correct operation as stated in steps (7) and (8).

54 mm 2-1/8” (2.125 in.)

Figure 75 LIMIT SWITCH 2LS D.

2-5 Page 98 August 2017

FRONT OF DECK FULLY DOWN (4LS) ADJUSTMENT (1)

Raise the deck to the FIRST maintenance stands position and install both maintenance stands.

(2)

Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

MAINTENANCE AND REPAIR

Halvorsen (4)

Adjust the limit switch arm so the center of the roller is 48 mm (1-7/8 in.) below the limit switch body as shown. Refer to Figure 76.

(5)

Apply Loctite 242 to the switch set screw on the 4LS limit switch arm and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

(6)

Remove the maintenance stands and completely lower the deck until it is resting on the chassis frame.

48 mm 1-7/8”in.) (1.875

Figure 76 LIMIT SWITCH 4LS (7)

Verify the following loader functions while the deck is resting on the chassis frame. (a)

The NO PITCH indicator light (RED) is illuminated when the PITCH joystick is activated in either direction.

(b)

The deck pitch is inactive when the PITCH joystick is activated in either direction.

(8)

Raise the deck 125–150 mm (5–6 in.) off the chassis frame. Push the PITCH joystick forward until the NO PITCH indicator light (RED) is illuminated then release the PITCH joystick.

(9)

Verify the following loader functions while the deck is pitched DOWN.

(10)

(a)

The deck and chassis structures are not contacting each other.

(b)

The deck will not lower when the LIFT joystick is held in the DOWN position.

This adjustment is precise and may take several small adjustments to obtain the correct operation as stated in step (7) and (9).

MAINTENANCE PROCEDURES

2-5 Page 99 August 2017

Halvorsen E.

REAR OF DECK FULLY DOWN (5LS) ADJUSTMENT (1)

Raise the deck to the FIRST maintenance stands position and install both maintenance stands.

(2)

Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arm so the center of the roller is 60 mm (2-3/8 in.) below the limit switch body as shown. Refer to Figure 77.

(5)

Apply Loctite 242 to the switch set screw on the 5LS limit switch arm and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

60 mm (2.375 in.)

2-3/8” 5LS

5LS

Figure 77 LIMIT SWITCH 5LS

2-5 Page 100 August 2017

MAINTENANCE AND REPAIR

Halvorsen (6)

Remove the maintenance stands and completely lower the deck until it is resting on the chassis frame.

(7)

Verify the following loader functions while the deck is resting on the chassis frame: (a)

The NO PITCH indicator light (RED) is illuminated when the PITCH joystick is activated in either direction.

(b)

The deck pitch is inactive when the PITCH joystick is activated in either direction.

(8)

Raise the deck 125–150 mm (5–6 in.) off the chassis frame. Pull back on the PITCH joystick until the NO PITCH indicator light (RED) is illuminated then release the PITCH joystick.

(9)

Verify the following loader functions while the deck is pitched UP.

(10)

(a)

The deck and chassis structures are not contacting each other.

(b)

The deck will not lower when the LIFT joystick is held in the DOWN position.

This adjustment is precise and may take several small adjustments to obtain the correct operation as stated in steps (7) and (9).

MAINTENANCE PROCEDURES

2-5 Page 101 August 2017

Halvorsen F.

DECK ROLL RIGHT (14LS) ADJUSTMENT (1)

Raise the deck to the first Maintenance Stands position and install both Maintenance Stands.

(2)

Activate and hold the ROLL joystick to the RIGHT until the front and rear left roll cylinders are fully extended.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arm so the center of the roller is 89 mm (3-1/2 in.) above the steel plate on the scissors as shown. Refer to Figure 78.

(5)

Apply Loctite 242 to the set screw on the 14LS limit switch arm and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

(6)

Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(7)

Verify the following loader functions. (a)

The ROLL RIGHT indicator light (AMBER) is not illuminated.

(b)

The front and rear left roll cylinders are completely collapsed (cylinder rod not visible).

89 mm

3-1/2” (3.5 in.)

Figure 78 LIMIT SWITCH 14LS

2-5 Page 102 August 2017

MAINTENANCE AND REPAIR

Halvorsen G.

DECK ROLL LEFT (15LS) ADJUSTMENT (1)

Raise the deck to the first Maintenance Stands position and install both Maintenance Stands.

(2)

Activate and hold the ROLL joystick to the LEFT until the front and rear right roll cylinders are fully extended.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arm so the center of the roller is 89 mm (3-1/2 in.) above the steel plate on the scissors as shown. Refer to Figure 79.

(5)

Apply Loctite 242 to the switch set screw on the 15LS limit switch arm and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

(6)

Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(7)

Verify the following loader functions. (a)

The ROLL LEFT indicator light (AMBER) is not illuminated.

(b)

The front and rear right roll cylinders are completely collapsed (cylinder rod not visible).

89 mm 3-1/2” (3.5 in.)

Figure 79 LIMIT SWITCH 15LS

MAINTENANCE PROCEDURES

2-5 Page 103 August 2017

Halvorsen H.

DECK SHIFTED LEFT (17LS) AND DECK SHIFTED RIGHT (18LS) ADJUSTMENT (1)

Raise the deck to the FIRST maintenance stands position and install both maintenance stands.

(2)

Verify the deck is centered by measuring the distance between the front roll cylinders to the inside of the left and right deck I-beams. Both measurements should be equal. Adjust the deck accordingly until the measurements are equal.

(3)

Adjust the limit switch arms so they are fully extended. The end of the arms is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arms and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arms so the attached wire rope has approximately 25 mm (1 in.) of slack. Refer to Figure 80.

(5)

Apply Loctite 242 to the set screw on the 17LS and 18LS limit switch arms and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74. OF SLACK AT FIRST WIRE ROPE WITH SLACK AT FIRST MAINTENANCE STAND MAINTENANCE STAND POSITION POSITION

Figure 80 LIMIT SWITCHES 17LS AND 18LS (6)

Verify the following loader functions. (a)

The SHIFT LEFT and SHIFT RIGHT indicator lights should illuminate when the SHIFT toggle switch is activated to the appropriate direction.

(b)

Actuate and hold the AUTO CENTER AND LEVEL toggle switch until the SHIFT indicator lights are not illuminated.

(7)

Raise the deck to its maximum height.

(8)

Verify the following loader functions. Shift the deck to either side until the appropriate shift indicator light is illuminated. Actuate and hold the AUTO CENTER AND LEVEL toggle switch until the SHIFT indicator lights are not illuminated.

2-5 Page 104 August 2017

MAINTENANCE AND REPAIR

Halvorsen NOTE: (9) I.

THE DECK WILL JERK BACK AND FORTH WHEN APPROXIMATELY CENTERED IF THE WIRE ROPE IS TOO TIGHT. This adjustment is precise and may take several small adjustments to obtain the correct operation as stated in step (6) through (8).

AIR TRANSPORT PIN (16LS) AND CLEVIS (16LS-A) ADJUSTMENTS (1)

Raise the deck to the first maintenance stands position and install both maintenance stands.

(2)

Level and center the deck by actuating and hold the AUTO CENTER AND LEVEL toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(3)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(4)

Adjust the limit switch arm on 16LS so the center of the roller is aligned with limit switch guard as shown. Refer to Figure 81.

LIMIT SWITCH GUARD

Figure 81 LIMIT SWITCH 16LS AND 16LS-A

MAINTENANCE PROCEDURES

2-5 Page 105 August 2017

Halvorsen (5)

Apply Loctite 242 to the set screw on 16LS and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

(6)

Adjust the limit switch arm on 16LS-A so the arm is perpendicular (90º) to the limit guard as shown in Figure 81.

(7)

Apply Loctite 242 to the set screw on 16LS-A and tighten to 4 N·m (35 lbf-in.). Refer to Figure 74.

(8)

Remove the maintenance stands and completely lower the deck until it is resting on the chassis frame.

(9)

At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air transport pin to lock the deck and chassis frame together. Refer to Figure 82.

Figure 82 AIR TRANSPORT PIN AND CLEVIS INSTALLATION

CAUTION IF THE ENGINE SPEEDS UP WHILE ACTIVATING THE LIFT JOYSTICK WHILE IN AIR TRANSPORT MODE, RELEASE THE LIFT JOYSTICK IMMEDIATELY AND LOWER THE DECK. STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE. (10)

2-5 Page 106 August 2017

Verify the following loader functions. (a)

The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.

(b)

The front and rear pallet stops should be inactive to the operator’s controls when their associated toggle switches are in the “ON” position.

(c)

All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch to 108 or 88 position during this process.

MAINTENANCE AND REPAIR

Halvorsen J.

(d)

The deck ROLL joystick is inactive to the operator’s controls.

(e)

The engine RPM do not change when the LIFT joystick is in the UP position. Immediately release the LIFT joystick if the engine rpm change during this process. Structural damage to the deck and chassis frame will occur.

AIR TRANSPORT MODE (3LS-A) ADJUSTMENT

CAUTION IF THE ENGINE SPEEDS UP WHILE ACTIVATING THE LIFT JOYSTICK WHILE IN AIR TRANSPORT MODE, RELEASE THE LIFT JOYSTICK IMMEDIATELY AND LOWER THE DECK. STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE. (1)

At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air transport pin to lock the deck and chassis frame together. Refer to Figure 82.

(2)

Verify the following loader functions before proceeding. (a)

The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.

(b)

The front and rear pallet stops should be inactive to the operator’s controls when their associated toggle switches are in the “ON” position.

(c)

All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch to 2743 mm (108 in.) or 2235 mm (88 in.) position during this process.

(d)

The deck ROLL joystick is inactive to the operator’s controls.

(e)

The engine RPM do not change when the LIFT joystick is in the UP position. Immediately release the LIFT joystick if the engine rpm change during this process. Structural damage to the deck and chassis frame will occur.

(3)

Move the LIFT joystick to the UP position until the helper cylinders are fully extended.

(4)

Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m (35 lbf-in.).

(5)

Position the limit switch arm so it is firmly contacting the rear axle swing arm. Refer to Figure 83.

(6)

Using a flat head screw driver, rotate the knurled shaft on the limit switch counterclockwise while holding the limit switch arm firmly against the rear axle swing arm until the AIR TRANSPORT indicator light (RED) on the dash panel begins to flash. Then, gently rotate the knurled shaft clockwise until the AIR TRANSPORT indicator light (RED) on the dash panel is solid. Apply Loctite 242 to the set screw on 3LS-A and tighten to 4 N·m (35 lbf-in.).

(7)

Verify the following loader functions.

(8)

(a)

Lower the helper cylinders a few inches by positioning the LIFT joystick in the DOWN position. The AIR TRANSPORT red indicator should begin to flash.

(b)

Move the LIFT joystick to the UP position until the helper cylinders are fully extended. The AIR TRANSPORT red indicator should be solid.

This adjustment is precise and may take several small adjustments to obtain the correct operation as stated in step (6).

MAINTENANCE PROCEDURES

2-5 Page 107 August 2017

Halvorsen

Figure 83 LIMIT SWITCH 3LS-A K.

RPM ADJUSTMENT (TRANSMISSION ACCESSORY BOX) Refer to Figure 84 and Figure 85. (1)

Place parking brake switch in the ON position and let engine run until operating temperature is indicated on engine temperature gauge.

(2)

With an accurate tachometer, check the engine idle speed. Idle speed is 850–900 rpm with the transmission in neutral. Adjust idle speed to 850–900 rpm if required.

(3)

Open the door on the main panel and check the red led lamp on side “B” of the transmission accessory box to verify if it is illuminated.

NOTE:

2-5 Page 108 August 2017

(a)

If the lamp is OFF, turn the LOW SET adjusting screw clockwise until the RED LED lamp is illuminated.

(b)

If the lamp is ON, turn the LOW SET adjusting screw counterclockwise until lamp is not illuminated, then slowly turn the adjusting screw clockwise until the RED LED lamp is illuminated.

THE SHIFT-SHOCK THRESHOLD IS NOW SET AT THE CURRENT ENGINE IDLE SPEED.

MAINTENANCE AND REPAIR

Halvorsen VIEW SIDE “B” OF TRANSMISSION ACCESSORY BOX

Figure 84 TRANSMISSION ACCESSORY BOX IN MAIN PANEL

MAINTENANCE PROCEDURES

2-5 Page 109 August 2017

Halvorsen LED LIGHT

ADJUSTMENT SCREW

WIRE 182 NEU

WIRE 165 REV

WIRE 15L IGNR-RED (+24VDC IN)

WIRE 7 BATT-BLUE

WIRE 4 RPM (POS)

WIRE 165 BU-RED/BLK

WIRE 15C SHIFT PWR (+24VDC OUT)

WIRE 1 BU-RED/BLK

WIRE 1 GND-BLK

Figure 85 ACCESSORY BOX - PART NO. 623-7300

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MAINTENANCE AND REPAIR

Halvorsen (4) NOTE:

THIS WILL BE THE SHIFT-SHOCK THRESHOLD TO RESTRICT ANY SHIFTING OUT OF NEUTRAL TO ANY FORWARD RANGE OR TO REVERSE WHEN ENGINE RPM IS ABOVE THRESHOLD SETTING.

(5)

Allow engine to return to idle speed. The RED LED must remain ON.

(6)

Select N with the transmission range selector and increase engine rpm above the threshold setting of 1025–1050 rpm.

(7)

(8) L.

Increase engine speed to 1025–1050 rpm, hold throttle steady and turn adjusting screw clockwise until RED LED is not illuminated.

(a)

The RED LED should not illuminate.

(b)

Transmission should not shift out of NEUTRAL range.

Verify rpm adjustments. (a)

With engine at idle rpm, shift transmission out of N range and increase engine speed to above the threshold of 1025–1050 rpm. The RED LED should be illuminated.

(b)

Hold the engine speed above 1025–1050 rpm and shift transmission to N. The RED LED should go out and remain not illuminated until engine rpm falls below the threshold setting of 1025–1050 rpm.

(c)

The RED LED will illuminate when engine rpm falls below the threshold of 1025–1050 rpm.

The setting of SHIFT-SHOCK is complete.

PITCH UP AND DOWN (4PRS AND 5PRS) ADJUSTMENTS Refer to Figure 86. (1)

Level the deck by actuating and holding, the AUTO CENTER AND LEVEL switch on the dash panel until the PITCH, ROLL and SHIFT indicator lights are not illuminated.

(2)

Shut down the engine.

(3)

Verify that the deck is level with a spirit level or by measuring from the deck to the chassis frame.

NOTE:

IF THE DECK IS NOT LEVEL, START ENGINE AND ACTUATE THE PITCH SWITCH TO LEVEL THE DECK WITH THE CHASSIS FRAME.

(4)

Turn the ignition switch to the ON position and watch the indicator lights on the dash panel.

(5)

Move the upper proximity switch (4PRS), up in the slot until the indicator light just illuminates on the dash, then carefully move the switch down until the light is not illuminated.

(6)

Secure the switch with the lock nut.

NOTE:

THE 2 MM (3/32 IN.) NOMINAL GAP MUST BE MAINTAINED BETWEEN THE SWITCH AND THE TARGET WHEN MAKING AN ADJUSTMENT.

(7)

Move the lower proximity switch (5PRS) down in the slot until the indicator light just illuminates on the dash, then carefully move the switch up until the light is not illuminated.

(8)

Secure the switch with the lock nut.

MAINTENANCE PROCEDURES

2-5 Page 111 August 2017

Halvorsen NOTE: (9)

THE 2 MM (3/32-IN.) NOMINAL GAP MUST BE MAINTAINED BETWEEN THE SWITCH AND THE TARGET WHEN MAKING AN ADJUSTMENT. Verify adjustment of 4PRS and 5PRS by actuating pitch switch. Indicator lights on dash panel must illuminate when deck is pitched UP or DOWN and are not illuminated when deck is level.

TARGET

2 mm (3/32 in.) GAP (3/32-in) GAP 4PRS

5PRS GAP 2 mm (3/32-in) (3/32 in.) GAP

TARGET

Figure 86 PROXIMITY SWITCHES 4PRS AND 5PRS

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MAINTENANCE AND REPAIR

Halvorsen Section 6. Troubleshooting 1.

GENERAL The Halvorsen, 25 000 lb. Loader for Aircraft, is hydraulically operated and electrically controlled. The hydraulic and electrical systems are complex and require a thorough understanding to determine the cause of a malfunction or failure of a component. System diagnosis is mandatory to locate a component that is out of adjustment or has failed, in the minimum amount of time. The information contained in this section is provided as a guide to assist technical service personnel in troubleshooting operational malfunctions in the vehicle hydraulic and electrical systems. The information should be used in conjunction with the Troubleshooting section, Schematics, Reference Designators and Maintenance Procedures incorporated in this manual. A.

BEFORE TROUBLESHOOTING Before starting troubleshooting procedures, verify that the correct operating procedures were used. An incorrect operating procedure can cause apparent malfunctions. Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and suspected defective parts to verify that there are no open circuits or defective grounding.

B.

HYDRAULIC SYSTEM CLEANLINESS A very important practice to observe when working on the hydraulic system is cleanliness. Serious damage can result quickly from foreign material (contamination) in the hydraulic system. When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material and moisture-laden air (contamination) from entering the system. DO NOT use Teflon tape or pipe compound on straight threads.

2.

HYDRAULIC SYSTEM A.

PRESSURE READINGS AND ADJUSTMENTS Test ports are provided and hydraulic system diagnosis is accomplished by observing pressure readings on a test gauge when a particular hydraulic circuit is actuated. The hydraulic schematics and adjustment procedures indicate the correct setting for each pressure adjustment.

B.

MALFUNCTIONS ISOLATION The first step in diagnosing a malfunction is to isolate the malfunction to the hydraulic system or to the electrical control system.

C.

TROUBLESHOOTING Refer to troubleshooting guides to assist in locating the cause of a malfunction when incorrect pressure or incorrect flow has been determined. Also, for hydraulic components and locations, refer to Chapter 4, ILLUSTRATED PARTS LIST.

TROUBLESHOOTING

2-6 Page 1 August 2017

Halvorsen INCORRECT PRESSURE

A

B

C

D

NO PRESSURE

LOW PRESSURE

ERRATIC PRESSURE

EXCESSIVE PRESSURE

No flow

Pressure relief path exists

Air in fluid

Pressure reducing or relief valve misadjusted

Pressure reducing valve set too low

Relief valve worn

Pressure reducing or relief valve damaged

Pressure reducing valve damaged

Contamination in fluid

Pump, motor or cylinder damaged

Pump, motor or cylinder worn

Shuttle valve stuck

INCORRECT FLOW

A

B

C

NO FLOW

LOW FLOW

EXCESSIVE FLOW

Pump not receiving fluid

Flow control or relief valve set too low

Flow control set too high

Pump-to-drive coupling sheared

Flow by-passing through partially open valve

Directional control set in wrong position

External leak in system

Entire flow passing over relief valve

RPM of pump drive incorrect

Pump damaged

Pump, valve, motor or other component worn

Figure 1 HYDRAULIC SYSTEM TROUBLESHOOTING 2-6 Page 2 August 2017

MAINTENANCE AND REPAIR

Halvorsen 3.

ELECTRICAL SYSTEM The main electrical system components are located in the main panel. Sensors detect a specific position of a mechanical component for the actuation and interlocking of electrical circuits.

CAUTION BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES. PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE THE WELDER’S GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO THE WELDING OPERATION AS POSSIBLE. 4.

TROUBLESHOOTING GUIDELINES A.

SCOPE Troubleshooting guide tables list malfunctions and some possible causes of a listed malfunction. When there is a problem or malfunction of the vehicle, read through the list on the left side of the chart. Possible causes are listed to the right. This guide lists the most common problems that could be encountered, but is not meant to replace troubleshooting procedures that require diagnosing a system malfunction using the hydraulic and electrical schematics.

B.

DIAGNOSTIC TOOLS The status panel in the cabin and an accurate voltmeter must be used to identify electrical problems. Electrical schematics must be referred to when troubleshooting the electrical system. Proximity switches and pressure switches must be adjusted to specifications when they are replaced. Refer to Chapter 2, Section 5, “Maintenance Procedures”. Hydraulic troubleshooting can be done connecting a liquid-filled pressure gauge to the test ports in conjunction with the hydraulic schematics.

C.

COMPONENTS REPLACEMENT When a component is repaired or replaced, always check the hydraulic circuit for the correct indicated pressure and correct actuator speeds. Refer to Chapter 2, Section 5, “Maintenance Procedures” and Chapter 1, Section 4, “Specifications”. The troubleshooting guides do include some obvious causes such as burned out light bulbs, loose wire connections, physical damage to wire harnesses, components, etc., but it is assumed that the technician will check these items before proceeding with detailed troubleshooting procedures and adjustments.

D.

SENSORS LOCATION Refer to Chapter 2, Section 2, “System Overview” for solenoid valves and sensors location.

TROUBLESHOOTING

2-6 Page 3 August 2017

Halvorsen NOTE:

5.

THE HYDRAULIC AND ELECTRICAL SYSTEMS ARE COMPLEX AND REQUIRE A THOROUGH UNDERSTANDING TO DETERMINE THE CAUSE OF A MALFUNCTION OR FAILURE OF A COMPONENT. SYSTEM DIAGNOSIS IS MANDATORY TO LOCATE A COMPONENT THAT HAS FAILED OR IS OUT OF ADJUSTMENT IN THE MINIMUM AMOUNT OF TIME. THE FIRST STEP IN DIAGNOSING A MALFUNCTION IS TO ISOLATE THE MALFUNCTION TO THE HYDRAULIC SYSTEM OR TO THE ELECTRICAL CONTROL SYSTEM.

TROUBLESHOOTING GUIDE TABLES The following pages contain the Troubleshooting Guides (Table 1 through Table 6) to assist in locating the causes of malfunctions. Also, for components and locations, refer to “ELECTRICAL SCHEMATICS” and “HYDRAULIC SCHEMATICS” in Chapter 2, Section 7.

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MAINTENANCE AND REPAIR

Halvorsen TROUBLESHOOTING GUIDE TABLE 1 - ENGINE SYMPTOM Engine does not crank (turn over)

Low cranking speed

PROBABLE CAUSE

ACTION

Engine already running.

None.

Batteries discharged or voltage output low.

Check battery voltage; if low, charge batteries.

Battery has defective cell.

Replace battery.

Emergency stops pushed.

Reset switch.

Transmission range selector not in N (neutral).

Position range selector in N.

Starter or starter solenoid switch failure.

Replace failed component.

Battery terminals loose or corroded.

Clean and tighten.

Cold engine (diesel engine).

Do not start engine until engine preheat light on dash panel goes out.

Circuit breaker tripped or failed.

Reset circuit breaker. If circuit breaker trips again, check for short.

Circuit breaker faulty.

Replace circuit breaker.

Neutral safety switch failure.

Replace switch.

Ignition or starter switch failure.

Replace switch.

Engine locked up.

Rotate engine by hand. If engine cannot be rotated, check for internal damage. Replace engine.

Battery voltage low.

Test battery voltage before and during cranking. Charge or replace batteries.

Battery voltage low at starter terminal. Check battery cables for loose or corroded terminals. Replace defective battery cable.

TROUBLESHOOTING

Incorrect oil viscosity for temperature.

Drain and refill engine sump with oil with correct viscosity.

External power not connected (cold weather operation).

Check external power cord connection and circuit breaker.

Engine, transmission, coolant or hydraulic reservoir heating elements not operating.

Check elements and replace if defective.

2-6 Page 5 August 2017

Halvorsen TROUBLESHOOTING GUIDE TABLE 1 - ENGINE (CONT.) SYMPTOM Engine cranks, will not run

Engine will only run with SHUTDOWN OVERRIDE switch actuated

Engine overheats

2-6 Page 6 August 2017

PROBABLE CAUSE

ACTION

No fuel.

Check quantity of fuel in tank. Check fuel gauge and sender.

Fuel filter(s) clogged.

Replace fuel filter(s) element.

Air in fuel system.

Check fuel lines for leaks. Bleed and prime fuel system.

Oil pressure too low.

Check engine oil level. Hold SHUTDOWN OVERRIDE switch when cranking and observe engine oil pressure when engine starts.

Contaminated or incorrect grade of fuel.

Drain and clean fuel tank. Refill with fresh, clean fuel. Flush fuel lines, replace filter elements, bleed and prime fuel system.

Cold engine (diesel).

Do not start engine until engine preheat light on dash panel goes out.

Check for cause of engine shutdown condition: High engine temperature.

Refer to Engine overheats symptom.

High hydraulic oil temperature.

Check fluid level in reservoir.

High transmission oil temperature.

Check fluid level in transmission.

Oil pressure failure.

Check engine oil level. Check condition of engine.

Coolant level low.

Add coolant of proper mixture to coolant system.

Radiator fins dirty, restricted air flow.

Clean radiator.

Water pump belt slipping.

Adjust or replace pump drive belts.

Engine oil level low.

Check engine oil level and add oil to full mark on dipstick.

Thermostat faulty.

Replace thermostat.

Water pump faulty.

Replace water pump.

Cooling fan not operating.

Check fan control circuit

Temperature sensor for fans.

Replace temperature sensor.

Solenoid valve for fans.

Replace solenoid valve.

Hydraulic motor for fan failed.

Replace hydraulic motor.

MAINTENANCE AND REPAIR

Halvorsen TROUBLESHOOTING GUIDE TABLE 1 - ENGINE (CONT.) SYMPTOM Coolant temperature does not rise to normal

Engine runs but vehicle will not move

Excessive loss of coolant

Loss of engine power

TROUBLESHOOTING

PROBABLE CAUSE

ACTION

Engine thermostat faulty.

Replace engine thermostat.

Range selector in neutral.

Move selector out of N position to a forward range or the R range.

Parking brake applied.

Release parking brake.

Engine speed (rpm) too high (above preset level).

Check engine speed. Engine must be below 900 rpm.

Transmission fluid low.

Fill transmission to FULL mark on dipstick.

Rear wheel brakes locked.

Unlock brakes.

Front axle drive shaft brake locked.

Unlock drive shaft brake.

Coolant loss due to loose clamps on coolant hoses.

Tighten all clamps.

Defective coolant hoses.

Pressure check coolant system to locate defective hoses. Replace any hose that leaks when system is pressurized.

Defective coolant system pressure cap.

Pressure check coolant system cap and replace as required.

Engine gaskets and/or seals.

Repair or replace engine.

Insufficient fuel.

Inspect fuel lines for air leaks and restriction.

Fuel filters clogged.

Replace filter elements.

Fuel transfer pump defective.

Replace pump.

Fuel injectors dirty or worn.

Replace injectors.

Fuel injection pump defective.

Replace injection pump.

Insufficient air.

Clean or replace air filter element.

Restricted exhaust.

Check for exhaust pipe damage. Replace exhaust silencer.

Engine adjustments incorrect.

Service engine. Check injector pump timing.

Turbocharger faulty.

Replace turbocharger.

2-6 Page 7 August 2017

Halvorsen TROUBLESHOOTING GUIDE TABLE 1 - ENGINE (CONT.) SYMPTOM Excessive black exhaust

Engine operating too cold

PROBABLE CAUSE

ACTION

Insufficient air.

Service air cleaner, replace element.

Faulty fuel injectors.

Replace injectors.

Injection pump timing.

Adjust to specifications.

Turbocharger faulty.

Replace turbocharger.

Contaminated or incorrect fuel.

Drain and clean fuel tank, replace fuel filter elements and refill with fuel.

Coolant thermostat faulty.

Replace coolant thermostat.

TROUBLESHOOTING GUIDE TABLE 2 - TRANSMISSION SYMPTOM Loader will not move

PROBABLE CAUSE

ACTION

Range selector in neutral.

Move selector out of N position to a forward range or the R range.

Parking brake applied.

Release parking brake.

Engine rpm too high (above preset level).

Adjust engine idle rpm to specifications.

Transmission fluid low.

Fill transmission with fluid.

Shifter valve not operating.

Check valve for input voltage. Replace shift valve coil.

Wire harness to shifter valve has fault. Repair or replace wire harness. Range selector shifter defective.

Replace shifter.

Broken axle.

Replace axle.

Damaged differential.

Repair or replace differential.

Rear wheel brakes locked.

Check brake valve. Repair or replace.

Transmission shift points are low (high engine rpm)

Transmission governor malfunction.

Clean or replace governor screen and governor.

Rough shifting

Governor valve malfunctioning.

Clean or replace governor screen and governor.

Control valves sticking.

Rebuild or replace main control valve body assembly.

2-6 Page 8 August 2017

MAINTENANCE AND REPAIR

Halvorsen TROUBLESHOOTING GUIDE TABLE 2 - TRANSMISSION (CONT.) SYMPTOM

PROBABLE CAUSE

Shifter will not Shift Engine not running. into forward or Parking brake in “ON” position. reverse Service brake not applied.

ACTION Start engine. Turn parking brake to “OFF” position. Apply service brake.

Engine RPM too high.

Refer to the engine manual and adjust to specifications.

Shift shock set low.

Refer to Chapter 2, Section 5 for adjusting the rpm setting on the transmission accessory box.

Relays -16CR, -46CR or 47CR are inoperative.

Inspect relays and troubleshoot circuit.

Connector or wires in the wiring harness going to shaft actuator defective

Inspect and repair as necessary.

Shorted brake pressure switch +CPS_B.

Replace switch.

+CP-USCR_2 failed.

Replace relay.

Will not auto shift to neutral

+CP-2CR_A defective.

Replace relay.

Joystick display does not read properly

Transmission linkage out of adjustment.

Adjust per vendor’s manual, Chapter 5.

Bad ground.

Inspect and repair as necessary.

Transmission overheating

Fluid level low.

Replace filter and or elements. Add fluid to correct level.

Fluid filters clogged.

Replace filter and elements.

Aerated fluid. Improper fluid level.

Adjust fluid to proper level.

Incorrect or contaminated fluid.

Drain and refill with correct fluid. Replace filter elements.

Cooler fluid flow loss due to internal leakage.

Overhaul or replace transmission.

Transmission fluid dirty, dark in color and/or has odor due to failure to change fluid at proper interval.

Drain and refill with new fluid, clean sump and install new filter elements.

Will not shift from 2nd to 1st gear

Excessive heat

Refer to Transmission overheating above.

Clutch failure

Damaged filter or filter elements.

TROUBLESHOOTING

Overhaul or replace transmission.

2-6 Page 9 August 2017

Halvorsen TROUBLESHOOTING GUIDE TABLE 2 - TRANSMISSION (CONT.) SYMPTOM

PROBABLE CAUSE

Transmission Dipstick loose. throws fluid out of fill tube or breather Fluid level too high. Fluid level too low.

Noise (buzzing noise) occurring intermittently Noise (buzzing noise) occurring intermittently (Cont.)

ACTION Tighten or replace cap. Drain to proper fluid level. Fill to proper fluid level.

Fill tube is plugged or not vented.

Clean vent of restriction.

Breather clogged.

Clean or replace breather.

Water in transmission fluid.

Drain and refill transmission with clean fluid. Replace filter elements.

Low fluid level.

Add fluid to proper level.

Clogged filter or filter elements.

Replace filter and elements.

Aerated fluid or improper fluid level.

Adjust fluid to proper level.

Damaged filter or filter elements.

Replace filter and elements.

Air leak at intake tube.

Remove sump and replace intake tube seal and filter.

Piston seals leaking or clutch plates Excessive engine flare (slipping) on slipping in range involved. full throttle up-shift Sticking governor valve.

Overhaul or replace transmission. Clean or replace governor screen and governor.

TROUBLESHOOTING GUIDE TABLE 3 - HYDRAULIC SYSTEM SYMPTOM

PROBABLE CAUSE

ACTION

Parking brake does not release

Parking brake solenoid valve 3SOL.

Replace valve.

Brake assembly.

Repair or replace brake assembly.

Loader hard to steer or no power steering

Steering valve.

Replace valve.

Hydraulic cylinder for steering.

Repair or replace hydraulic cylinder.

Loader steers in one direction only

Steering valve.

Replace valve.

Hydraulic cylinder.

Repair or replace hydraulic cylinder.

Loader has little or no braking action when pedal depressed

Service brake hydraulic actuating valve.

Replace valve.

2-6 Page 10 August 2017

MAINTENANCE AND REPAIR

Halvorsen TROUBLESHOOTING GUIDE TABLE 3 - HYDRAULIC SYSTEM (CONT.) SYMPTOM No steering and service brakes

PROBABLE CAUSE

ACTION

Deck supply cut-off valve in the off position.

Turn to the on position.

No system pressure.

Check or repair main hydraulic pump.

Helper cylinder will not raise

8SOL inoperative.

Repair or replace.

No system pressure.

Check or repair main hydraulic pump. Repair or replace 9SOL.

Deck will not raise above helper cylinders

7SOL inoperative.

Repair or replace.

No system pressure.

Check or repair main hydraulic pump. Repair or replace 9SOL.

Deck will not lower

10SOL or 11SOL inoperative. 9SOL inoperative.

Repair or replace.

Helper cylinder will not lower

13SOL inoperative. 9SOL inoperative.

Repair or replace.

Deck will not side shift front

14SOL or 16SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

Deck will not side shift rear

15SOL or 17SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

Deck will not pitch

19SOL or 20SOL inoperative. Deck supply cut-off valve in off position. 9SOL inoperative.

Repair or replace. Turn to on position.

Deck slow to side shift

Low system pressure.

Check or repair main hydraulic pump.

Speed adjustment out of specifications.

Adjust per specifications in Chapter 2, Section 4.

Deck will not roll left

23SOL or 24SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

Deck will not roll right

25SOL or 26SOL inoperative. Deck supply cut-off valve in off position. 9SOL inoperative.

Repair or replace. Turn to on position.

TROUBLESHOOTING

2-6 Page 11 August 2017

Halvorsen TROUBLESHOOTING GUIDE TABLE 3 - HYDRAULIC SYSTEM (CONT.) SYMPTOM Deck pitch speed slow

PROBABLE CAUSE

ACTION

Pressure at pitch manifold low.

Set pressure at TP port to 1500 psi.

Speed adjustment out of specifications.

Adjust as per specifications in Chapter 2, Section 4.

9SOL inoperative.

Repair or replace.

Pallet stop inoperative front

30SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

Pallet stop inoperative rear

32SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

Traction rollers will not retract

29SOL inoperative. Deck supply cut-off valve in off position. 9SOL inoperative.

Repair or replace. Turn to on position.

Emergency pump inoperative

Electric motor inoperative.

Repair or replace.

Pump inoperative.

Repair or replace.

Emergency pump will not raise deck above Helper Cylinders with a load

Deck supply cut-off valve in the on position

Turn and hold in the off position.

9SOL inoperative.

Repair or replace.

Air conditioning system compressor inoperative

51SOL inoperative. Deck supply cut-off valve in off position.

Repair or replace. Turn to on position.

2-6 Page 12 August 2017

MAINTENANCE AND REPAIR

Halvorsen TROUBLESHOOTING GUIDE TABLE 4 - ELECTRICAL SYSTEM SYMPTOM

PROBABLE CAUSE

ACTION

Battery disconnect switch not turned on.

Turn on switch.

Battery 1BAT or 2BAT discharged.

Recharge or replace battery.

Circuit breaker 4CB tripped.

Reset circuit breaker.

Oil pressure gauge does not indicate pressure (engine has oil pressure)

Oil pressure sending unit (1POT).

Replace oil pressure sending unit.

Oil pressure gauge (1GA).

Replace oil pressure gauge.

Coolant temperature gauge does not indicate temperature

Engine temperature sending unit (2POT).

Replace engine temperature sending unit.

Engine temperature gauge (2GA).

Replace engine temperature gauge.

Fuel gauge does not indicate fuel level

Fuel sending unit (3POT).

Replace fuel sending unit.

Fuel gauge (3GA).

Replace fuel gauge.

Voltmeter does not indicate

V-belt loose.

Tighten belt.

Voltmeter.

Replace voltmeter.

Generator regulator.

Replace generator.

Generator failure light does not go out when engine is running

V-belt loose.

Tighten belt.

1CR relay.

Replace relay.

Generator

Repair or replace generator.

Oil pressure warning light does not go out when engine is running (oil pressure is 4 psi or higher)

Oil pressure switch.

Replace switch.

Oil pressure low.

Check engine condition.

Engine coolant temperature warning light illuminates

Low coolant level.

Add coolant.

Engine thermostat.

Replace thermostat.

Hydraulic oil temperature warning light illuminates

Hydraulic oil temperature switch.

Replace switch.

Hydraulic oil temperature above 180 ºF.

Check oil level in reservoir.

No warning lights on dash panel with ignition switch in the ON position

TROUBLESHOOTING

2-6 Page 13 August 2017

Halvorsen TROUBLESHOOTING GUIDE TABLE 4 - ELECTRICAL SYSTEM (CONT.) SYMPTOM

PROBABLE CAUSE

ACTION

Headlamps and parking lights do not illuminate

Circuit breaker 9CB tripped.

Reset circuit breaker.

Stoplights do not illuminate

Stoplight switch.

Replace switch.

Turn signals do not Circuit breaker 8CB tripped. function Flasher. Turn signal switch.

Reset circuit breaker. Replace flasher. Replace switch.

Backup lights do 43CR relay. not illuminate when loader is in reverse

Replace relay.

Horns do not sound Horn switch.

Replace switch.

Emergency pump

Deck does not convey in any direction

2-6 Page 14 August 2017

Circuit breaker 1CB, 15CR relay.

Reset circuit breaker and/or relay.

Circuit breaker 1CB tripped, 7TGS, 8TGS switches.

Reset circuit breaker. Replace switches.

Electric pump motor or contactor.

Repair or replace.

Circuit breaker 13CB tripped.

Reset circuit breaker.

MAINTENANCE AND REPAIR

Halvorsen 6.

D3 AND D4 HEATER TROUBLESHOOTING A.

BASIC TROUBLESHOOTING

TABLE 5 - D3 AND D4 HEATER TROUBLESHOOTING SYMPTOM Heater does not ignite

Heater ignites, but shut downs at random. Heater smokes and builds up carbon

PROBABLE CAUSE

ACTION

Heater switch is OFF.

Turn switch to ON.

Blower motor does not run.

Check: fuse in power harness, power to control unit, electrical connections and power into and from switch.

Blower motor runs approximately 20 seconds and then shuts off.

Ensure voltage at control unit remains above 10 volts during start-up with glow pin circuit on.

Blower motor runs and fuel metering pump starts and then shuts down after two start-up attempts.

Check fuel lines and fuel filter and fuel level in tank. Check combustion air or exhaust tube blockage.

Blower motor runs but there is no fuel flow.

Verify electrical pulses at fuel metering pump. Check for pump freeze and fuel line blockage.

No fuel flow.

Check fuel metering pump flow.

Overheating.

Check for possible overheat.

No proper voltage to control unit.

Verify control unit input voltage.

Exhaust pipe blocked.

Inspect for exhaust blockage.

Combustion air intake blocked.

Inspect for air intake blockage.

Exhaust gases entering air intake pipe.

Inspect for cracks or leaks from exhaust and air intake pipes.

Short cycling on rapid ON-OFF operation.

TROUBLESHOOTING

Fuel system failing.

Verify fuel system proper operation.

Fuel flow incorrect.

Fuel metering pump flow.

Blower motor speed incorrect.

Verify motor speed (rpm).

2-6 Page 15 August 2017

Halvorsen B.

SELF DIAGNOSTICS The heater is equipped with self diagnostic capability. To retrieve information on the heater's last five (5) faults, a retrieval device is required (part no. 624-8951). There is a pig tail to accommodate the connector on the main harness from heater. Connect the fault code retrieval device as shown. (1)

(2)

Self-diagnostics Device Functions (a)

Access the current fault which is affecting the heater.

(b)

Access the five previous faults which affected the heater.

(c)

Clear the fault memory to erase previous fault history.

(d)

Unlock “Lockout Features” which exist for some control units.

(e)

Start heater.

Device Face and Controls Symbols that are seen on the display face are as follows. AF F1 through F5

ACTUAL FAULT Up to five stored faults can be accessed. The AF and F1 are the same number. This symbol is displayed when the heater is in operation.

2-6 Page 16 August 2017

DIAG

The word ‘dIA’ for diagnostic will come on when the unit is connected.

000

Three digit diagnostic fault code number.

MAINTENANCE AND REPAIR

Halvorsen

1.

DELETE FAULT MEMORY

2.

DELETE FAULT MEMORY

3.

SWITCH HEATER ON-OFF (REQUEST DIAGNOSTIC FAULT CODES)

4.

BACKWARDS, FAULT F5 THROUGH F1, AF

5.

FORWARD AF, F1 THROUGH F5

6.

DISPLAY SCREEN

Figure 2 FAULT CODE RETRIEVAL DEVICE NOTE:

IF THERE ARE NO HEATER FAULTS, THE HEATER WILL GO THROUGH A NORMAL START CYCLE AND REGULATE BASED ON THERMOSTAT SETTING. (a)

Turn ON the fault code retrieval device and wait 10 seconds.

(b)

Press the “D” button.

(c)

Wait 3 to 5 seconds for the current fault code to appear (AF).

(d)

To review the previous faults use the arrow buttons (F1 = most recent, F5 = oldest).

(e)

Consult the fault code chart for code number descriptions.

(f)

To erase the faults stored in the memory press both “L” keys at the same time for 5 seconds. This will also unlock the control unit in the case of an operational lockout.

TROUBLESHOOTING

2-6 Page 17 August 2017

Halvorsen C.

HEATER FAULT CODES, CAUSES AND ACTIONS

TABLE 6 - D3 AND D4 HEATER FAULT CODES FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION

000

Normal Operation

004

Warning - short circuit in control unit, fresh air outlet

Disconnect connection S1-B1 at AIRTRONIC at connector 81, pin 16 check for short between pin and blower relay. If no short exists replace control unit.

005

Warning - short circuit at control unit anti-theft alarm output

Disconnect connection S1-B1 at AIRTRONIC at connector 81, pin 16 check the line through to the relay isolating switch or theft warning in line for short circuit to chassis. If no short exists replace control unit.

009

TRS - shut down

Switch oft due to signal change. Check for change of signal from (+) to (-) at pin 13 (S1) or a (+) signal at pin 14 (S1).

010

Over voltage

Start vehicle motor. Check voltage at (B1) between terminals 1 and 10. This must be less than 16 volts (15.2 volts with glow pin on). Check vehicle charging system. AIRTRONIC 24 V - voltage must be less than 32 volts

011

Under voltage shut down

Start vehicle motor. Check voltage at connector (B1) between terminals 1 and 10. This must be more than 10 volts. Check vehicle charging system. Check batteries and connections. AIRTRONIC 24 V - voltage must be more than 21 volts. Sensor has detected excessive temperatures. Check for clogged hot air ducting.

012

013

014

2-6 Page 18 August 2017

Overheat at overheating sensor

Check that the total number of ducting pieces in unison is not too large. Re-route if necessary. Check overheat sensor resistance values. If OK measure fuel flow.

Overheat at flame sensor

Flame sensor detects excessive temperature at heat exchanger Check for clogged hot air ducting. Check that the total number 01 ducting pieces in unison is not too large. Re-route if necessary. Measure fuel quantity. Check flame sensor resistance (refer to component value chart).

Temperature difference between flame sensor and overheat sensor too large

Check for clogged hot air ducting. Check that the total number of ducting pieces in unison is not too large. Check flame sensor, if OK, check overheat sensor. If over-heat sensor is defective replace COMB sensor. If over-heat sensor is OK measure fuel quantity. If fuel flow amount is OK replace control unit.

MAINTENANCE AND REPAIR

Halvorsen TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.) FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION

Overheat with excessive temperatures

Fault code 015 is shown when the AIRTRONIC is switched on again alter fault code 017. The hardware limit value for the overheat sensor, has been exceeded control unit is locked. Check sensor. Unlock control unit.

017

Overheat with excessive temperature

The hardware limit value for the overheat sensor, has been exceeded, because the control unit has not detected fault code 012, 013. The control unit is locked. If AIRTRONIC is switched on again, fault code 015 is displayed. Unlock control unit. Check sensor.

019

Glow Pin Resistance

Power consumed by glow pin is too low (glow pin resistance is too high). Replace the glow pin.

015

Check continuity of glow pin. 020

Open circuit - glow pin

AIRTRONIC 12 V - approx. 0.5  ± 0.05  AIRTRONIC 24 V - approx. 2.0  ± 0.20 

021

Short circuit - glow pin

Check functions 01 glow pin in installed condition, disconnecting connector from controller.

CAUTION!

AIRTRONIC 12 VDC and 24 VDC.

For AIRTRONIC 12 V - Check functions with max. 8 volts.

Apply voltage of 8 V and 18 V to glow pin respectively and measure current intensity after 40 seconds.

For AIRTRONIC 24 V - Check functions with max. 18 volts.

Glow pin is OK for the following values:

If voltage values are exceeded the component is destroyed.

•

Glow pin 8 V, current = 9 A +1.5/-1.2 A

•

Glow pin 18 V, current = 4 A ± 0.5 A

Check short-circuit resistance of main unit: 20 A minimum.

If the values differ, replace glow pin. If the values of the continuity test and function test are OK, check glow pin cable harness for damage and continuity. If OK replace control unit.

022

Glow plug, output (+) - short circuit after UB (battery voltage)

Check glow plug lead harness for correct laying and damage and continuity, if OK → replace control box.

025

Diagnostics cable B1-WS - short circuit - after UB (battery voltage)

This fault code cannot be displayed as the diagnostics cable is probably defective. Check diagnostics cable for correct laying and possible damage.

Blower motor interrupted

Check blower motor cable harness for correct routing and damage. If OK, disconnect cable harness from control unit and check for continuity, if OK, replace control unit.

031

TROUBLESHOOTING

2-6 Page 19 August 2017

Halvorsen TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.) FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION

Blower motor, short circuit CAUTION!

032

For AIRTRONIC 12 V check functions with 8 volts maximum!

Check functions of blower motor, disconnecting connector from control unit.

For AIRTRONIC 24 V check functions with 18 volts maximum!

Apply voltage of 8 volts or 18 volts ± 0.1 to blower motor and measure current intensity after 40 seconds.

If voltage values are exceeded the component is destroyed.

Current < 6.5 A - blower motor OK, replace controller. Current > 6.5 A - replace blower.

Check short-circuit resistance of main unit: 20 A minimum.

033

Blower motor does not turn

Motor speed varies from specification by more than 10% for longer than 30 seconds. If too slow, check for restriction and check for short in motor circuit or control unit. If none found, replace blower. If too fast, check for damage or missing magnetic sensor on control unit. Replace blower motor if damaged. Replace control unit otherwise. Disconnect connector from fuel metering pump, if fault code 048 (interruption) is displayed then the fuel metering pump is defective, replace FMP.

047

Short circuit - fuel metering pump

If fault code 047 is still displayed, then disconnect connection S1-B1. At connector B1, Pin 5, check line1 (green-red) through to FMP for short circuit to pin 10, if OK replace control unit.

048

Open circuit - fuel metering pump

Disconnect connector from fuel pump and measure resistance value of fuel pump (refer to values). If resistance values OK, then reconnect cable harness to the fuel pump. Disconnect connection S1-81 and measure the resistance value between pin 5 and pin 10. If OK, replace control unit.

049

Metering pump outlet (+) Short circuit - after UB (battery voltage)

Check that the lead harness of the metering pump has been correctly laid and check for damage, if OK → remove lead harness and check for continuity, if OK → replace control box.

Too many no start attempts

Control unit is locked after too many unsuccessful start attempts. (Maximum 255 start attempts). Check fuel, glow pin, combustion air and exhaust flow. Unlock the control box by deleting the fault memory with the timer, diagnostic unit, Edith costumer service program or diagnostic tool.

050

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MAINTENANCE AND REPAIR

Halvorsen TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.) FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION If the resistance value of flame sensor is 1274  after switching on (> 70 ºC [> 158 ºF]), then the blower or the AIRTRONIC runs for approx. 15 minutes to cool down.

051

Faulty flame recognition

If resistance does not fall below the above value within 15 min., this is followed by fault shut down. Check flame sensor, diagrams and values. If OK, replace control unit.

052

No start safety time exceeded

No flame detected on start attempt. Check exhaust and combustion air lines. Check fuel supply and measure fuel flow (refer to following pages). Check glow pin (refer to fault code 020 and 021). Check flame sensor, diagram and values table on following pages, if OK, replace control unit.

053

Flame cutout in boost mode

Heater has started successfully but the flame has extinguished.

054

Flame cutout in high mode

055

Flame cutout in medium mode

Check exhaust and combustion air lines. Check fuel supply and measure fuel flow, refer to values.

056

Flame cutout in low mode

Check flame sensor, diagram and values table on following pages, if OK, replace control unit. Temperature sensor detects a value beyond it's range sensor.

060

061

Open circuit - external temperature

Short circuit - external temperature

Disconnect connection S1-B1 (main harness), measure resistance value at connector B1, pins 6 and 12. If there is an open circuit, the ohmic value between the pins is > 7175. If the resistance value is OK, then the control unit is defective. Replace control unit. Disconnect connection S1-B1 (main harness). Measure resistance value at connector B1, between pins 6 and 12. If there is a short circuit, the ohmic value between the pins is < 486 . If fault 061 continues to be displayed, then the control unit is detective. Replace control unit. Potentiometer values outside of range on thermostat (switch).

062

Thermostat - rheostat - timer, open circuit

Check resistance between pins 6 and 7 at B1. Resistance value for interruption between pins > 7175  Normal value: 1740  through 2180  (± 80 ). If resistance value is OK, replace control unit. If not replace thermostat switch.

TROUBLESHOOTING

2-6 Page 21 August 2017

Halvorsen TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.) FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION If a ventilating switch has been built-in, disconnect and check function. If faulty, replace switch.

Switch control short circuit

063

Fault recognition only works in heating mode. However, if a short circuit already exists and the AIRTRONIC is subsequently switched on, ventilating mode will be active (no fault code).

Disconnect wires from thermostat or switch. If fault code 062 is displayed, replace switch. If switch is OK, check connection lines gray and red and brown and white for short-circuit. If OK, reconnect wires to thermostat or switch. Disconnect connection B1. If fault 063 is still displayed, replace control unit. Resistance value for short circuit between pins 6 and 7 < 486 . Normal value: 1740  to 2180  (± 80 ). Sensor is detecting value outside of range. Open AIRTRONIC shell and remove control unit from casing.

064

Open circuit - flame sensor

Disconnect green connector from control unit. At connector measure resistance value between green wire and brown-white wire. Check flame sensor, diagram and values. If flame sensor is OK, replace control unit. Resistance value for interruption > 7175  Open AIRTRONIC shell and remove control unit from casing.

065

Short circuit - flame sensor

Disconnect green connector from control unit. If fault 064 is displayed, replace combination sensor (flame-temperature). If fault 065 is still displayed, replace control unit. Resistance value for short circuit < 486 , refer to values on following pages. Open AIRTRONIC shell and remove control unit from casing.

071

Open circuit - overheat sensor

Disconnect blue and green connectors from control unit. Measure the resistance value at blue connector pin 1 (blue wire) and at green connector pin 2 (brown-white wire). Refer to values on following pages. If OK, replace control unit. Resistance value for interruption > 223 

072

Short circuit - overheat sensor

Open AIRTRONIC shell and remove control unit from casing. Disconnect blue connector from control unit. If fault 071 displayed, replace combination sensor (flame-temperature). If fault 072 is still displayed, replace control unit. Resistance value for short circuit < 183 . Refer to the following pages for values.

2-6 Page 22 August 2017

MAINTENANCE AND REPAIR

Halvorsen TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.) FAULT CODE AND DESCRIPTION

FAULT CAUSE AND ACTION

090

Control unit defect

Internal failure. Replace control unit.

091

External voltage disturbance

Check vehicle charging system. Poor battery, battery charger, eliminate fault.

092

Control unit defective (ROM fault)

093

Control unit defective (ROM fault)

094

Control unit defective (EEPROM fault)

095

Control unit defective (ROM fault)

096

Internal temperature sensor defect

Replace control unit or use external temperature sensor if possible.

097

Control unit defective (power failure)

Internal failure. Replace control unit.

Disconnect heater from power for 10 seconds by disconnecting it from harness or pull out the fuses. Reconnect and test again. If the problem persists, replace ECU.

Voltage short-term < 5 6 volt (for 12 volt) or < 7 8 volt (for 24 volt). 099

Too many resets in sequence

Transistor error in control box

TROUBLESHOOTING

In case of a voltage drop, check the fuses, the supply cables, the negative connections and the positive support point on the battery for corrosion and correct contact. Test control box with testing device, if OK → check lead harness of the external components has been correctly laid and check for damage, if OK → check lead harness for continuity, if OK → replace control box.

2-6 Page 23 August 2017

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Halvorsen Section 7. System Schematics 1.

GENERAL INFORMATION The schematics contained in this section are provided as a guide to assist technical service personnel in troubleshooting operational malfunctions in the vehicle hydraulic and electrical systems. These schematics should be used in conjunction with the troubleshooting, reference designators and maintenance procedures sections incorporated in this manual. A.

BEFORE TROUBLESHOOTING Before starting troubleshooting procedures, verify that the correct operating procedures were used. An incorrect operating procedure can cause apparent malfunctions. Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and suspected defective parts to verify that there are no open circuits or defective grounding.

B.

HYDRAULIC SYSTEM CLEANLINESS A very important practice to observe when working on the hydraulic system is cleanliness. Serious damage can result quickly from foreign material (contamination) in the hydraulic system. When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material and moisture laden air (contamination) from entering the system. DO NOT use Teflon tape or pipe compound on straight threads.

SYSTEM SCHEMATICS

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Halvorsen 2.

ELECTRICAL SCHEMATICS NOTE:

THIS SECTION MAY NOT CONTAIN ALL SCHEMATICS LISTED. REFER TO THE PRODUCT SPECIFICATION AT THE FRONT OF THE MANUAL FOR THE APPLICABLE SCHEMATICS FOR YOUR EQUIPMENT.

•

ELECTRICAL SCHEMATIC - 2100SP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

521-3504

•

INTERCONNECT DIAGRAM - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

624-3491-001

•

SP2100 HE WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

625-9070

Electrical Option Schematics NOTE:

OPTION SCHEMATICS ARE PART OF A CUSTOM OPTION. COMPONENTS CAN BE LOCATED IN CHAPTER 4, ILLUSTRATED PARTS LIST.

SYSTEM SCHEMATICS

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Halvorsen

Figure 1 ELECTRICAL SCHEMATIC - 2100SP - 521-3504

SYSTEM SCHEMATICS

2-7 Page 5 August 2017

Halvorsen

Figure 2 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 3 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 7 August 2017

Halvorsen

Figure 4 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

2-7 Page 8 August 2017

MAINTENANCE AND REPAIR

Halvorsen

Figure 5 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 9 August 2017

Halvorsen

Figure 6 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 7 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 11 August 2017

Halvorsen

Figure 8 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 9 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 13 August 2017

Halvorsen

Figure 10 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 11 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 15 August 2017

Halvorsen

Figure 12 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 13 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 17 August 2017

Halvorsen

Figure 14 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 15 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 19 August 2017

Halvorsen

Figure 16 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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Halvorsen

Figure 17 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 21 August 2017

Halvorsen

Figure 18 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 19 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 23 August 2017

Halvorsen

Figure 20 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 21 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

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Halvorsen

Figure 22 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 23 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 27 August 2017

Halvorsen

Figure 24 ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 25 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001

SYSTEM SCHEMATICS

2-7 Page 29 August 2017

Halvorsen

Figure 26 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 27 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 31 August 2017

Halvorsen

Figure 28 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 29 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 33 August 2017

Halvorsen

Figure 30 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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Halvorsen

Figure 31 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

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Halvorsen

Figure 32 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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Halvorsen

Figure 33 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 37 August 2017

Halvorsen

Figure 34 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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Halvorsen

Figure 35 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 39 August 2017

Halvorsen

Figure 36 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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Halvorsen

Figure 37 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 41 August 2017

Halvorsen

Figure 38 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 39 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 43 August 2017

Halvorsen

Figure 40 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

2-7 Page 44 August 2017

MAINTENANCE AND REPAIR

Halvorsen

Figure 41 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 45 August 2017

Halvorsen

Figure 42 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)

2-7 Page 46 August 2017

MAINTENANCE AND REPAIR

Halvorsen

Figure 43 WIRE HARNESS - SP2100 - 625-9070

SYSTEM SCHEMATICS

2-7 Page 47 August 2017

Halvorsen

Figure 44 WIRE HARNESS - SP2100 - 625-9070 (CONT.)

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MAINTENANCE AND REPAIR

Halvorsen

Figure 45 WIRE HARNESS - SP2100 - 625-9070 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 49 August 2017

Halvorsen Refer to Figure 43 through Figure 44.

TABLE 1 - WIRE HARNESS - SP2100 - 625-9070 ITEM

PART NO.

DESCRIPTION

QTY.

1

DWG-623-9526

ELECT FABRICATION PRACTICES

1

2

620-1317-003

FLEX-GARD, NYLON:SLIT 1/2”

3

3

620-1317-004

FLEX-GARD, NYLON:SLIT 5/8”

1

4

620-1317-006

FLEX-GARD, NYLON:SLIT 1”

12

5

620-3900-018

WIRE STRD YEL 18GA GXL

364

6

622-2962-009

CONN, SEALING PLUG

7

7

622-2967-006

CONN, PLUG 4POS (FEMALE)

2

8

622-2967-008

CONN, PLUG 8POS (FEMALE)

2

9

622-2967-009

CONN, RECP 8POS (MALE)

1

10

622-2967-013

CONN, PIN 16-18AWG SOLID

7

11

622-2967-015

CONN, SOCKET (16-18AWG) SOLID

18

12

622-2967-022

CONN, WEDGE 4POS PLUG

2

13

622-2967-024

CONN, WEDGE 6POS PLUG

2

14

622-2967-025

CONN, WEDGE 8POS RECP

1

15

622-2967-042

CONN, BOOT 4 POS. PLUG

2

16

622-2967-043

CONN, BOOT 6 POS. PLUG

2

17

622-2967-050

CONN, BOOT 8 POS. RECP

1

18

622-2967-054

RECEPTACLE, 6 POS. W/BUSSED PINS

1

19

622-2967-055

RECEPTACLE, 6 POS. W/BUSSED PINS

2

20

623-4929-005

CONDUIT, FLEXIBLE NYLON 0.75”

2

21

623-4929-008

CONDUIT, FLEXIBLE NYLON 1”

1

22

625-9092-024

CONN ASSY, 24F TWIST LOCK

1

23

625-9092-025

GROMMET COVER, 24-WAY

1

24

625-9092-026

WIRE DRESS, 24-WAY

1

25

625-9092-027

CONVOLUTE CAPTR, WIRE DRESS

1

26

625-9092-080

CONN ASSEMBLY, 80F BOLT

1

27

625-9092-081

GROMMET COVER, 80-WAY

1

28

625-9092-082

BACKSHELL, 90 DEG. DIR A

1

29

625-9092-083

WIRE DRESS, LOWER 80-WAY 90 DEG

1

2-7 Page 50 August 2017

MAINTENANCE AND REPAIR

Halvorsen TABLE 1 - WIRE HARNESS - SP2100 - 625-9070 (CONT.) ITEM

PART NO.

30

625-9093-001

CONN ASSY, GT150 HALF SHROUD

3

31

625-9093-002

CPA LOCK, GRAY

3

32

625-9093-003

TERMINAL, F GT150

6

33

625-9093-004

SEAL ASSY, CABLE 1-WAY, YELLOW

6

34

625-9093-005

TPA LOCK, BLACK, CONVOLUTE CAPT

3

35

625-9093-006

CONN ASSY, 3-WAY W/P TWR BLK

1

36

625-9093-007

TERMINAL, M W/P PIN

3

37

625-9093-008

SEAL ASSY, CABLE 1-WAY W/P PPL

3

38

625-9093-009

PLUG, CAVITY SEAL

44

39

625-9116

CABLE, TWISTED PAIR, 18AWG

41

40

625-9121-031

CONN, REC., 9-WAY, J9139

1

41

625-9121-046

COVER, HDC16-9, RECPT

1

42

625-9121-050

CONN, STRAIN RELIEF, HD

1

43

625-9121-051

PIN, SIZE 16, GOLD

5

44

626-3024-200

TERM, FEMALE CRIMP

60

45

622-2967-064

RECEPTACLE, BUS PINS 6POS SPLIT

1

46

625-7012-120

AE-RESISTOR, 120:OHM

1

47

623-4929-001

CONDUIT, FLEXIBLE NYLON 0.312”

3

48

623-4995

TY-RAP LARGE 14.5” 50#

10

SYSTEM SCHEMATICS

DESCRIPTION

QTY.

2-7 Page 51 August 2017

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen 3.

HYDRAULIC SCHEMATICS NOTE:

•

THIS SECTION MAY NOT CONTAIN ALL SCHEMATICS LISTED. REFER TO THE PRODUCT SPECIFICATION AT THE FRONT OF THE MANUAL FOR THE APPLICABLE SCHEMATICS FOR YOUR EQUIPMENT.

HYDRAULIC SYSTEM SCHEMATIC - 2100SP . . . . . . . . . . . . . . . . . . . . . . .

623-5420-001

Hydraulic Option Schematics NOTE:

OPTION SCHEMATICS ARE PART OF A CUSTOM OPTION. COMPONENTS CAN BE LOCATED IN CHAPTER 4, ILLUSTRATED PARTS LIST.

SYSTEM SCHEMATICS

2-7 Page 53 August 2017

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen

Figure 46 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001

SYSTEM SCHEMATICS

2-7 Page 55 August 2017

Halvorsen

Figure 47 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)

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Figure 48 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)

SYSTEM SCHEMATICS

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Halvorsen

Figure 49 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)

2-7 Page 58 August 2017

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Figure 50 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)

SYSTEM SCHEMATICS

2-7 Page 59 August 2017

Halvorsen

Figure 51 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)

2-7 Page 60 August 2017

MAINTENANCE AND REPAIR

Halvorsen Refer to Figure 46 through Figure 51.

TABLE 2 - HYDRAULIC SYSTEM COMPONENTS ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5410

MANIFOLD, ASSEMBLY - CHASSIS

1

2

623-5411

MANIFOLD, ASSEMBLY - PITCH

1

3

620-2565

GAUGE, PRESSURE

1

4

623-5413

MANIFOLD, ASSEMBLY

2

5

623-8652

PUMP, PISTON ASSEMBLY

1

6

623-5415

MANIFOLD, ASSEMBLY - STOPS/TR. LIFT

1

8

623-8653

VALVEPAC - FAN DRIVE

1

9

623-5403

VALVE, STEERING CONTROL

1

10

624-0330

PUMP, 2-SECTION - EMERGENCY

1

11

623-5393

CYLINDER, FRONT SIDE SHIFT

1

12

623-5394

CYLINDER, REAR SIDE SHIFT

1

13

623-5930

RESERVOIR, ASSEMBLY

1

14

623-5396

CYLINDER, MAIN LIFT

2

15

623-5397

CYLINDER, HELPER

2

16

623-8650

CYLINDER, PITCH

2

17

623-5399-001

CYLINDER, ROLL - FRONT

2

18

623-5639-001

CYLINDER, PALLET STOP

2

19

623-6556

CYLINDER, TRACTION WHEEL LIFT

18

20

514-8244

FILTER, HIGH PRESSURE

1

21

514-8244-002

ELEMENT, HIGH PRESSURE

22

620-0128

VALVE, SHUTTLE

2

24

623-2906-003

SWITCH, PRESSURE

1

25

623-5460

VALVE, BRAKE, TANDEM

1

26

621-5556

FILTER, RETURN - CASE DRAIN

27

621-5556-002

ELEMENT, FILTER - CASE DRAIN

28

620-1428-001

MOTOR, HYDRAULIC

9

29

623-5399-002

CYLINDER, ROLL - REAR

2

30

623-6380

SWITCH - PRESSURE - STOP LIGHTS

1

31

621-5556-001

INDICATOR, GAUGE

1

SYSTEM SCHEMATICS

REF.

1 REF.

2-7 Page 61 August 2017

Halvorsen TABLE 2 - HYDRAULIC SYSTEM COMPONENTS (CONT.) ITEM

PART NO.

DESCRIPTION

QTY.

32

232-7645

HEAT EXCHANGER

33

623-6703

BREATHER, RESERVOIR

REF.

34

621-5724

FILTER, RETURN - RESERVOIR

REF.

35

620-0461

ELEMENT, RETURN - 5 MICRON

REF.

36

623-6774

MOTOR, HYDRAULIC

1

37

623-5416

MANIFOLD, CONVEY

1

38

623-8712

ACTUATOR, THROTTLE

1

39

624-4218

SWITCH, BRAKE PRESSURE DIFFERENTIAL

1

40

624-8907

VALVE, PRESSURE REDUCER

1

41

624-7180

SWITCH ASSY, PRESSURE

1

42

625-4073

MANIFOLD, AC-MOTOR

1

43

625-3089-005

MOTOR, AC COMP HYD

1

44

623-7300-001

ACTUATOR, STONE BENNETT SHFTR

1

45

625-4427

PLUG, CAVITY

1

46

625-4428

VALVE, CHECK IN-LINE 1908F

1

-

623-7300-006

ACTUATOR, STONE BENNETT SHFTR

1

-

623-8717

VALVE, PROPORTIONAL

2

2-7 Page 62 August 2017

1

MAINTENANCE AND REPAIR

Halvorsen TABLE OF CONTENTS CHAPTER 3. OVERHAUL

Section 1. Overhaul Procedures 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

EQUIPMENT RE-COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3.

REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

4.

ADJUSTMENTS AFTER REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

5.

PRECAUTIONS BEFORE WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Section 2. Removal and Installation 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

BRAKES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

A.

PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

B.

SERVICE BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

PARKING BRAKE FUNCTION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

A.

PARKING BRAKE FORWARD MOVEMENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

B.

PARKING BRAKE REVERSE MOVEMENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

PARKING BRAKE LINING REPLACEMENT AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . .

4

A.

REPLACE PARKING BRAKE LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

5.

PARKING BRAKE, INSTALL REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6.

CHANGE SEAL KIT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

7.

FRONT AXLE BRAKE, REPLACE BRAKE LININGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

8.

FRONT AXLE BRAKE, INSTALL REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

9.

REAR BRAKE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

A.

PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

B.

REMOVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

C.

DISASSEMBLY OF CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

D.

ASSEMBLY OF CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

E.

HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

BOLT-ON DECK HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

A.

17

3.

4.

10.

DAMAGED WALK-DECK WELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

3-Contents Page 1 August 2017

Halvorsen B.

REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Table 1 - BOLT-ON DECK HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

D4 CAB HEATER KIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

A.

INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

12.

CAB SUSPENSION SHOCK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

13.

BOLT-ON DECK BUMPER DOUBLE PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

Table 2 - DECK BUMPER DOUBLER BOLT-ON KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

A.

VEHICLE AND DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

B.

DAMAGED ITEM REMOVAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

C.

RECIPROCATING SAW CUTTING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

D.

CARBIDE BUR CUTTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

E.

PRIME AND PAINT AFFECTED AREAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

F.

KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

SEAT SUSPENSION KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

Table 3 - SEAT SUSPENSION KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

Table 4 - 628-8712. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

A.

SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

B.

SLIDE THE SEAT OFF THE TRACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

C.

DISASSEMBLE THE SEAT FROM THE CAB FLOOR WITH TRACKS ATTACHED . . . . . . .

58

D.

SEAT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

E.

SEAT SUSPENSION INSERT SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

F.

SEAT SUSPENSION INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

G.

SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

H.

INSTALL THE NEW SEAT ASSEMBLY IN THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

I.

OPERATIONAL CHECKOUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

J.

SEAT SUSPENSION KIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

MAIN PANEL CONVERTER KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

A.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

Table 5 - CONVERTER KIT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

Table 6 - TOOLS LIST FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

B.

LOADER PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

C.

CONVERTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

D.

MAIN PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

E.

DRILL NEW HOLES IN THE MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

F.

REINSTALL THE MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

G.

CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

H.

MAIN PANEL CABLE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

I.

CLOSE DOOR ON MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

J.

OPERATIONAL CHECKOUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

11.

14.

15.

3-Contents Page 2 August 2017

OVERHAUL

Halvorsen 16.

RIGHT FRONT HANDRAIL BRACE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

A.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

Table 7 - HALVORSEN BRACE KIT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

Table 8 - TOOLS LIST FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

B.

LOADER PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

C.

INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

D.

ASSEMBLE BRACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

E.

FIT THE BRACE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

F.

TIGHTENING THE BRACE ASSEMBLY IN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

TABLE OF CONTENTS

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Halvorsen LIST OF FIGURES CHAPTER 3. OVERHAUL

Section 1. Overhaul Procedures

Section 2. Removal and Installation 3-2

Figure 1

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3-2

Figure 2

PARKING BRAKE SEALS, REPAIR AND LINING KITS. . . . . . . . . . . . . . . . . . . .

5

3-2

Figure 3

COVER CAP SCREWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

3-2

Figure 4

BELLEVILLE SPRINGS STACKING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . .

8

3-2

Figure 5

FRONT AXLE BRAKE SEALS, REPAIR AND LINING KITS . . . . . . . . . . . . . . . .

12

3-2

Figure 6

CALIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

3-2

Figure 7

BOLT-ON DECK HINGE - PART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

3-2

Figure 8

BOLT-ON DECK HINGE - PART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

3-2

Figure 9

BOLT-ON DECK HINGE - PART 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

3-2

Figure 10

BOLT-ON DECK HINGE - PART 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

3-2

Figure 11

BOLT-ON DECK HINGE - PART 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

3-2

Figure 12

BOLT-ON DECK HINGE - PART 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

3-2

Figure 13

BOLT-ON DECK HINGE - PART 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

3-2

Figure 14

BOLT-ON DECK HINGE - PART 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

3-2

Figure 15

BOLT-ON DECK HINGE - PART 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

3-2

Figure 16

BOLT-ON DECK HINGE - PART 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

3-2

Figure 17

BOLT-ON DECK HINGE - PART 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

3-2

Figure 18

SIDE CONSOLE PANEL AND HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

3-2

Figure 19

INTAKE, EXHAUST AND FUEL LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

3-2

Figure 20

WIRING SPLICE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

3-2

Figure 21

FUEL PUMP INSTALLATION REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

3-2

Figure 22

D4 CUSTOM HEATER REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

3-2

Figure 23

CUBE RELAY REFERENCE SCHEMATIC AND VIEW . . . . . . . . . . . . . . . . . . . .

35

3-2

Figure 24

THERMOSTAT WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

3-2

Figure 25

AUTO LUBRICATION PUSH BUTTON WIRING . . . . . . . . . . . . . . . . . . . . . . . . .

35

3-2

Figure 26

CAB LEFT SHOCK TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

3-2

Figure 27

CAB LEFT SHOCK TOWER WITH CAP REMOVED . . . . . . . . . . . . . . . . . . . . . .

37

LIST OF FIGURES

3-Figures Page 1 August 2017

Halvorsen 3-2

Figure 28

RIGHT SIDE CONSOLE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

3-2

Figure 29

RIGHT SIDE CAB SHOCK TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

3-2

Figure 30

TEMPLATE POSITIONING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

3-2

Figure 31

TEMPLATE HOLE MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

3-2

Figure 32

LIMIT SWITCH REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

3-2

Figure 33

LIMIT SWITCH GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

3-2

Figure 34

LIMIT SWITCH GUARD REMOVAL USING RECIPROCATING SAW . . . . . . . . .

43

3-2

Figure 35

LIMIT SWITCH GUARD REMOVAL USING CYLINDRICAL CARBIDE BUR STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

3-2

Figure 36

LIMIT SWITCH GUARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

3-2

Figure 37

REMAINDER OF C-CHANNEL REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . .

45

3-2

Figure 38

BUMPER GRINDING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

3-2

Figure 39

GRIND WELD FROM BOTTOM OF DOUBLER PLATE . . . . . . . . . . . . . . . . . . . .

46

3-2

Figure 40

CUT THE BOTTOM WELD ON THE DECK DOUBLER PLATE STEPS . . . . . . . .

46

3-2

Figure 41

GRIND DOWN WELD FROM AROUND DECK DOUBLER PLATE STEPS . . . . .

47

3-2

Figure 42

DOUBLER PLATE WELD RELIEF CUT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . .

47

3-2

Figure 43

DOUBLER PLATE REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

3-2

Figure 44

GRIND AREA SMOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

3-2

Figure 45

PRIME AND PAINT AFFECTED AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

3-2

Figure 46

DRILL SIX HOLES IN DECK BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

3-2

Figure 47

LUBRICATE FASTENER BEFORE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . .

50

3-2

Figure 48

DOUBLER PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

3-2

Figure 49

TORQUE FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

3-2

Figure 50

LIMIT SWITCH GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

3-2

Figure 51

LIMIT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

3-2

Figure 52

DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

3-2

Figure 53

AGED CLEVIS REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

3-2

Figure 54

REPLACEMENT CLEVIS AND COLLAR INSTALLATION STEPS . . . . . . . . . . . .

54

3-2

Figure 55

CHECK AIR TRANSPORT SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . .

55

3-2

Figure 56

OPERATOR’S SEAT MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

3-2

Figure 57

STOP AND BENT TAB RIGHT SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

3-2

Figure 58

REAR TAB ON UPPER SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

3-2

Figure 59

UPPER LEFT SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

3-2

Figure 60

UPPER SLIDE RAILS AND S-BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

3-2

Figure 61

SEAT SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

3-2

Figure 62

SEAT SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

3-2

Figure 63

SEAT SUSPENSION ALIGNMENT WITH SLIDE RAILS . . . . . . . . . . . . . . . . . . .

61

3-2

Figure 64

SLIDE RAILS FASTENED TO SEAT SUSPENSION . . . . . . . . . . . . . . . . . . . . . .

62

3-2

Figure 65

SEAT SUSPENSION INSERT ADAPTER PLATE . . . . . . . . . . . . . . . . . . . . . . . . .

63

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OVERHAUL

Halvorsen 3-2

Figure 66

FASTEN ADAPTER PLATE TO SEAT SUSPENSION . . . . . . . . . . . . . . . . . . . . .

64

3-2

Figure 67

INSERT FASTENERS INTO ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

3-2

Figure 68

FASTEN ADAPTERS TO SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

3-2

Figure 69

TIGHTEN ADAPTERS TO SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . .

66

3-2

Figure 70

REMOVE SUSPENSION INSERT SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

67

3-2

Figure 71

TORQUE FASTENERS ON SUSPENSION SUBASSEMBLY . . . . . . . . . . . . . . .

67

3-2

Figure 72

SEAT SUSPENSION ASSEMBLY ATTACHMENT. . . . . . . . . . . . . . . . . . . . . . . .

68

3-2

Figure 73

SEAT INSTALLATION - RAILS ATTACHED TO CAB FLOOR. . . . . . . . . . . . . . .

69

3-2

Figure 74

SEAT INSTALLATION - RAILS NOT ATTACHED TO CAB FLOOR . . . . . . . . . .

70

3-2

Figure 75

TORQUE SEAT MOUNTING FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

3-2

Figure 76

MAIN PANEL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

3-2

Figure 77

POSITIVE AND NEGATIVE CABLES INSIDE MAIN PANEL . . . . . . . . . . . . . . . .

74

3-2

Figure 78

CONVERTER PART NO. 624-8698-030. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

3-2

Figure 79

CONVERTER PART NO. 624-7172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

3-2

Figure 80

REMOVE BATTERY CABLES FROM MAIN PANEL . . . . . . . . . . . . . . . . . . . . . .

76

3-2

Figure 81

COVER PLATE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77

3-2

Figure 82

LOWER MOUNTING FASTENERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .

77

3-2

Figure 83

UPPER MOUNTING FASTENERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .

78

3-2

Figure 84

MAIN PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

3-2

Figure 85

NEW HOLE PATTERN ON BOTTOM OF MAIN PANEL . . . . . . . . . . . . . . . . . . .

80

3-2

Figure 86

MAIN PANEL RE-INSTALLATION ON LOADER . . . . . . . . . . . . . . . . . . . . . . . . .

81

3-2

Figure 87

CHASSIS HARNESS PLATE RE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

81

3-2

Figure 88

CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

3-2

Figure 89

CABLE-RETAINING CLAMP TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

3-2

Figure 90

CABLE-RETAINING CLAMP HAND TIGHTENING . . . . . . . . . . . . . . . . . . . . . . .

83

3-2

Figure 91

ELECTRICAL BOX DOOR CLAMPS TIGHTENING . . . . . . . . . . . . . . . . . . . . . . .

84

3-2

Figure 92

HANDRAIL AND WALK-DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

3-2

Figure 93

HANDRAIL AND WALK-DECK ASSEMBLY (CONT.) . . . . . . . . . . . . . . . . . . . . .

88

3-2

Figure 94

BRACE KIT INSTALLED ON RIGHT FRONT HANDRAIL . . . . . . . . . . . . . . . . . .

89

3-2

Figure 95

PAIRING BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

3-2

Figure 96

LOOSELY CONNECTING BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

3-2

Figure 97

ATTACHING BRACKETS TO HANDRAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

3-2

Figure 98

FITTING UPPER BRACKET TO VERTICAL RAIL . . . . . . . . . . . . . . . . . . . . . . . .

92

3-2

Figure 99

ATTACHING CLAMPING U-BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

3-2

Figure 100

TIGHTENING TO TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .

93

3-2

Figure 101

TIGHTENING ALL OTHER FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

LIST OF FIGURES

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Halvorsen CHAPTER 3. OVERHAUL

Section 1. Overhaul Procedures 1.

GENERAL If an overhaul or a system component is required, refer to Chapter 5, MANUFACTURERS’ APPENDICES for pertinent information. The section or sections that cover the component or system should be read in full and understand completely before attempting any part of an overhaul. Units operating in extreme conditions (such as high or low temperatures, long periods of sustained operation, continued operation in sand or dust, or continued exposure to sea air moisture) need regular inspection. Overhaul periods can be set as necessary.

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS.

WARNING HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF THE POWER UNIT AND DEPLETE SYSTEM PRESSURE BEFORE INSPECTING OR LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP AWAY FROM HYDRAULIC LEAKS. DO NOT ATTEMPT TO “FEEL” FOR THE SOURCE OF A LEAK. PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER SERIOUS INJURY.

CAUTION PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED. ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER UNIT. NOTE:

FOR THE ADJUSTMENT OF COMPONENTS, REFER TO CHAPTER 2, SECTION 5, “MAINTENANCE PROCEDURES”.

OVERHAUL PROCEDURES

3-1 Page 1 August 2017

Halvorsen 2.

EQUIPMENT RE-COMMISSIONING After and overhaul or major repair, the equipment must be thoroughly inspected and serviced as stated in the corresponding maintenance schedules in Chapter 2, Section 3, “Preventative Maintenance”. Also, before placing the vehicle back into service, it must be re-commissioned utilizing the “EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3, “Preventative Maintenance”. NOTE:

THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” SHOULD BE UTILIZED WHEN COMMISSIONING NEW EQUIPMENT AND FOR RE-COMMISSIONING AFTER A MAJOR OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THE-ROAD TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR MORE THAN SIX MONTHS.

CAUTION COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF ENVIRONMENTALLY SENSITIVE MATERIALS, SUCH AS TIRES, BELTS, BATTERIES, MOTOR OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS. 3.

REMOVAL AND INSTALLATION Main components may be necessary to be removed and replaced during overhaul procedures. The sections on removal and installation within this manual include the main assemblies and sub-assemblies and it is not intended to cover all components that could possibly be removed or repaired. Refer to Chapter 4, ILLUSTRATED PARTS LIST and Chapter 5, MANUFACTURERS’ APPENDICES for information on specific components and for the list of spare parts. For safety and reliability use only JBT replacement parts.

4.

ADJUSTMENTS AFTER REPAIRS To ensure proper operation of assemblies and overall components, it is necessary to follow the corresponding adjustment procedures stated in this manual and perform the recommended tests. Refer to Chapter 2, Section 5, “Maintenance Procedures” for the adjustment of components and Chapter 5, MANUFACTURERS’ APPENDICES for additional information.

5.

PRECAUTIONS BEFORE WELDING Proper precautions must be taken to prevent damage to electronic equipment.

CAUTION BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES. PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE THE WELDER’S GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO THE WELDING OPERATION AS POSSIBLE.

3-1 Page 2 August 2017

OVERHAUL

Halvorsen Section 2. Removal and Installation 1.

GENERAL The following procedures for removal, installation and overhaul of vehicle components outline the steps and precautions to take when removing items for replacement and repair. Make sure to read and understand each procedure before attempting to perform it. In addition, after removing and replacing components, adjustments must be performed. Refer to Chapter 2, Section 5, “Maintenance Procedures” for this purpose.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, ENSURE THE VEHICLE IS ON A CLEAN AND LEVEL SURFACE, WHEELS ARE SECURELY CHOCKED, POWER UNIT IS OFF, HYDRAULIC PRESSURE IS DEPLETED AND BATTERIES HAVE BEEN DISCONNECTED. PLACE A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL THAT THE VEHICLE IS BEING WORKED ON.

WARNING BEFORE PERFORMING ANY PROCEDURE THAT REQUIRES THE DECK TO BE IN AN ELEVATED POSITION, INSTALL THE MAINTENANCE STANDS AND LOWER THE DECK FULLY AGAINST THE MAINTENANCE STANDS.

WARNING VEHICLE MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS.

WARNING BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, START ENGINE, RAISE DECK TO SUFFICIENT HEIGHT TO INSTALL THE MAINTENANCE STANDS, THEN LOWER THE DECK UNTIL SCISSORS ROLLERS ARE IN CONTACT WITH THE MAINTENANCE STANDS OR BLOCKS. CHOCK WHEELS TO PREVENT MOVEMENT OF THE LOADER IN EITHER DIRECTION, APPLY THE PARK BRAKE AND TURN OFF THE ENGINE.

WARNING WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.

REMOVAL AND INSTALLATION

3-2 Page 1 August 2017

Halvorsen WARNING TURN THE BATTERY DISCONNECT SWITCH TO THE “OFF” POSITION TO AVOID ELECTRICAL HAZARDS WHILE WORKING ON THE ELECTRICAL SYSTEM.

WARNING WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS, IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL AND PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION.

WARNING USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE VEHICLE (REFER TO JACKING REQUIREMENTS IN SPECIFICATIONS SECTION).

WARNING ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. BLEED AIR FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.

WARNING TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN PANEL.

CAUTION WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS, CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.

CAUTION AFTER REPLACING THE PUMP, FILL THE CASE DRAIN PUMP CAVITY WITH NEW HYDRAULIC OIL BEFORE STARTING THE VEHICLE.

CAUTION PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED. ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER UNIT.

CAUTION DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED.

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OVERHAUL

Halvorsen 2.

BRAKES ADJUSTMENTS A.

PARKING BRAKE ADJUSTMENT NOTE:

THE PARKING BRAKE IS SPRING APPLIED AND HYDRAULICALLY RELEASED. THE LOADER MUST BE RUNNING IN ORDER TO ADJUST THE PARKING BRAKE.

Refer to Figure 1. (1)

Start the loader. Keep the transmission selector in the neutral position. Ensure the parking brake is disengaged (parking brake switch in the OFF position).

(2)

To adjust the parking brake, loosen the lock nut (1) and adjusting screw (2) on brake caliper.

(3)

Place a 0.30 mm (0.012 in.) thick shim (3) between the disc and one of the linings (loader must be running with the parking brake disengaged).

(4)

Tighten the adjusting screw (2) until it is just possible to remove the shim.

(5)

Torque lock nut (1) at 30 to 37 N·m (22 to 27 lbf-ft.) while holding the adjusting screw (2) with a wrench. Remove the shim and release the hydraulic pressure by positioning the parking brake switch in the ON position (applies the brake).

(6)

Remove the maintenance safety blocks and lower the deck fully. Remove wheel chocks.

For parking brake overhaul, refer to ‘5. PARKING BRAKE, INSTALL REPAIR KIT’.

Figure 1 PARKING BRAKE

REMOVAL AND INSTALLATION

3-2 Page 3 August 2017

Halvorsen B.

SERVICE BRAKE ADJUSTMENT (1)

Drive Axle Service Brakes Drive shaft disc brake assembly does not require adjusting. For service brake overhaul, refer to ‘8. FRONT AXLE BRAKE, INSTALL REPAIR KIT’.

(2)

Bogy Wheels Service Brakes Bogy wheels have internal wet disc brake assemblies and do not require adjusting.

3.

PARKING BRAKE FUNCTION TESTS

CAUTION DO NOT RUN ENGINE HIGHER THAN 1200 RPM DURING BRAKE FUNCTION TESTS. NOTE: A.

PARKING BRAKE FORWARD MOVEMENT TEST

B.

4.

PERFORM PARKING BRAKE FUNCTION CHECK FROM THE CAB.

(1)

Start the loader.

(2)

Place foot pressure on the service brake foot pedal and release parking brake.

(3)

Shift transmission to drive.

(4)

Apply parking brake.

(5)

Release foot brake.

(6)

Increase engine speed slowly to verify parking brake holds. Ensure loader does not move.

PARKING BRAKE REVERSE MOVEMENT TEST (1)

Start the loader.

(2)

Place foot pressure on the service brake foot pedal and release parking brake.

(3)

Shift transmission to drive.

(4)

Apply parking brake.

(5)

Release foot brake.

(6)

Increase engine speed slowly to verify parking brake holds. Ensure loader does not move.

PARKING BRAKE LINING REPLACEMENT AND ADJUSTMENT NOTE: A.

3-2 Page 4 August 2017

NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.

REPLACE PARKING BRAKE LINING (1)

Position the parking brake switch in the OFF position to apply hydraulic pressure to release the brake.

(2)

Loosen lock nut (1) and back off adjusting screw (2). Refer to Figure 1).

(3)

Disconnect fluid line from the brake. Cap end of fluid line to prevent entry of dirt into the hydraulic system.

OVERHAUL

Halvorsen (4)

Remove bolts used to fasten the brake assembly to the drive axle. Remove brake assembly.

(5)

Place brake in a soft-jawed vise with disc clearance slot facing up.

NOTE:

CLAMPING SHOULD BE DONE ON THE SIDES OF THE BRAKE ON MACHINED SURFACES.

NOTE:

REFER TO FIGURE 2 FOR (6) THROUGH (9).

(6)

Remove screws (28) and bushings (25). Using a thin-blade tool, pry lining (26) from housing (27) and remove through disc clearance slot.

(7)

Rotate lining assembly (23) until screws (22) are aligned with access holes in housing (27). Remove flat head screws (22). Pry lining (21) from piston (20) and remove through disc clearance slot.

(8)

Install new lining (21) into piston (20) through disc clearance slot. Install new flat head screws (22) and torque to 3.4 to 4.5 N·m (30 to 40 lbf-in.).

(9)

Insert new bushings (25) into new lining (26). Install new lining into housing through disc clearance slot. Align the holes with the housing and fasten with new screws (28). Torque screws (28) 2.5 to 3.2 N·m (22 to 28 lbf-in.).

Figure 2 PARKING BRAKE SEALS, REPAIR AND LINING KITS

REMOVAL AND INSTALLATION

3-2 Page 5 August 2017

Halvorsen

5.

(10)

Reinstall brake on axle and connect hydraulic line.

(11)

Have assistant start engine and place the parking brake switch in the OFF position to apply hydraulic pressure to release the brake.

(12)

Bleed all air from the brake assembly.

NOTE:

PERFORM PARKING ADJUSTMENT’.

BRAKE

ADJUSTMENT

AS

PER

‘A.

PARKING

BRAKE

NOTE:

PERFORM PARKING BRAKE FUNCTION CHECK AS PER ‘3. PARKING BRAKE FUNCTION TESTS’.

PARKING BRAKE, INSTALL REPAIR KIT NOTE:

WHEN REMOVING SEALS AND BACK-UP RINGS, BE CAREFUL NOT TO SCRATCH OR MAR PISTONS. WHEN INSTALLING NEW SEALS IN THE BRAKE, ENSURE THE KIT IS THE PROPER ONE FOR HYDRAULIC FLUID.

NOTE:

NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.

(1)

Position the parking brake switch in the OFF position to apply hydraulic pressure to release the brake.

(2)

Loosen lock nut (1) and back off adjusting screw (2). Refer to Figure 1.

(3)

Disconnect fluid line from brake.

(4)

Disconnect fluid line from the brake. Cap end of fluid line to prevent entry of dirt into hydraulic system.

(5)

Remove bolts used to fasten the brake assembly to the drive axle. Remove brake assembly.

NOTE: (6) NOTE:

Place brake in a soft-jawed vise with cover (3) in a vertical position. CLAMPING SHOULD BE DONE ON THE SIDES OF THE BRAKE ON MACHINED SURFACES.

(7)

Remove bleeder screw (30).

(8)

Using a sharp-bladed tool, carefully remove two seals (29) from housing (27). Note direction of seals.

(9)

To remove cover (3), loosen four cap screws (1).

NOTE:

3-2 Page 6 August 2017

REFER TO FIGURE 2 FOR STEPS (6) THROUGH (31).

LOOSEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER UNTIL SPRING PRE-LOAD IS RELEASED. REFER TO FIGURE 3.

OVERHAUL

Halvorsen

Figure 3 COVER CAP SCREWS (10)

Remove cap screws (1), lock washers (2), cover (3) and gasket (24). Using a thin-blade tool, remove seal (4) from cover.

(11)

Remove Belleville springs (6) and washer (7). Note the stacking sequence of Belleville springs.

(12)

Remove piston (10) from housing (27) bore. Remove O-ring (12) and back-up ring (11) from piston. Push rod (13) should also come out with the piston.

(13)

Remove piston (16) from housing (27) bore. Remove O-rings (14 and 17) and back-up rings (15 and 18) from piston.

(14)

Remove lining assembly (23) from housing (27) bore. Hold assembly on a flat surface and separate lining (21) and piston (20) by removing flat head screws (22). Remove O-rings (19) from piston (20).

(15)

Loosen vise jaws and rotate brake so that disc clearance slot is facing upward. Remove pan head screws (28), lining (26) and bushings (25) from housing (27).

(16)

Lubricate all rubber components from kit with clean hydraulic fluid used in the system.

(17)

Clean all parts and housing bore thoroughly with clean hydraulic fluid used in the system and keep free of all contaminants, dirt and debris.

NOTE:

USE A HEAVY, WATERPROOF GREASE TO LUBRICATE SURFACES AS SHOWN IN FIGURE 2.

(18)

Install new lining (26) in housing (27) using new bushings (25) and new pan head screws (28). Torque screws (28) at 2.5 to 3.2 N·m (22 to 28 lbf-in.).

(19)

Install new lining (21) on piston (20) using new flat head screws (22). Torque screws (22) at 2.7 to 3.4 N·m (24 to 30 lbf-in.). Install new O-rings (19) on piston (20) and insert lining assembly (23) into housing (27) bore.

REMOVAL AND INSTALLATION

3-2 Page 7 August 2017

Halvorsen (20)

Carefully install two new seals (29) in housing (27). Be sure to install seals (29) in the same direction as they were removed.

(21)

Install new bleeder screw (30). Torque bleeder screw 12.2 to 20.3 N·m (9 to 15 lbf-ft.).

(22)

Install new O-rings (14 and 17) and new back-up rings (15 and 18) on piston (16). Note order of components.

(23)

Install piston (16) into housing (27) bore. Note direction of piston.

NOTE:

WHEN INSERTING PISTON, BE SURE NOT TO PINCH O-RING ON INLET PORTS.

(24)

Install new back-up ring (11) and new O-ring (12) on piston (10). Note order of components. Install push rod (13) in bore of piston. Install piston into housing (27) bore.

(25)

Fully lubricate threads of adjusting screw (8) and lock nut (9); install into piston (10).

(26)

Install washer (7), spacer (5) and Belleville springs (6) over end of piston (9). Follow the stacking sequence shown in Figure 4.

NOTE:

NOT ALL MODELS USE SPACER (5) OR WASHER (7). SOME MODELS USE TWO WASHERS (7).

Figure 4 BELLEVILLE SPRINGS STACKING SEQUENCE NOTE:

3-2 Page 8 August 2017

IF SEAL KIT IS BEING INSTALLED, USE EXISTING BELLEVILLE SPRINGS AFTER COMPLETELY LUBRICATING WITH A LIGHT COAT OF HEAVY, WATERPROOF GREASE. REFER TO FIGURE 2. IF REPAIR KIT IS BEING INSTALLED, USE NEW BELLEVILLE SPRINGS, ALREADY GREASED. NOTE THAT THE BELLEVILLE SPRING NEAREST THE COVER (3) WILL CONTACT THE COVER WITH ITS OUTSIDE DIAMETER.

(27)

Install new seal (4) in cover (3).

(28)

Install new gasket (24), cover (3), lock washers (2) and cap screws (1). Torque cap screws at 29.8 to 36.6 N·m (22 to 27 lbf-ft.).

OVERHAUL

Halvorsen NOTE:

6.

TIGHTEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER. REFER TO FIGURE 3.

(29)

Reinstall brake on axle and connect hydraulic line.

(30)

Have assistant start engine and place the parking brake switch in the OFF position to apply hydraulic pressure to release the brake.

(31)

Bleed all air from the brake assembly.

NOTE:

PERFORM PARKING ADJUSTMENT’.

BRAKE

ADJUSTMENT

AS

PER

‘A.

PARKING

BRAKE

NOTE:

PERFORM PARKING BRAKE FUNCTION CHECK AS PER ‘3. PARKING BRAKE FUNCTION TESTS’.

CHANGE SEAL KIT PROCEDURE (1)

Loosen lock nut (9) and back off adjusting screw (8). Refer to Figure 1.

(2)

Disconnect fluid line from brake.

(3)

Remove bolts used to fasten the mounting bracket assembly to vehicle. Remove brake and mounting bracket assembly from vehicle and remove mounting bracket assembly from brake.

NOTE: (4) NOTE:

FOR STEPS (4) THROUGH (26), REFER TO FIGURE 2. Place brake in a soft-jawed vise with cover (3) in a vertical position. CLAMPING SHOULD BE DONE ON THE SIDES OF THE BRAKE ON MACHINED SURFACES.

(5)

Remove bleeder screw (30).

(6)

Using a sharp bladed tool, carefully remove two seals (29) from housing (27). Note direction of seals.

(7)

To remove cover (3), loosen four cap screws (1).

NOTE:

LOOSEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER UNTIL SPRING PRE-LOAD IS RELEASED. REFER TO FIGURE 3.

(8)

Remove cap screws (1), lock washers (2), cover (3) and gasket (24). Using a thin blade tool, remove seal (4) from cover.

(9)

Remove spacer (5), Belleville springs (6) and washer (7). Note the stacking sequence of Belleville springs.

NOTE:

NOT ALL MODELS USE SPACER (5) OR WASHER (7). SOME MODELS USE TWO WASHERS (7).

(10)

Remove piston (10) from housing (27) bore. Remove O-ring (12) and back-up ring (11) from piston. Push rod (13) should also come out with piston.

(11)

Remove piston (16) from housing (27) bore. Remove O-rings (14 and 17) and back-up rings (15 and 18) from piston.

(12)

Remove lining assembly (23) from housing (27) bore. Remove O-rings (19) from lining assembly.

REMOVAL AND INSTALLATION

3-2 Page 9 August 2017

Halvorsen NOTE:

NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.

(13)

Lubricate all rubber components from kit with clean type fluid used in the system.

(14)

Clean all parts and housing bore thoroughly with clean type fluid used in the system and keep free of all contaminants, dirt and debris.

NOTE:

USE A HEAVY, WATERPROOF GREASE TO LUBRICATE SURFACES. REFER TO FIGURE 2.

(15)

Carefully install two new seals (29) in housing (27). Be sure to install seals (29) the same direction as they were removed.

(16)

Install new O-rings (19) on lining assembly (23). Install lining assembly (23) in housing (27) bore.

(17)

Install new O-rings (14 and 17) and new back-up rings (15 and 18) on piston (16). Note order of components.

(18)

Install piston (16) into housing (27) bore. Note direction of piston.

NOTE:

WHEN INSERTING PISTON, BE SURE NOT TO PUNCH O-RING ON INLET PORTS.

(19)

Install new back-up ring (11) and new O-ring (12) on piston (10). Note order of components. Install push rod (14) in bore of piston. Install piston into housing (27) bore.

(20)

Fully lubricate threads of adjusting screw (8) and lock nut (9) and install into piston (10).

(21)

Install washer (7), spacer (5) and Belleville springs (6) over end of piston (10). Follow the stacking sequence shown in Figure 4. Not all models use spacer (5) or washer (7).

NOTE:

COMPLETELY LUBRICATE BELLEVILLE SPRINGS (6) WITH A LIGHT COAST OF HEAVY, WATERPROOF GREASE. REFER TO FIGURE 2.

(22)

Install new seal (4) in cover (3).

(23)

Install new gasket (24), cover (3), lock washers (2) and cap screws (1). Torque cap screws at 30 to 37 N·m (22 to 27 lbf-ft.).

NOTE:

TIGHTEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER. REFER TO FIGURE 3.

(24)

Reinstall brake on axle and connect hydraulic line.

(25)

Have assistant start engine and place the parking brake switch in the OFF position to apply hydraulic pressure to release the brake.

(26)

Bleed all air from the brake assembly.

NOTE:

PERFORM PARKING ADJUSTMENT’.

NOTE:

PERFORM PARKING BRAKE CHECK AS PER ‘3. PARKING BRAKE FUNCTION TESTS’.

3-2 Page 10 August 2017

BRAKE

ADJUSTMENT

AS

PER

‘A.

PARKING

BRAKE

OVERHAUL

Halvorsen 7.

FRONT AXLE BRAKE, REPLACE BRAKE LININGS NOTE:

NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.

Refer to Figure 5. (1)

Disconnect fluid line from brake.

(2)

Remove bolts used to fasten the brake assembly to axle. Remove brake assembly from vehicle.

(3)

Place brake in a soft-jawed vise with end plug (6) in a vertical position.

NOTE:

CLAMPING SHOULD BE DONE AT THE SIDES OF THE CALIPER ON THE MACHINED SURFACES.

(4)

Remove hex nut (1) from compensator assembly (9).

(5)

Remove Belleville spring (2), wedge ring (3), washer (4) and O-ring (5) from compensator assembly (9). Do not discard, save for reassembly.

(6)

Using a spanner wrench, remove end plug (6) from housing (18).

(7)

Remove piston (10) and lining (11) assembly from housing bore.

NOTE:

DO NOT REMOVE COMPENSATOR ASSEMBLY (9) FROM PISTON (10).

(8)

Remove flat head screws (12) to separate lining (11) and piston (10).

(9)

Install new lining (11) on piston (10) using new flat head screws (12).

(10)

Loosen vise jaws and rotate caliper so that disc clearance slot is facing up.

(11)

Remove flat head screws (16) and lining (17) from housing (18).

(12)

Install new lining (17) in housing (18) using new flat head screws (16).

(13)

Rotate caliper to original position in vise.

(14)

Remove seal (15) from housing bore.

(15)

Lubricate new seal (15) from lining kit in clean hydraulic fluid.

(16)

Install new seal (15) into groove of housing bore through the disc clearance slot end of bore. Note the direction of seal.

(17)

Carefully assemble piston (10) and lining (11) assembly to end plug (6).

(18)

Install O-ring (5), washer (4), wedge ring (3), Belleville spring (2) and hex nut (1) on compensator assembly (9).

NOTE:

ENSURE THAT WEDGE RING (3) AND BELLEVILLE SPRING (2) ARE INSTALLED IN PROPER DIRECTION.

REMOVAL AND INSTALLATION

3-2 Page 11 August 2017

Halvorsen

Figure 5 FRONT AXLE BRAKE SEALS, REPAIR AND LINING KITS 3-2 Page 12 August 2017

OVERHAUL

Halvorsen (19) NOTE:

Tighten hex nut (1) securely. ASSEMBLY CREATED FROM STEPS (17) AND (18) IS THE END PLUG AND PISTON ASSEMBLY.

(20)

Lightly lubricate housing bore and piston (10) with clean hydraulic fluid.

(21)

Carefully reinstall end plug and piston assembly into housing bore keeping lining face free of hydraulic fluid and contamination. Tighten end plug (6) with a spanner wrench until it bottoms out on housing (18).

(22)

Install brake on axle and bleed brake to remove all air.

WARNING DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED, AFTER BLEEDING BRAKES. 8.

FRONT AXLE BRAKE, INSTALL REPAIR KIT NOTE:

WHEN REMOVING SEALS AND BACK-UP RINGS, BE CAREFUL NOT TO SCRATCH OR MAR PISTONS. WHEN INSTALLING NEW SEALS IN THE BRAKE, ENSURE THAT THE REPAIR KIT USED IS THE PROPER ONE FOR THE SYSTEM FLUID USED.

NOTE:

NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.

Refer to Figure 5. (1)

Disconnect fluid line from brake.

(2)

Remove bolts used to fasten the brake assembly to axle. Remove brake assembly from vehicle.

(3)

Place brake in a soft-jawed vise with end plug (6) in a vertical position.

NOTE:

CLAMPING SHOULD BE DONE AT THE SIDES OF THE CALIPER ON THE MACHINED SURFACES.

(4)

Remove bleeder screw (19).

(5)

Remove hex nut (1) from compensator assembly (9).

(6)

Remove Belleville spring (2), wedge ring (3), washer (4) and O-ring (5) from compensator assembly (9). Do not discard, save for reassembly.

(7)

Using a spanner wrench, remove end plug (6) from housing (18).

(8)

Remove piston (10) and lining (11) assembly from housing bore.

(9)

Remove flat head screws (12) to separate lining (11) and piston (10).

(10)

Remove compensator assembly (9) from piston (10).

(11)

Loosen vise jaws and rotate caliper so that disc clearance slot is facing up.

(12)

Remove O-ring (8) and back-up ring (7) from end plug (6).

(13)

Using a thin-blade tool, remove back-up ring (14), O-ring (13) and seal (15) from housing bore.

REMOVAL AND INSTALLATION

3-2 Page 13 August 2017

Halvorsen (14)

Remove flat head screws (16) and lining (17) from housing.

(15)

Install new lining (17) in housing (18) using new flat head screws (16).

(16)

Rotate caliper to original position.

(17)

Lubricate all seals, O-rings and back-up rings from repair kit in clean hydraulic fluid.

(18)

Carefully install new back-up ring (7) and O-ring (8) over non-threaded end of end plug (6) and into groove. Ensure they are installed in proper position in groove.

CAUTION WHEN INSTALLING BACK-UP RINGS, IT IS ESSENTIAL THAT SURFACES OF DIAGONAL SPLICE MATCH WITH EACH OTHER AFTER BACK-UP RING IS INSTALLED IN GROOVE. (19)

Install new O-ring (13) and new back-up ring (14) in housing bore. Ensure they are installed in proper position in groove.

(20)

Install new seal (15) into groove of housing bore through the disc clearance slot end of bore. Note the direction of seal.

(21)

Install new compensator assembly (9) in piston (10) and tighten.

(22)

Install new lining (11) on piston (10) using new flat head screws (12).

(23)

Carefully assemble piston (10) and lining (11) assembly to end plug (6).

(24)

Install new O-ring (5), new washer (4), new wedge ring (3), new Belleville spring (2) and new hex nut (1) on compensator assembly (9).

NOTE:

ENSURE THAT WEDGE RING (3) AND BELLEVILLE SPRING (2) ARE INSTALLED IN THE PROPER DIRECTION.

(25) NOTE:

Tighten hex nut (1) securely. THE END PLUG AND PISTON ASSEMBLY CREATED FROM STEPS (25), (26) AND (27).

(26)

Lightly lubricate housing bore and piston (10) with clean hydraulic fluid.

(27)

Carefully reinstall end plug and piston assembly into housing bore keeping lining face free of hydraulic fluid and contamination. Tighten end plug (6) with a spanner wrench until it bottoms out on housing (18).

(28)

Install new bleeder screw (19). Torque approximately 13.6 N·m (10 lbf-ft.).

(29)

Install brake on axle and bleed brake to remove all air.

WARNING DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED, AFTER BLEEDING BRAKES.

3-2 Page 14 August 2017

OVERHAUL

Halvorsen 9.

REAR BRAKE OVERHAUL PROCEDURES A.

B.

C.

D.

PREPARATION (1)

Raise deck to sufficient height to perform all maintenance and install maintenance stands.

(2)

Raise the loader and remove each rear wheel assembly as outlined in Chapter 2, Section 5, “Maintenance Procedures”.

(3)

Relieve pressure from the caliper by loosening the bleeder screw. Remove and cap hydraulic line.

(4)

Remove the two outermost bolts from the caliper assembly and remove caliper and the two brake pad assemblies (make note of all washers and their position for reassembly).

REMOVE HUB ASSEMBLY (1)

Remove the snap ring and cover and cover assembly.

(2)

Remove the outer Timken bearing nut, lock washer and inner nut.

(3)

Remove outer wheel bearing.

(4)

Remove hub.

(5)

Unscrew the 18 button head hex screws and remove the rotor assembly.

(6)

Inspect rotor for any bluing and heat cracks. Rotor should be resurfaced whenever pads are replaced, do not allow less than 10 mm (0.40 in.) minimum thickness. If there are any signs of abnormal wear discard and replace with a new rotor assembly.

DISASSEMBLY OF CALIPER (1)

Detach boot from the pistons.

(2)

Remove the pistons.

(3)

Remove the boot from the housing groove.

(4)

Remove the O-ring.

(5)

Remove the bleeder screw.

(6)

Clean and inspect all components for abnormal wear.

ASSEMBLY OF CALIPER (1)

Internal grooves in housing must be free of sand, dirt, chips and particle contaminants.

(2)

Lubricate O-rings and the housing grooves with hydraulic fluid (MIL-H-32282).

(3)

Install bleeder screw.

(4)

Install O-rings into the second groove of the housing bores.

(5)

Install Piston assemblies.

(6)

Expand small end of the boot and install this end first over the closed end of the piston.

(7)

Push the piston all of the way into the cavity depth and engage the small end of the boot into the groove of the piston.

(8)

Push the piston in slowly until it bottoms out in the bore.

REMOVAL AND INSTALLATION

3-2 Page 15 August 2017

Halvorsen E.

HOUSING ASSEMBLY (1)

Assemble the housing with the pistons fully retracted, the spacer, secondary plate and four center bolts with the washers under the heads of the bolts and lock nuts. Refer to Figure 6.

(2)

Torque the four center bolts to 108 to 122 N·m (80 to 90 lbf-ft.).

(3)

Repack wheel bearings and install new wheel seal.

(4)

Install new or resurfaced rotor to the hub assembly. Install rotor screws with a non-permanent thread locking compound. Torque the screws to 39 N·m (29 lbf-ft.).

(5)

Install hub assembly, outer wheel bearing and inner wheel bearing nut.

(6)

Tighten inner wheel bearing nut while rotating the hub assembly, keep tightening the inner wheel bearing nut until the rotating hub begins to drag. Then loosen the nut slightly to free up the hub assembly.

(7)

Install the lock washer and outer wheel bearing nut and torque to 68 to 81 N·m (50 to 60 lbf-ft.). Recheck that the hub rotates freely. ONE WASHER BETWEEN CALIPER AND MOUNTING BRACKET P/N: 624-8920-003

TWO WASHERS UNDER EACH HEAD P/N: 624-8970-003

ONE NUT ON CALIPER BOLT P/N: 624-8970-006

ONE SPACER BETWEEN CALIPER AND MOUNTING BRACKET P/N: 624-8970-004

ONE OUTER CALIPER BOLT POINTED TOWARDS TIRE/WHEEL ASSEMBLY P/N: 624-8970-005

Figure 6 CALIPER ASSEMBLY 3-2 Page 16 August 2017

OVERHAUL

Halvorsen (8)

NOTE:

10.

Install the caliper assembly and new brake pads to the bracket and install the two end bolts, placing the two washers under the head of the bolts and one spacer between the calipers and mounting bracket. THE BOLT THREAD ENDS SHOULD POINT TOWARD THE WHEEL.

(9)

Install the locking nut and torque to 20 to 27 N·m (15 to 20 lbf-ft.).

(10)

Reinstall tire and wheel assembly as per procedure in Chapter 2, Section 5.

BOLT-ON DECK HINGE

WARNING SECURE THE WALK-DECK SO THAT IT IS COMPLETY SUPPORTED, SO THAT WHEN IT IS DISCONNECTED FROM THE HINGES IT WILL NOT FALL.

WARNING THE EDGES ON THE METAL ARE SHARP AND CAN CAUSE INJURY. A.

DAMAGED WALK-DECK WELD A damaged weld walk-deck or guide hinge is to be replaced by the following steps.

B.

(1)

Remove the walk-deck and guide that is attached to the damaged hinge in such a way as to leave other walk-decks and guides still attached to the adjacent hinges.

(2)

Remove the welds and the damaged hinge from the deck beam Using a plasma cutter or die grinder.

(3)

Attach a new bolt-on hinge using a variable thickness (“peelable”) shims and supplied hardware by match drilling the deck beam.

REPLACEMENT PROCEDURE NOTE:

THE INSTRUCTIONS ARE WRITTEN FOR A WALK-DECK HINGE REPLACEMENT; REPLACEMENT OF A GUIDE WOULD BE SIMILAR.

(1)

Gain access to the damaged hinge by placing the loader deck at working height. The hinge damage may vary. Refer to Figure 7.

(2)

Pull out the quick release pins to allow the deck to hinge upward freely.

(3)

Empty all compartments of the walk-deck to be removed. Attach the lifting straps to the walk-deck and support with the overhead lift.

(4)

Ensure the spacers between the sections of the walk-decks and the guide arms that are going to be removed. They must be replaced in the same location when reinstalling the walk-deck if they fall out. The spacers and washers maintain the proper relationships (gaps) between the adjacent walk-deck and guides.

(5)

The walk-deck containing the broken hinge is to be removed at this point. It must be removed from the adjacent undamaged hinges in such a way as not to disturb the other walk-decks and guides attached to the same hinges. In order to do this, loosen the center pivot nut on the undamaged hinge on the side facing the damaged hinge.

REMOVAL AND INSTALLATION

3-2 Page 17 August 2017

Halvorsen (6)

With a hammer, tap the pivot bolt into the hinge until it is flush with the hinge. While using a drift pin, continue tapping the pivot bolt into the hinge until the inserted pin takes up the support of the guide that is also in the hinge (if present).

(7)

From the other side, continue to pull out the center hinge bolt to the point where it still supports the guides and walk-deck that are not to be removed. Take care not to remove the bolt too far. Repeat steps (3) through (7) for the adjacent undamaged hinge, if required.

(8)

Using a lifting device capable of 340kg (750 lb.) remove the walk-deck to gain access to the damaged hinge.

(9)

Using a plasma cutter or a die grinder, remove the welds on the broken hinge. Remove as little material as possible from the deck beam.

(10)

Using a hammer, remove the hinge from the deck beam. If the hinge does not come loose, repeat step (8), do not remove too much material from the deck beam.

(11)

Using a grinder, clean the remaining welds from the beam surfaces so that they are smooth and flat.

(12)

Place the replacement hinge part number (part no. 624-8935) into the beam approximately where the broken hinge was removed.

NOTE:

THERE IS A TOP AND A BOTTOM ORIENTATION. THE TOP HOLE IN THE SIDE PLATES IS HIGHER THAN THE FLANGE, WHILE THE LOWER HOLE IS LEVEL WITH THE FLANGE.

(13)

Reinstall the walk-deck tap the center threaded rod back into place, driving out the temporary drift pin installed in step (6), ensure all spacers (if present) remain in place. Tighten locking nuts until SNUG against hinge.

(14)

Attach the replacement hinge to the walk-deck using the original hardware and spacers (if there are any). While holding the hinge straight, measure the gap between the back of the hinge and the deck beam. Using the supplied “peelable” aluminum shim (part no. 624-8925), remove enough laminates, so that the resulting shim thickness matches the measurement of the gap. Peel back small layers at a time, using a knife on the corner to expose enough material to grab and pull back with pliers.

(15)

Holding the hinge and the shim in place, match drill at least two holes on each side of the hinge. Attach the hinge (part no. 624-8935) and the back shim (part no. 624-8925) using the supplied hardware. Finish drilling all of the other usable holes and attach the hardware inserting the bolt from the hinge side.

CAUTION ONLY SELECT PREDRILLED HOLES THAT WILL NOT ALLOW YOU TO DRILL INTO THE BLIND CAVITIES BEHIND THE DECK BEAM, AS A NUT IS GOING TO BE INSTALLED ON THE BACK SIDE OF THE DECK BEAM. (16)

3-2 Page 18 August 2017

Ensure to use the supplied “peelable” aluminum shims (part no. 624-8920) to fill the spaces between the top and bottom of the hinge and the deck beam. Tap in place of steel flat stock.

OVERHAUL

Halvorsen

TYPICAL DAMAGED WALK-DECK HINGE

ADJACENT HINGE

DAMAGED HINGE

ADJACENT HINGE

BOLT-IN REPLACEMENT HINGE AND SHIMS INSTALLED Figure 7 BOLT-ON DECK HINGE - PART 1

REMOVAL AND INSTALLATION

3-2 Page 19 August 2017

Halvorsen (17)

Using a right angle drill, match drill the holes on the top of the deck beam at the bottom.

NOTE:

IF A RIGHT ANGLE DRILL IS NOT AVAILABLE, MEASURE THE DISTANCE FROM THE HOLE IN THE OUTSIDE OF THE BEAM AND TRANSFER THIS DISTANCE TO THE OTHER SIDE OF THE BEAM TO LOCATE THE DRILL POINT. INSERT BOLTS FROM THE OUTSIDE OF THE DECK BEAM, SO THAT THE NUT ENDS UP ON THE NEW HINGE.

(18)

Tighten all hardware to 34 N·m (25 lbf-ft.). Touch up exposed unpainted surfaces with paint.

(19)

Ensure to check for correct movement of the walk-deck.

TYPICAL DAMAGED HINGE

PULL OUT TOP RELEASE PINS

ATTACH LIFTING STRAPS TO WALK DECK Figure 8 BOLT-ON DECK HINGE - PART 2

3-2 Page 20 August 2017

OVERHAUL

Halvorsen

REMOVE BROKEN HINGE

SPACERS AND WASHERS (IF PRESENT)

LOOSEN CENTER PIVOT NUT ON UNDAMAGED HINGE

NUT REMOVED ON UNDAMAGED ADJACENT HINGE CLOSEST TO THE DAMAGED HINGE SIDE Figure 9 BOLT-ON DECK HINGE - PART 3

REMOVAL AND INSTALLATION

3-2 Page 21 August 2017

Halvorsen

TAP IN CENTER BOLT FLUSH WITH OUTSIDE HINGE FACE.

INSERT A DRIFT PIN, INTILL SUPPORTS THE GUIDE.

CONTINUE TO PULL OUT THE CENTER HINGE BOLT TO THE POINT WHERE IT STILL SUPPORTS THE GUIDES. DECK HAS BEEN REMOVED SPACERS REMAIN IN THEIR ORGINAL LOCATIONS.

Figure 10 BOLT-ON DECK HINGE - PART 4

3-2 Page 22 August 2017

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Halvorsen

SUITABLE LIFTING DEVICE CAPABLE OF LIFTING 340 kg (750 lb.)

DAMAGED HINGE TO BE REMOVED

GRIND OUT WELDS ONLY ON BOTH SIDES OF THE HINGE

Figure 11 BOLT-ON DECK HINGE - PART 5

REMOVAL AND INSTALLATION

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Halvorsen

SOAPY WATER WILL HELP GRINDER FROM JAMMING WITH ALUMINUM FILLINGS.

REMOVE WELDS, USING DYE GRINDER.

REMOVE THE HINGE FROM THE DECK BEAM. IF THE HINGE DOES NOT COME LOOSE, REPEAT STEP 1.

Figure 12 BOLT-ON DECK HINGE - PART 6

3-2 Page 24 August 2017

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Halvorsen

USING THE DYE GRINDER, CLEAN ALL REMAINING WELDS; BEAM SURFACES MUST BE SMOOTH AND FLAT.

REST ALL THE WALK-DECK. TAP THE CENTER THREADED ROD BACK INTO PLACE DRIVING OUT THE TEMPORARY DRIFT PIN. ENSURE ALL SPACERS REMAIN IN PLACE.

Figure 13 BOLT-ON DECK HINGE - PART 6

REMOVAL AND INSTALLATION

3-2 Page 25 August 2017

Halvorsen

TAP THE CENTER THREADED ROD BACK INTO PLACE.

USE A KNIFE OR OTHER SHARP EDGE TO LIFT THE LAMINAT ON ONE CORNER.

TYPICAL “PEELABLE” ALUMINUM SHIM, PART NO. 624-8920 SHOWN (STEP 13) USES PART NO. 624-8925.

WARNING: EDGES OF METAL ARE VERY SHARP.

Figure 14 BOLT-ON DECK HINGE - PART 7

3-2 Page 26 August 2017

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Halvorsen

CHECK FOR CORRECT MOVEMENT OF THE WALK-DECK

Figure 15 BOLT-ON DECK HINGE - PART 8

REMOVAL AND INSTALLATION

3-2 Page 27 August 2017

Halvorsen 624-8935

624-8925

SHIM, LAMINATED BACK M-HINGE SUPPORT NGSL

624-8959

625-4369 SHIM, LAMINATED BACK-REAR SHIM, LAMINATED BACK-DOUBLE 624-8956 624-8960

SHIM, LAMINATED DOUBLE M-HINGE SUPPORT, DOUBLE 625-4123 625-4370

SHIM-LAMINATED REAR

M-HINGE REAR SUPPORT, NGSL Figure 16 BOLT-ON DECK HINGE - PART 9

3-2 Page 28 August 2017

OVERHAUL

USE 624-8955

REMOVAL AND INSTALLATION USE 624-8955

USE 624-8971

USE 624-8971

USE 624-8955

USE 624-8955

USE 624-8971

USE 625-4459

USE 624-8971

USE 624-8955

USE 624-8955

USE 625-4459

USE 625-4258

USE 625-4258

Halvorsen

Figure 17 BOLT-ON DECK HINGE - PART 10

3-2 Page 29 August 2017

Halvorsen Refer to Figure 16 and Figure 17.

TABLE 1 - BOLT-ON DECK HINGE 624-8954 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9307

SCR, HHC-F 10.9 M8 x 1.25 x 50 MG

18

2

107-9259

NUT PTH 10.9 x 1.25 MG

18

3

107-9275

WASHER FLAT STD HD M8 MG

36

4

107-9307

SCR, HHC-F 10.9 M8 x 1.25 x 50 MG

20

5

107-9259

NUT PTH 10.9 M8 x 1.25 MG

20

6

107-9275

WASHER FLAT STD HD M8 MG

40

7

107-9307

SCR, HHC-F 10.9 M8 x 1.25 x 50 MG

12

8

107-9259

NUT PTH 10.9 M8 x 1.25 MG

12

9

107-9275

WASER FLAT STD HD M8 MG

24

10

107-9307

SCR, HHC-F 10.9 M8 x 1.25 x 50 MG

10

11

107-9259

NUT PTH 10.9 M8 x 1.25 MG

10

12

107-9275

WASHER FLAT STD HD M8 MG

20

13

624-8953

M-HINGE SUPPORT NGSL

1

14

624-8925

SHIM, LAMINATED BACK

1

15

624-8920

SHIM, LAMINATED TOP AND BOTTOM

2

16

624-8955

K-HINGE, BOLT-ON DECK, SINGLE

17

624-8971

K-HINGE, BOLT-ON DECK, DOUBLE

18

624-8956

M-HINGE SUPPOPRT, DOUBLE

1

19

624-8959

SHIM, LAMINATED BACK-DOUBLE

1

20

624-8960

SHIM, LAMINATED DOUBLE

2

21

625-4258

K-HINGE REAR NGSL

22

625-4123

M-HINGE REAR SUPPORT, NGSL

1

23

625-4369

SHIM, LAMINATED BACK-REAR

1

24

625-4370

SHIM, LAMINATED REAR

2

25

625-4459

K-HINGE SUPPORT, REAR GUIDERAIL

26

625-4446

M-HINGE SUPPORT, REAR GUIDERAIL

1

27

624-4369

SHIM, LAMINATED BACK-REAR

1

28

625-4370

SHIM, LAMINATED TOP-BACK

2

3-2 Page 30 August 2017

OVERHAUL

Halvorsen 11.

D4 CAB HEATER KIT REPLACEMENT

WARNING DRAIN ALL FUEL FROM THE HEATER FUEL TANK BEFORE PROCEEDING.

A.

NOTE:

BEFORE BEGINNING PROCEDURES, VERIFY THAT THE FAULTY HEATER THAT IS BEING REPLACED IS A D3LC HEATER BY CHECKING THE ID DECAL.

NOTE:

TURN THE BATTERY DISCONNECT SWITCH, LOCATED ON THE BATTERY BOX, TO THE OFF POSITION AND INSTALL CHOCKS BEFORE WORK IS PERMITTED ON THE LOADER.

NOTE:

INSTALLATION INSTRUCTIONS REQUIRE ONE TECHNICIAN AND ONE ASSISTANT.

INSTALLATION PROCEDURES Refer to Figure 18. (1)

Turn the battery disconnect switch, located on the battery box, to the OFF position and install wheel chocks.

(2)

Pull the cab all the way out to safely drain all fuel from the heater fuel tank before proceeding.

(3)

Completely remove the side console panel from the cab to fully access the heater. The convey panel, auto lubrication push button, transmission joystick and heater thermostat must be unplugged and removed during this step. Save all removed hardware for reassembly later.

Figure 18 SIDE CONSOLE PANEL AND HEATER

REMOVAL AND INSTALLATION

3-2 Page 31 August 2017

Halvorsen (4)

Completely remove the heater and heater hood from the cab by removing the four (4) mounting nuts and washers securing the heater to the cab. The intake and exhaust hoses, intake fuel line, hot air duct and heater electrical harness must also be disconnected from the heater during this step. Refer to Figure 19. Keep all removed hardware and clamps for installation of new heater.

Figure 19 INTAKE, EXHAUST AND FUEL LINE (5)

Completely remove and discard the heater fuel pump. Keep fuel pump hose and clamps for installation of new heater fuel pump.

(6)

Completely remove the heater electrical harness from the cab by cutting wire number 1 and wire number 14 on the cab electrical harness.

NOTE:

3-2 Page 32 August 2017

CUT BOTH WIRES LABELED WIRE NUMBER 1 DURING THIS STEP. SOME LOADER MAY BE CONFIGURED WITH A BROWN WIRE (NUMBER 1) AND A RED WIRE (NUMBER 13).

(7)

Remove the splices from wire number 1 and wire number 13, leaving as much wire on the cab electrical harness as possible. Disconnect the red wire from 3CR-A (30). The wire splices and 3CR-A are located under the dash pane. Refer to Figure 20.

(8)

Strip both wires labeled wire number 1 and the single wire labeled wire number 13 approximately 0.25 inches.

(9)

Crimp the supplied female spade (part no. 239-3650-001) to the single wire labeled wire number 13.

(10)

Crimp the supplied female spade (part no. 239-3650-002) to both wires labeled wire number 1.

(11)

Place a 19 mm (0.75 in.) long piece of heat shrink tubing (part no. 624-8942-004) over both crimped connections on female spades referenced in steps (9) and (10). Refer to Figure 22.

OVERHAUL

Halvorsen

Figure 20 WIRING SPLICE REMOVAL (12)

Install D4 24 VDC Heater (part no. 627-5930-001) and hood (part no. 627-5930-003) in the locations of the previously removed heater, heater hood and fuel pump using all the previously removed hardware. The heater fuel pump must be fastened to the cab at a 15º to 35º angle from the horizontal. Refer to Figure 21.

(13)

Next, connect the intake and exhaust hoses, intake fuel line, fuel tank line and hot air duct to D4 24 VDC Heater (part no. 627-5930-001) and hood (part no. 627-5930-003) using the previously removed clamps.

(14)

Install D4 Custom Heater (part no. 627-5930-002) by following the routing of the previously removed heater harness.

(15)

Route the two (2) loose green wires through the fuel pump access hole. Insert both wires in the black fuel pump connector that is provided with D4 Custom Heater (part no. 627-5930-002) and then connect it to the fuel pump. Refer to Figure 21. The fuel pump is not affected by wire polarity.

(16)

Connect the red wire with red male spade from item number 2 to 3CR-A (30). Refer to Figure 22 that shows 3CR-A (cube relay) schematic for reference. Next, connect the red wire with blue female spade to wire number 13 on the cab electrical harness and connect the brown wire with the blue female spade to wire number 1 on the cab electrical harness.

(17)

Reinstall the side console panel and all previously removed electrical components. Verify that the heater thermostat and the auto lubrication push button are wired properly before proceeding. Refer to Figure 22.

REMOVAL AND INSTALLATION

3-2 Page 33 August 2017

Halvorsen (18)

Fill the heater fuel tank with one of the following fuels listed in table below. Turn the battery disconnect switch to the ON position then verify that the heater thermostat and all other components are operating correctly. It may take a few minutes for the heater to reach full output capabilities.

Figure 21 FUEL PUMP INSTALLATION REFERENCE

627-5930-002 Figure 22 D4 CUSTOM HEATER REFERENCE

3-2 Page 34 August 2017

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Halvorsen

Figure 23 CUBE RELAY REFERENCE SCHEMATIC AND VIEW

Figure 24 THERMOSTAT WIRING DIAGRAM

Figure 25 AUTO LUBRICATION PUSH BUTTON WIRING

REMOVAL AND INSTALLATION

3-2 Page 35 August 2017

Halvorsen 12.

CAB SUSPENSION SHOCK ADJUSTMENT (1)

Shut off the engine and turn off the battery disconnect switch.

(2)

Open the cab door.

(3)

Remove the black shock tower cap from the left shock tower. Refer to Figure 26 and Figure 27.

Cab Left Shock Tower with Cap 625-4873

Figure 26 CAB LEFT SHOCK TOWER

3-2 Page 36 August 2017

(4)

Starting from the complete unscrewed position, screw the dampening adjustment screw clockwise 13 detent clicks.

(5)

Re-install the black tower cap on the shock tower. Refer To Figure 26.

(6)

Sitting in the cab, remove and electrically disconnect the transmission shifter joystick panel from the right side console.

(7)

Remove the electrically disconnect the convey panel from the right side console.

OVERHAUL

Halvorsen

Cab Left Shock Tower

Shock SDAS

Figure 27 CAB LEFT SHOCK TOWER WITH CAP REMOVED (8)

Remove the right side console by unscrewing the seven (7) M10 bolts. Three (3) bolts are on the inside of the panel and four (4) bolts are on the outside along the bottom. Refer to Figure 28. Transmission Shifter Joystick Panel

Convey Panel

Four (4) M10 Outside Bolts

Figure 28 RIGHT SIDE CONSOLE PANEL

REMOVAL AND INSTALLATION

3-2 Page 37 August 2017

Halvorsen (9)

Lift the right side console out of the way and remove the black shock tower cap from the shock tower at the right of the seat. Refer to Figure 29.

Right Side Convey Console

Right Shock Tower with Cap

Figure 29 RIGHT SIDE CAB SHOCK TOWER

3-2 Page 38 August 2017

(10)

Rotate the red SDAS counter clockwise until fully unscrewed position.

(11)

Starting from the complete unscrewed position, screw the dampening adjustment screw clockwise 13 detent clicks.

(12)

Re-install the black shock tower cap on the shock tower.

(13)

Re-install the right side console and the seven (7) bolts to their locations.

(14)

Electrically re-connect and re-install the transmission shifter joystick and convey panel to the right side console.

(15)

Ensure the loader transmission is shifting properly and that the convey functions are completely restored. Refer to the operator and maintenance manuals if necessary.

OVERHAUL

Halvorsen 13.

BOLT-ON DECK BUMPER DOUBLE PLATE INSTALLATION

TABLE 2 - DECK BUMPER DOUBLER BOLT-ON KIT 628-1494

A.

ITEM

PART NO.

DESCRIPTION

QTY.

1

105-0327-901

LOCTITE 242 (24205) 0.5ML

1

2

107-9084

SCR,HHC 8.8 M10X1.5X50 MG

2

3

107-9214

SCR,SFH-F 10.9 M12X1.75X50 MG

4

4

107-9260

NUT,PTH 8 M10X1.50 MG

2

5

107-9276

WSHR,FLAT STD HD M10 MG

4

6

628-1805

W-CLEVIS, AIR TRANSPORT

1

7

625-8097

GUARD, LIMIT SW BOLT-ON

1

8

627-6384-001

STEP BIT, 1/8–1/2, 1/4 SHANK

1

9

628-1512

PLATE, DECK BUMPER OUTER DOUBLER

1

10

628-1516

PLATE, DECK BUMPER INNER DOUBLER

1

12

628-1774

DECAL, ATS CLEVIS AND PIN INSTAL

1

13

628-4094

W-TEMPLATE, ATS DOUBLER BOLT-ON

1

14

DWG-628-1595

PROCEDURES, ATS DOUBLER BOLT-ON

1

15

107-9302

SCR,HHC 10.9 M8X1.25X25 MG

1

16

628-2891-002

CYLINDRICAL END CARBIDE BUR

1

17

628-2561

ALUMINUM GRINDING WHEEL

2

18

628-2557

ALUMINUM CUTOFF WHEEL

2

VEHICLE AND DECK PREPARATION

CAUTION THE DECK MUST BE CENTERED AND LEVEL BEFORE ANY MODIFICATIONS ARE TO BE PERFORMED. FAILURE TO CENTER AND LEVEL THE DECK MAY CAUSE MISALIGNMENT ISSUES LATER IN THE PROCEDURES. (1)

Apply the park brake and chock wheels to prevent movement of the loader in either direction.

REMOVAL AND INSTALLATION

3-2 Page 39 August 2017

Halvorsen (2)

Raise deck past the FIRST maintenance stand position and install both maintenance stands, then lower the deck until the scissor rollers rest on both maintenance stands.

(3)

Verify the deck is level and centered by actuating and holding, the auto center and level switch on the cab dash panel until the pitch, roll and shift indicator lights are not illuminated.

(4)

From outside the loader, visually verify the side shift cylinders are centered, all four roll cylinders are completely lowered and the pitch arm is in the correct position for a level deck. Refer to Chapter 2, Section 5, “Maintenance Procedures” for more information.

(5)

Shut down the engine and turn the battery disconnect switch, located on the battery box, to the OFF position.

(6)

Install item number 13 (part no. 628-4094 W-TEMPLATE, ATS DOUBLER BOLT-ON) as shown in Figure 30, step 1.

(7)

Push item number 13 (part no. 628-4094 TEMPLATE, ATS DOUBLER BOLT-ON) upwards so that the top of the template keyway is contacting the top surface of the slotted hole in the deck bumper. Align the bottom edge of item number 13 (part no. 628-4094 TEMPLATE, ATS DOUBLER BOLT-ON) horizontally with the bottom edge of the deck bumper. Refer to Figure 30, step 2.

Figure 30 TEMPLATE POSITIONING STEPS

3-2 Page 40 August 2017

(8)

The template keyway should fit inside the slotted hole in the deck bumper and the template should fit flush against the deck bumper. The template may be held in position using a locking welding clamp or suitable clamping device. Refer to Figure 31.

(9)

Mark the center of the six (6) holes on item number 13 (part no. 628-4094 TEMPLATE, ATS DOUBLER BOLT-ON) with a center punch or suitable marking device. Refer to Figure 31. The markings will be used to drill six holes in the deck bumper later in these procedures.

OVERHAUL

Halvorsen

Figure 31 TEMPLATE HOLE MARKINGS (10)

Remove item number 13 (part no. 628-2841 TEMPLATE, ATS DOUBLER BOLT-ON).

(11)

Label the three (3) limit switches shown in Figure 32, step 1. This will help identify these items during the reassembly portion of these procedures.

(12)

Remove the three (3) limit switches from the limit switch guard. Save all hardware for later reuse. Refer to Figure 32, step 2. As a note, it will not be possible to lower the deck after these limit switches have been removed.

Figure 32 LIMIT SWITCH REMOVAL STEPS

REMOVAL AND INSTALLATION

3-2 Page 41 August 2017

Halvorsen B.

DAMAGED ITEM REMOVAL PROCEDURES Remove the limit switch guard from the inside of the deck bumper. Use caution to avoid damaging surrounding electrical harnesses while removing this item. Refer to Figure 33. Two different cutting methods can be used to accomplish this task. The limit switch guard may be removed with a reciprocating saw or a die grinder with suitable cutting attachments. Please select one of these methods depending upon the available tools and refer to the corresponding section.

LIMIT SWITCH GUARD

ELECTRICAL HARNESS

Figure 33 LIMIT SWITCH GUARD

CAUTION DO NOT CUT INTO OR REMOVE MATERIAL FROM THE DECK BUMPER WHEN REMOVING ITEMS USING CUTTING OR GRINDING TOOLS.

3-2 Page 42 August 2017

OVERHAUL

Halvorsen C.

RECIPROCATING SAW CUTTING METHOD Remove the limit switch guard by cutting the C-channel with a reciprocating saw and a cutting blade suitable for cutting aluminum. Refer to Figure 34 for before and after images.

BEFORE

AFTER

Figure 34 LIMIT SWITCH GUARD REMOVAL USING RECIPROCATING SAW D.

CARBIDE BUR CUTTING METHOD (1)

Weaken the weld around the C-channel and the limit switch guard using a die grinder and the item number 16 (part no. 628-2891-002 CYLINDRICAL END CARBIDE BUR). Refer to Figure 35. Before and throughout the cutting process apply WD-40 or liquid soap to the carbide bur to reduce clogging issues.

Figure 35 LIMIT SWITCH GUARD REMOVAL USING CYLINDRICAL CARBIDE BUR STEPS

REMOVAL AND INSTALLATION

3-2 Page 43 August 2017

Halvorsen (2)

Break the weld around the C-channel to remove the limit switch guard using a medium sized sledge hammer. Refer to Figure 36.

Figure 36 LIMIT SWITCH GUARD REMOVAL

3-2 Page 44 August 2017

(3)

Weaken the weld around the C-channel using a 4 inch angle grinder and item number 18 (part no. 628-2557 ALUMINUM CUT-OFF WHEEL). Do not cut into or remove material from the deck bumper when performing this task. Refer to Figure 37.

(4)

Remove the remainder of the C-channel using a medium sized sledge hammer. Refer to Figure 37, step 3.

(5)

The remainder of the C-channel and weld material should be removed and ground flat using a 4 inch angle grinder and item number 17 (part no. 628-2561 ALUMINUM GRINDING WHEEL). Refer to Figure 38.

(6)

Grind down the weld on the bottom of the deck bumper doubler plate using a 4 inch angle grinder and item number 17 (part no. 628-2561 ALUMINUM GRINDING WHEEL). This process will reduce the profile of the weld so it may be accurately cut out later in these procedures. Do not cut into or remove material from the deck bumper when performing this task. Refer to Figure 39.

(7)

Cut through the bottom weld on the deck bumper doubler plate using a 4 inch angle grinder and item number 18 (part no. 628-2557 ALUMINUM CUT-OFF WHEEL). Do not cut into or remove material from the deck bumper when performing this task. Refer to Figure 40.

(8)

Grind the remainder of the weld around deck doubler plate using a die grinder and item number 16 (part no. 628-2891-002 CYLINDRICAL END CARBIDE BUR). Be sure to keep the cutting tool perpendicular to the doubler plate. Throughout the cutting process apply WD-40 or liquid soap to the carbide bur to reduce clogging issues. Do not cut into or remove material from the deck bumper when performing this task. Refer to Figure 41.

OVERHAUL

Halvorsen (9)

Cut two small openings in the doubler plate top left and right corners using a 4 inch angle grinder and item number 18 (part no. 628-2557 ALUMINUM CUT-OFF WHEEL). These openings should be large enough so a steel chisel can be inserted and used to pry the doubler plate away from the deck. Do not cut into or remove material from the deck bumper when performing this task. Refer to Figure 42.

(10)

Insert a steel chisel in each of the openings in the doubler plate. Break the welds around the doubler plate by driving the chisel into the openings using a small sledge hammer. Refer Figure 43, steps 1 and 2. Additional weld grinding may be required in some circumstances.

STEP 1

STEP 2

STEP 3

Figure 37 REMAINDER OF C-CHANNEL REMOVAL STEPS

Figure 38 BUMPER GRINDING STEPS

REMOVAL AND INSTALLATION

3-2 Page 45 August 2017

Halvorsen

Figure 39 GRIND WELD FROM BOTTOM OF DOUBLER PLATE

STEP 1

STEP 2

STEP 3

Figure 40 CUT THE BOTTOM WELD ON THE DECK DOUBLER PLATE STEPS

3-2 Page 46 August 2017

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Halvorsen

STEP 1

STEP 2

STEP 3

Figure 41 GRIND DOWN WELD FROM AROUND DECK DOUBLER PLATE STEPS

STEP 1

STEP 2

STEP 3

Figure 42 DOUBLER PLATE WELD RELIEF CUT STEPS (11)

3.12 Use a large crowbar to pry the doubler plate from the deck bumper. Refer to Figure 43, step 3.

REMOVAL AND INSTALLATION

3-2 Page 47 August 2017

Halvorsen

STEP 1

STEP 2

STEP 3

Figure 43 DOUBLER PLATE REMOVAL STEPS (12)

Grind the area around the slotted hole on the deck bumper flat using a 4 inch angle grinder and item number 17 (part no. 628-2561 ALUMINUM GRINDING WHEEL). Periodically use a straight edge to verify the area is flat. Refer to Figure 44.

STEP 1

STEP 2

Figure 44 GRIND AREA SMOOTH

3-2 Page 48 August 2017

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Halvorsen E.

PRIME AND PAINT AFFECTED AREAS (1)

Apply a coat of primer to the areas that require paint. A fast-drying, gray spray primer for aluminum is recommended. Allow primer to fully dry before proceeding. Refer to Figure 45, step 1.

(2)

4.2 Apply a coat of green paint over the primed area. A fast drying OD green spray paint is recommended. Allow paint to fully dry before proceeding. Refer to Figure 45, step 2.

STEP 1

STEP 2

Figure 45 PRIME AND PAINT AFFECTED AREA F.

KIT INSTALLATION (1)

Drill six (6) 0.5 inch holes in the deck bumper at the locations of the six (6) previously marked locations using a hand-held drill and item number 8 (part no. 627-6384-001 STEP BIT, 1/8-1/2, 1/4 SHANK). Throughout the drilling process apply WD-40 or liquid soap to the drill bit to reduce clogging issues. Refer to Figure 46. Remove all burrs and sharp edges afterwards.

(2)

Lubricate the heads on item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12 X 1.75 X 50 MG) with WD-40. Refer to Figure 47. This will reduce friction during installation so the desired torque can be achieved without damaging the fasteners.

(3)

Position item number 9 (part no. 628-1512, PLATE, DECK BUMPER OUTER DOUBLER) and item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12 X 1.75 X 50 MG) as shown in Figure 48, step 1.

(4)

Apply several drops of item number 1 (part no. 105-0327-901, LOCTITE 242 (24205) 0.5 ml) to the leading threads on item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12 X 1.75 X 50 MG). Refer to Figure 48, step 2.

(5)

Position item number 10 (part no. 628-1516, PLATE, DECK BUMPER INNER DOUBLER) as shown in Figure 48, step 3. Finger tighten item number 3 (part no. 107-9214, SCRSFH-F 10.9 M12 X 1.75 X 50 MG).

REMOVAL AND INSTALLATION

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Halvorsen (6)

Tighten the four fasteners in a cross pattern to approximately 41 N·m (30 lbf-ft.) using an 8 mm or 5/16 inch Allen head socket and torque wrench. Then, torque the four fasteners in a cross pattern to 95 N·m (70 lbf-ft.). Refer to Figure 49.

STEP 1

STEP 2

STEP 3

Figure 46 DRILL SIX HOLES IN DECK BUMPER

Figure 47 LUBRICATE FASTENER BEFORE INSTALLATION

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Halvorsen

STEP 1

STEP 2

STEP 3

Figure 48 DOUBLER PLATE INSTALLATION

Figure 49 TORQUE FASTENERS (7)

Install item number 7 (part no. 625-8097, GUARD, LIMIT SW BOLT-ON) using item number 2 (part no. 107-9084, SCR, HHC 8.8 M10 X 1.5 X 50 MG), item number 4 (part no. 107-9260, NUT,PTH 8 M10 X 1.50 MG) and item number 5 (part no. 107-9276, WSHR, FLAT STD HD M10 MG). Refer to Figure 50.

REMOVAL AND INSTALLATION

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Halvorsen

Figure 50 LIMIT SWITCH GUARD INSTALLATION (8)

Reinstall the three limit switches in their appropriate locations using the previously removed hardware. Refer to Figure 51.

Figure 51 LIMIT SWITCH INSTALLATION (9)

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Clean the surface of the deck bumper shown in Figure 60 with isopropylic alcohol and install item number 12 (part no. 628-1774, DECAL, ATS CLEVIS AND PIN INSTAL) as shown in Figure 52.

OVERHAUL

Halvorsen

Figure 52 DECAL INSTALLATION (10)

Loosen the socket head set screw on the clevis collar shown in Figure 53, step 1.

(11)

Remove and discard of the hex head cap screw that retains the clevis collar to the chassis bumper. Refer to Figure 53, step 2.

(12)

Remove the clevis collar and air transport clevis. The air transport clevis will be replaced during this modification and can be discarded.

STEP 1

STEP 2

Figure 53 AGED CLEVIS REMOVAL STEPS

REMOVAL AND INSTALLATION

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Install item number 6 (part no. 628-1805 W-CLEVIS, AIR TRANSPORT), the previously removed clevis collar and item number 15 (part no. 107-9302 SCR, HHC 10.9 M8 X 1.25 X 25 MG) as shown in Figure 54, step 1. Be sure to align the access hole in clevis collar to the threaded hole on the chassis bumper.

(14)

Tighten the socket head set screw on the clevis collar to secure the collar to the chassis frame. Refer to Figure 54, step 2.

(15)

Torque item number 15 (part no. 107-9302 SCR,HHC 10.9 M8 X 1.25 X 25 MG) to approximately 20 to 27 N·m (15 to 20 lbf-ft.). Refer to Figure 54, step 3.

STEP 1

STEP 2

STEP 3

Figure 54 REPLACEMENT CLEVIS AND COLLAR INSTALLATION STEPS

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(16)

Turn the battery disconnect switch, located on the battery box, to the ON position. Start the loader and lift the deck enough so the maintenance stands can be removed.

(17)

Remove the maintenance stands and stow them in the maintenance stand holders. Lower the deck to rest on the chassis frame.

(18)

Install the air transport system pin and clevis as shown in Figure 55, step 1. The traction modules should lift automatically when this step is performed.

OVERHAUL

Halvorsen (19)

From inside the cab, perform the following functionality checks before proceeding. Troubleshoot any functionality issues. Refer to Chapter 2, Section 6 for troubleshooting guidance: •

The red air transport indicator light should be flashing.

•

Deck roll, pitch and side shift should be inactive.

CAUTION DO NOT CONTINUE TO ENGAGE THE LIFT JOYSTICK IF THE ENGINE REVS UP WHILE THE AIR TRANSPORT SYSTEM CLEVIS AND PIN ARE INSTALLED. STRUCTURAL DAMAGE WILL OCCUR. TROULESHOOT THE ISSUE BEFORE PROCEEDING. •

Move the lift joystick to the RAISE position. The engine RPM should not change during this task.

•

When the helper cylinders are fully extended the red air transport indicator light should become solid.

Figure 55 CHECK AIR TRANSPORT SYSTEM OPERATION (20)

Lower the deck completely to rest on the chassis frame. Remove the air transport clevis and pin and stow these items appropriately in the chassis frame.

REMOVAL AND INSTALLATION

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Halvorsen 14.

SEAT SUSPENSION KIT INSTALLATION The optional Seat Suspension Kit improves comfort for operators.

TABLE 3 - SEAT SUSPENSION KIT (OPTIONAL) TABLE 4 - 628-8712 ITEM

PART NO.

DESCRIPTION

QTY.

-

628-8712

K-SEAT SUSPENSION

1

107-1111

NUT, PTH A2 TH 0.31-18 SS

4

2

107-1339

WASHER, FLAT 5/16 304 SS

4

3

107-1341

WASHER, FLAT A2 TH 0.38 SS

8

4

107-0364

NUT, PTH A2 TH 0.38-16

4

5

107-2979

SCREW, SBH A2 0.31-18X1 SS

4

6

107-9017

SCREW, HHC-F 8.8 M6X1X20 MG

4

7

107-9450

WASHER, FNDR STD HD M6 MG

4

8

110-2213

SCREW, HHC A2 0.38-16X1 SS

4

9

629-1390

M-INSERT, SEAT SUSPENSION

1

10

628-8714

ADAPTER, SEAT INSERT

2

11

DWG-628-8803

SEAT SUSPENSION KIT INSTALLATION PROCEDURE

1

A.

REF

SEAT REMOVAL Remove Seat from Cab The seat normally slides on tracks mounted to the cab floor. The tracks consist of upper and lower slide rails which slide back and forth on each other. The upper slide rails are mounted on two S-brackets attached to the bottom of the seat with four screws. Refer to Figure 56. The upper right slide rail has two tabs bent down at both ends of the travel. The bent tabs interfere with a stop in the middle of the lower right slide rail. This intentional interference prevents the seat from sliding off the tracks. One of two methods may be used to remove the seat from the cab: (1)

Slide the seat off the tracks (preferred).

(2)

Disassemble the seat from the cab floor with tracks attached. If unable to slide the seat off the tracks, then it must be removed by disassembling the bolted connections to the cab floor.

Main components of the seat as removed from cab are shown in the following illustration.

3-2 Page 56 August 2017

OVERHAUL

Halvorsen S-brackets

Seat

Side lever on right slide rail

Seat tracks

SEAT REMOVED FROM CAB Figure 56 OPERATOR’S SEAT MAIN COMPONENTS B.

SLIDE THE SEAT OFF THE TRACKS (1)

Operate side lever to allow the seat to slide on the tracks. Push seat forward until it slides against the stop.

(2)

View right slide rails under the seat from the front.

(3)

Locate the bent tab restricting travel at the rear of the upper right slide rail. The bent rear tab contacts the stop in the middle of the lower right slide rail when the seat is pushed forward. Refer to Figure 57.

Tab bent down at the rear of upper right slide rail

Stop in middle of the lower right slide rail

VIEW UNDER SEAT Figure 57 STOP AND BENT TAB RIGHT SLIDE RAIL

REMOVAL AND INSTALLATION

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Place the blade of a screwdriver under the bent rear tab. Push the tab up with the screwdriver to clear the height of the stop on the lower right slide rail. Refer to Figure 58.

Push tab up over the stop with screwdriver

BEND REAR TAB UP TO SLIDE THE SEAT FORWARD. Figure 58 REAR TAB ON UPPER SLIDE RAIL

C.

D.

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(5)

Push seat forward until it slides of the tracks.

(6)

Leave lower slide rails bolted to the cab floor.

DISASSEMBLE THE SEAT FROM THE CAB FLOOR WITH TRACKS ATTACHED (1)

Perform steps in this section only if unable to remove the seat in the previous section.

(2)

Operate side lever to allow the sea to slide on the tracks Push seat forward or backward to access four screws securing the tracks to the cab floor.

(3)

Remove the four screws, nuts and washers attaching the seat lower slide rails to the cab floor. Access the screws from inside the cab and the washers from the outside. Use a 13-mm socket wrench and a 13-mm end-box combination wrench.

(4)

Save all fasteners for reassembly. Replace with new fasteners if deemed necessary.

(5)

Remove seat from the cab with all slide rails attached.

SEAT DISASSEMBLY (1)

Remove and discard the S-brackets from the bottom of the seat.

(2)

Place seat on a flat surface to make the bottom accessible. The bottom of the slide rails should face up.

(3)

If still attached, slide the lower slide rails off the upper slide rails. Save the lover slide rails for reassembly.

(4)

Disassemble the upper slide rails from the S-brackets and save them for reassemble. Use a 3/16-inch Allen wrench and a 1/2-inch end-box combination wrench. Discard spacers, screws, nuts and washers removed. Refer to Figure 59.

OVERHAUL

Halvorsen Remove and discard M6 screws and washers

Upper left slide rail

Remove and discard button head screws and related washers, nuts, and spacers

S-bracket

VIEW AT SEAT BOTTOM Figure 59 UPPER LEFT SLIDE RAIL (5)

Remove the four M6 screws and washers securing the S-brackets to the seat using a 10-mm socket wrench. Discard the screws and washers removed. Discard the S-brackets. Refer to Figure 60.

Upper left slide rail has no side lever

Upper right slide rail with side lever attached

Remove and discard four M6 screws and washers

Remove and discard the S-brackets

VIEW AT SEAT BOTTOM Figure 60 UPPER SLIDE RAILS AND S-BRACKETS

REMOVAL AND INSTALLATION

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Halvorsen E.

(6)

Mark the location of the four holes through the seat fabric as you remove screws.

(7)

Enlarge holes in the fabric with a utility knife, as needed. This will help locate the threaded holes in the seat during reassembly.

SEAT SUSPENSION INSERT SUBASSEMBLY (1)

Place the part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9) on a flat working surface. The bottom of part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9) must be face up.

(2)

Mark a line on part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9) passing through the center of one of the rear slide rail mounting holes. The line must be parallel to the sides of the part. Refer to Figure 61.

(3)

Mark a parallel line 11 inches from the first line. This line should pass through the center of the opposite rear slide rail mounting hole.

(4)

These lines will be used to align the centers of the upper slide rails.

REAR

Rear slide rail mounting holes

Mark parallel lines on each side of the suspension insert

Front slide rail mounting slots

FRONT

279 mm (11 in.) MARK LINES ON BOTTOM OF SUSPENSION INSERT TO ALIGN UPPER SLIDE RAILS. Figure 61 SEAT SUSPENSION INSERT 3-2 Page 60 August 2017

OVERHAUL

Halvorsen (5)

Set the upper slide rails on the lines marked on part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9). The slide lever on the upper right slide rail must be oriented toward the front of part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9). Refer to Figure 61 and Figure 62.

Upper left slide rail (Shown not yet installed)

Large slots on bottom plate

Ride adjustment knob

Upper right slide rail

Side lever

SEAT SUSPENSION UPSIDE DOWN Figure 62 SEAT SUSPENSION INSERT (6)

Align the rear mounting holes on the slide rails with the rear mounting holes on part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).

(7)

Insert a part no. 107-2979, SCREW (item number 5) through each hole aligned. Refer to Figure 63.

Button head screw

Button head screw

ALIGN UPPER SLIDE RAILS CENTER WITH LINES ON SEAT SUSPENSION. Figure 63 SEAT SUSPENSION ALIGNMENT WITH SLIDE RAILS

REMOVAL AND INSTALLATION

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Halvorsen (8)

Thread a part no. 107-1111, NUT (item number 1) and part no. 107-1339, Washer (item number 2) on each screw from below.

(9)

Align the front mounting holes on the slide rails with the front mounting slots on part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).

(10)

Insert a part no. 107-2979, SCREW (item number 5) through each hole aligned.

(11)

Thread a part no. 107-1111, NUT (item number 1) and part no. 107-1339, Washer (item number 2) on each screw from below.

(12)

Tighten the four bolted joints snug. Use a 3/16-inch Allen wrench and a 1/2-inch end-box combination wrench. Be sure to keep the center of the slide rails aligned to the lines marked on 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).

(13)

Use torque wrench and 1/2-inch end/combination wrench to tighten to 15 N·m (11 lbf-ft. or 132 lbf-in.) maximum. Refer to Figure 64.

NOTE:

AFTER THE SLIDE RAILS ARE ATTACHED TO part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9), IT IS IDENTIFIED AS THE SEAT SUSPENSION INSERT SUBASSEMBLY.

INSTALL FASTENERS AND TORQUE TO SPECIFICATIONS. Figure 64 SLIDE RAILS FASTENED TO SEAT SUSPENSION

3-2 Page 62 August 2017

OVERHAUL

Halvorsen F.

SEAT SUSPENSION INSERT ASSEMBLY (1)

Install adapters on the seat suspension insert subassembly

(2)

The kit includes two steel part no. 628-8714, ADAPTER, SEAT INSERT (item number 10) to secure the seat to the top of the seat suspension insert subassembly. Each part no. 628-8714, ADAPTER, SEAT INSERT (item number 10) is a black strip with four holes. Notice the larger holes are offset from the centerline.

(3)

Place two part no. 628-8714, ADAPTER, SEAT INSERT (item number 10) across the top of the seat suspension insert subassembly. The inner holes should be offset outward to the front and rear on each end. Align the inner holes with matching holes in the seat suspension insert subassembly. Refer to Figure 65.

FRONT

Inner holes offset from centerline outward

Adapters

Insert 3/8-16 screws with washers through each inner hole (4 places)

REAR ADAPTER PLATE TO FIT SEAT SUSPENSION INSERT TO SEAT Figure 65 SEAT SUSPENSION INSERT ADAPTER PLATE (4)

Insert four part no. 110-2213, SCREW (item number 8) with part no. 107-1341, WASHER (item number 3) through the aligned holes.

REMOVAL AND INSTALLATION

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Halvorsen (5)

Thread part no. 107-0364, NUT (item number 4) and part no. 107-1341, WASHER (item number 3) on each screw from below.

(6)

Use 9/16-inch end-box combination wrench to tighten these joints. However, leave loose enough to allow the part no. 628-8714, ADAPTER, SEAT BINSERT (item number 10) to move. Refer to Figure 66.

NOTE:

AFTER PART NO. 628-8714, ADAPTER, SEAT INSERT (ITEM NUMBER 10) ARE ATTACHED TO THE SEAT SUSPENSION INSERT SUBASSEMBLY, IT IS IDENTIFIED AS THE SEAT SUSPENSION INSERT ASSEMBLY.

FASTEN SCREWS AND NUTS LOOSELY TO ALLOW ADAPTER MOVEMENT AS NEEDED. Figure 66 FASTEN ADAPTER PLATE TO SEAT SUSPENSION

3-2 Page 64 August 2017

(7)

Place seat suspension insert assembly on the bottom of the seat with the adapters touching the seat. The ride adjustment knob must face toward the front of the seat.

(8)

Insert four part no. 107-9017, SCREW (item number 6) and part no. 107-9450, WASHER (item number 7) through the outer holes of the adapters. Refer to Figure 67.

OVERHAUL

Halvorsen

INSERT M6 SCREWS AND WASHERS THROUGH APAPTERS. Figure 67 INSERT FASTENERS INTO ADAPTERS (9)

Allow parts to move around, as needed, to locate the matching holes in the seat through the fabric.

(10)

Thread four part no. 107-9017, SCREW (item number 6) into the seat by hand. Do not tighten them. Refer to Figure 68.

THREAD M6 SCREWS INTO SEAT TO PIN SUSPENSION INSERT IN POSITION. Figure 68 FASTEN ADAPTERS TO SEAT

REMOVAL AND INSTALLATION

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Halvorsen (11)

The adapters are now pinned to the seat by the four part no. 107-9017, SCREW (item number 6).

(12)

Securely tighten all fasteners attaching adapters to the seat suspension insert subassembly to prevent and motion. Use a 9/16-inch socket wrench and 9/16-inch end-box combination wrench. Refer to Figure 69.

TIGHTEN ADAPTERS TO SUSPENSION INSERT TO PREVENT MOTION AND MAKE THE SUSPENSION INSERT AND ADAPTERS INTO A SUBASSEMBLY. Figure 69 TIGHTEN ADAPTERS TO SUSPENSION INSERT (13)

3-2 Page 66 August 2017

Remove the four (4) SCREWS, part no. 107-9017 (item 6) and four (4) WASHERS, part no. 107-9450 (item 7). Refer to Figure 70.

OVERHAUL

Halvorsen

REMOVE PREVIOUSLY INSTALLED M6 SCREWS FROM SEAT. Figure 70 REMOVE SUSPENSION INSERT SUBASSEMBLY (14)

Place the seat suspension insert assembly on a flat surface to access the screws on top of the adapters.

(15)

Use a torque wrench with a 9/16-inch socket and a 9/16-inch end-box combination wrench to tighten the four bolted joints to 27 N·m (20 lbf-ft. or 240 lbf-in.) maximum. Refer to Figure 71.

TORQUE SCREWS FASTEN ADAPTERS TO SUSPENSION INSERT. Figure 71 TORQUE FASTENERS ON SUSPENSION SUBASSEMBLY

REMOVAL AND INSTALLATION

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Halvorsen G.

SEAT ASSEMBLY (1)

Place the seat suspension insert assembly on the bottom of the seat with the adapters touching the seat. The ride adjustment knob must face toward the front of the seat.

(2)

Thread four part no. 107-9017, SCREW (item number 6) and part no. 107-9450, WASHER (item number 7) through the adapters and the seat fabric into the seat.

(3)

Use a torque wrench with a 10 mm socket and tighten the four part no. 107-9017, SCREW (item number 6) to 11 N·m (8 lbf-ft. or 96 lbf-in.) maximum. Use extension bar and deep socket, if necessary. Refer to Figure 72.

(4)

This is now the new seat assembly and is ready for installation in the cab.

Ride adjustment knob

TORQUE SEAT SUSPENSION SUBASSEMBLY TO THE SEAT. Figure 72 SEAT SUSPENSION ASSEMBLY ATTACHMENT

3-2 Page 68 August 2017

OVERHAUL

Halvorsen H.

INSTALL THE NEW SEAT ASSEMBLY IN THE CAB Install the new seat assembly in the cab using the appropriate of the following sections. If lower slide rails are already attached to the cab floor: (1)

Slide the seat assembly onto the lower slide rails. Be sure the bent tab clears the stop. Refer to Figure 73.

(2)

Use a screwdriver to reach and bend the rear tab down again to prevent the seat from sliding off the tracks.

CONSTRAIN SEAT TO TRACK BY BENDING REAR TAB DOWN. Figure 73 SEAT INSTALLATION - RAILS ATTACHED TO CAB FLOOR If lower slide rails are not attached to the cab floor: (3)

Slide the lower slide rails on the upper slide rails on the seat assembly.

(4)

Ensure the rear tab on the upper right slide rail is bent down to prevent the seat from sliding forward off the tracks.

(5)

Place the seat assembly with the lower slide rails on the cab floor.

(6)

Insert the fasteners that were removed in subsection ‘C. DISASSEMBLE THE SEAT FROM THE CAB FLOOR WITH TRACKS ATTACHED’, through the cab floor.

(7)

Tighten all fasteners using 13-mm sockets and 13-mm end-box combination wrench. Slide the seat on the tracks to gain clearance for the wrench as needed.

(8)

Use a torque wrench with a 13-mm sockets to tighten fasteners to 37 N·m (27 lbf-ft. or 324 lbf-in.) maximum. Refer to Figure 74.

REMOVAL AND INSTALLATION

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Halvorsen

Re-use mounting hardware that was previously removed

SEAT FRONT VIEW Figure 74 SEAT INSTALLATION - RAILS NOT ATTACHED TO CAB FLOOR

TORQUE SEAT MOUNTING FASTENERS THROUGH THE CAB FLOOR. Figure 75 TORQUE SEAT MOUNTING FASTENERS

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OVERHAUL

Halvorsen I.

OPERATIONAL CHECKOUT REQUIREMENTS Verify seat travel

J.

(1)

Sit on the seat inside the cab.

(2)

Operate the side lever and push and pull the seat forward and backward between the stops.

(3)

Rotate the ride adjustment knob in the seat suspension as needed. This will minimize bottoming and topping out during driving operation.

(4)

Ensure all parts are properly secured to prevent them fro loosening.

SEAT SUSPENSION KIT OPERATION The ride of the seat can be adjusted to accommodate an operator’s weight and preferences by turning the adjustment knob on the front of the seat assembly. Turning the knob clockwise (while viewing it from the front) will create a “stiffer” ride with less movement, while turning the knob counter clockwise will create a “looser” ride with more movement. An optimal adjustment should prevent topping out or bottoming out of the seat suspension during operations.

15.

MAIN PANEL CONVERTER KIT INSTALLATION A.

GENERAL (1)

Purpose This document provides instructions for safely replacing the voltage converter in the Main Panel for the Halvorsen, 25 000 lb. Loader for Aircraft.

(2)

Manpower Requirements Estimated time to accomplish:

1 hour

Suggested personnel needed:

One (1) 5-skilled level Vehicle and Vehicular Equipment Maintenance Journeyman One (1) 1-skilled level Vehicle and Vehicular Equipment Maintenance Helper

(3)

References Halvorsen Technical Manual - OPERATOR INSTRUCTIONS, Change 10, 31 March 2013. Halvorsen Technical Manual - OPERATION AND MAINTENANCE INSTRUCTIONS, Change 10, 31 March 2013. Halvorsen Technical Manual - ILLUSTRATED PARTS LIST, Change 10, 31 March 2013.

(4)

Safety Precautions Adhere to all local standard shop safety practices when working to these instructions. Warnings and cautions will precede the text to which they apply. The following warnings and cautions are used in this document. Read all of them and follow the instructions when performing the procedures. The symbols shown below are used to call your attention to some procedures that may cause death or injury to personnel and damage to equipment.

REMOVAL AND INSTALLATION

3-2 Page 71 August 2017

Halvorsen CAUTION TO PREVENT DAMAGE TO ENCLOSURE WHEN DRILLING HOLES DO NOT PUSH ON DRILL WITH EXCESSIVE FORCE. NOTE:

TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN PANEL.

(5)

Parts List Inspect and inventory the kit per Table 5, before performing the installation. Report any missing kit items promptly to a Halvorsen Technical Support Representative. Refer to the OEM Point of Contact (POC) information section in this document.

TABLE 5 - CONVERTER KIT PARTS LIST ITEM

(6)

PART NO.

DESCRIPTION

QTY.

K - Main Panel 24V/12V Converter

REF

-

629-0560

1-1

107-2091

. Washer, Flat #10 SS

4

1-2

107-2324

. Nut, PTH A2 #10-32 SS

4

1-3

107-2873

. Screw, PPAN A2 #10-32X1 SS

4

1-4

624-8698-030

. Converter, 24V/12V 30A

1

1-5

DWG-628-8577

. Kit Installation Procedure

REF

Tool List Common hand tools and general supplies listed in Table 6 are necessary for accomplishing this installation. Ensure that these tools and supplies are available before starting any work.

TABLE 6 - TOOLS LIST FOR INSTALLATION TOOLS AND SUPPLIES

3-2 Page 72 August 2017

QUANTITY

General purpose drill bit, 7/32-inch

1

Drill stop, 7/32-inch drill size

1

Power drill

1

Pen, pencil or marking device

1

Combination adjustable square ruler

1

Tape measure

1

Center punch

1

Adjustable pliers

1

Ratcheting socket wrench (with extension)

1

OVERHAUL

Halvorsen TABLE 6 - TOOLS LIST FOR INSTALLATION (CONT.) TOOLS AND SUPPLIES

B.

C.

QUANTITY

Sockets, various sizes

As required

Combination wrenches, various sizes

As required

Flat blade screwdrivers, various sizes

As required

Phillips screwdrivers, various sizes

As required

Wood block, approximately 2 in. x 4 in. x 6 in. to protect components when drilling

As required

LOADER PREPARATION (1)

Raise the deck to gain access to the main panel electrical boxes.

(2)

Install both maintenance stands in the FIRST maintenance position on the chassis. Lower the deck until the scissor rollers are against the blocks.

(3)

Turn the battery disconnect switch, located on the battery box, to the OFF position.

CONVERTER INSPECTION (1)

Locate the main panel enclosure on the Halvorsen, 25 000 lb. Loader for Aircraft, as shown in Figure 76.

MAIN PANEL Figure 76 MAIN PANEL LOCATION

REMOVAL AND INSTALLATION

3-2 Page 73 August 2017

Halvorsen (2)

Disconnect the positive cable from the lower left corner of the Main Panel. Disconnect the negative cable from inside the bottom of the Main Panel. Refer to Figure 77.

(3)

Remove the cables by pulling them gently out of the panel.

Disconnect Positive Cable

Disconnect Negative Cable

Figure 77 POSITIVE AND NEGATIVE CABLES INSIDE MAIN PANEL (4)

Remove both the 4-pin and 6-pin receptacles from the converter as shown in Figure 78 and Figure 79.

(5)

Determine which model of the converter is in the main panel enclosure. (a)

3-2 Page 74 August 2017

If the converter installed resembles Figure 78 (part no. 624-8698-030, CONVERTER, 24V/12V 30A), remove all hardware and the converter from the main panel. Proceed to ‘G. CONVERTER INSTALLATION’, Figure 88 to replace the converter.

OVERHAUL

Halvorsen CONVERTER P/N: 624-8698-030

INSIDE OF MAIN PANEL

#1-2

#1-4

4-PIN (1 DCDC) RECEPTACLE

#1-1 6-PIN (2 DCDC) RECEPTACLE

#1-3

#1-3

Figure 78 CONVERTER PART NO. 624-8698-030 (b)

If the converter installed resembles Figure 79 (part no. 624-7172, Converter, 24/ 13.5V), remove all hardware and the converter from the Main Panel. Proceed to complete all steps in this instruction.

Converter P/N: 624-7172 Main Panel 4-pin and 6-pin Receptacles

Figure 79 CONVERTER PART NO. 624-7172

REMOVAL AND INSTALLATION

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Halvorsen D.

MAIN PANEL REMOVAL It is preferred to modify the Main Panel Assembly without having to dismount it from its location on the chassis. However, in order to accomplish this safely, the proper equipment must be available at the local shop. To modify the Main Panel without removing it from the loader: •

Raise the right front side of the loader off the ground following procedures for removing the front axle wheel. Refer to Chapter 2, Section 5, “Maintenance Procedures”.

•

Raise the loader enough to allow marking and drilling the converter mounting holes on the bottom of the Main Panel Assembly.

•

Skip ahead to ‘E. DRILL NEW HOLES IN THE MAIN PANEL’, Figure 85 to mark and drill the converter mounting holes in the Main Panel.

NOTE:

(1)

IF THE APPROPRIATE EQUIPMENT IS NOT AVAILABLE TO SAFELY PERFORM THE PREVIOUS PROCEDURES AT THE LOCAL SHOP, FOLLOW THE INSTRUCTIONS IN THIS SECTION FOR REMOVING AND MODIFYING THE MAIN PANEL. Remove the negative electrical cable from the rear single-hole connector and the positive electrical cable through the front single-hole connector on the left side of the Main Panel.

Figure 80 REMOVE BATTERY CABLES FROM MAIN PANEL (2)

3-2 Page 76 August 2017

Remove the part no. 623-6744 PLATE, COVER located on the chassis behind the main panel. Use a ratchet wrench to loosen the nuts and save the hardware for re-installation. Refer to Figure 81.

OVERHAUL

Halvorsen

Figure 81 COVER PLATE REMOVAL (3)

Loosen and remove the two lower fastener sets from the panel mounting ears using a ratchet wrench and a box wrench and save the hardware for re-installation. The view shown in Figure 82 is of the lower right mounting ear seen from the top of the panel.

Figure 82 LOWER MOUNTING FASTENERS REMOVAL

REMOVAL AND INSTALLATION

3-2 Page 77 August 2017

Halvorsen (4)

Loosen the upper two fastener sets in preparation for removing the main panel from the chassis. Refer to Figure 83.

Figure 83 UPPER MOUNTING FASTENERS REMOVAL (5) NOTE:

3-2 Page 78 August 2017

Place a piece of cardboard or protective mat on the ground in front of the main panel. TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN PANEL.

OVERHAUL

Halvorsen (6)

Remove the upper two fastener sets while supporting the Main Panel and save the hardware for re-installation. Swing the Main Panel away from the loader and carefully set it flat on the mat. Be careful not to put tension on the connected harnesses on the right side of the enclosure. Cut cable ties as necessary to remove any tension. Place a wood block under the Main Panel, if necessary, to provide better access to the bottom of the enclosure. Refer to Figure 84.

Do not disconnect these cables from right side of Main Panel Mounting Bracket

Bottom of Main Panel

Wooden Block

Cardboard

Figure 84 MAIN PANEL REMOVAL

REMOVAL AND INSTALLATION

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Halvorsen E.

DRILL NEW HOLES IN THE MAIN PANEL (1)

Mark the center of each drill hole on the bottom of the Main Panel part no. 624-2903 ME-ENCL (30 x 24 x 10) according to Figure 85.

(2)

Punch the four marked centers using a center punch.

Drill Holes

Figure 85 NEW HOLE PATTERN ON BOTTOM OF MAIN PANEL

3-2 Page 80 August 2017

(3)

Place a drill stop on a 7/32-inch diameter drill bit. Allow end of drill bit to protrude approximately 1/4-inch from the drill stop.

(4)

Open the enclosure and make sure all wiring and other components are cleared from the area to be drilled.

(5)

Drill a 7/32-inch diameter hole at each of the four locations noted in Figure 85 from the outside of the bottom of the main panel.

(6)

Use a deburring tool to remove burrs around the drilled holes inside and outside the box. Clean any debris that may have accumulated inside the box.

(7)

Test fit the new electrical converter in the bottom of the main panel. Check that the new holes align with the mounting holes in the new converter.

OVERHAUL

Halvorsen F.

REINSTALL THE MAIN PANEL (1)

Reinstall the Main Panel to its chassis-mounting bracket using previously removed hardware.

Figure 86 MAIN PANEL RE-INSTALLATION ON LOADER (2)

Reinstall the chassis electrical harness cover plate using previously removed hardware.

Figure 87 CHASSIS HARNESS PLATE RE-INSTALLATION

REMOVAL AND INSTALLATION

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Halvorsen G.

CONVERTER INSTALLATION Refer to the steps below to install the new converter (part no. 624-8698-030) in the main panel. Installation (1)

Place the converter (#1-4) into the bottom of the main panel.

(2)

From outside the bottom of the panel insert four screws (#1-3) upward through the newly drilled holes and the converter.

(3)

Tighten one nut (#1-2) and one washer (#1-1) at each screw location as shown below in Figure 88.

(4)

Re-connect both the 4-pin and 6-pin receptacles to the new converter.

#1-2

#1-4

4-PIN (1 DCDC) RECEPTACLE

#1-1 6-PIN (2 DCDC) RECEPTACLE

#1-3

#1-3

Figure 88 CONVERTER INSTALLATION H.

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MAIN PANEL CABLE CONNECTION (1)

Reinstall the negative electrical cable through the rear single-hole connector and reconnect the terminal ring to the left contact post on the bottom of the main panel. Refer to Figure 89.

(2)

Tighten the cable-retaining clamp on the outside of the Main Panel using adjustable pliers.

(3)

Reinstall the positive electrical cable through the front single-hole connector on the left side of the main panel. Re-attach the ring terminal to the electrical positive contact post inside the left side of the main panel. Refer to Figure 90.

(4)

Tighten the cable-retaining clamp on the outside of the main panel. Refer to Figure 90.

OVERHAUL

Halvorsen

Figure 89 CABLE-RETAINING CLAMP TIGHTENING

Figure 90 CABLE-RETAINING CLAMP HAND TIGHTENING

REMOVAL AND INSTALLATION

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Halvorsen I.

CLOSE DOOR ON MAIN PANEL (1)

Tighten all door clamps.

(2)

Use a screwdriver of appropriate size to tighten all door clamps on the electrical box. Refer to Figure 91.

Figure 91 ELECTRICAL BOX DOOR CLAMPS TIGHTENING J.

OPERATIONAL CHECKOUT REQUIREMENTS Perform loader functional tests and exercise the loader per the following functional tests:

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(1)

Turn the battery disconnect switch to the ON position.

(2)

Ensure transmission shift selector is in NEUTRAL.

(3)

Start the engine.

(4)

Perform all checks for cab and deck operation. Refer to the “EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3.

(5)

Shut down the engine.

(6)

Turn the battery disconnect switch to the OFF position.

OVERHAUL

Halvorsen 16.

RIGHT FRONT HANDRAIL BRACE KIT A.

GENERAL (1)

Purpose This document provides instructions for safely installing a brace kit on the right front handrail of the loader. SUMMARY: Cracks in the lower channel of part no. 623-6070 Right Front Handrail, requires installation of a brace kit to reduce the stress.

(2)

Manpower Requirements Estimated time to accomplish:

1 hour

Suggested personnel needed:

One (1) 5-skilled level Vehicle and Vehicular Equipment Maintenance Journeyman One (1) 3-skilled level Vehicle and Vehicular Equipment Maintenance Helper

(3)

OEM Point of Contact (POC) JBT Corp. Ground Support Equipment 7300 Presidents Drive Orlando, FL 32809 Halvorsen Technical Support Representative Telephone CONUS: 1-866-444-6475 Telephone OCONUS: 1-407-888-8284 Email: [email protected] Website: www.myjbtaerotech.com

(4)

References Halvorsen Technical Manual - OPERATOR INSTRUCTIONS, Change 11, 31 March 2014. Halvorsen Technical Manual - OPERATION AND MAINTENANCE INSTRUCTIONS, Change 11, 31 March 2014. Halvorsen Technical Manual - ILLUSTRATED PARTS LIST, Change 11, 31 March 2014.

(5)

Definitions and Conventions Used in these Instructions The following Halvorsen loader orientation conventions are used throughout this document: Left side from the point of view of the operator sitting in the cab (i.e., cab side). Right side from the point of view of the operator sitting in the cab (i.e., no-cab side).

(6)

Safety Precautions Adhere to all local standard shop safety practices when working to these instructions.

REMOVAL AND INSTALLATION

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Halvorsen (7)

Parts List Inspect and inventory the kit per Table 7, before performing the installation. Report any missing kit items promptly to a Halvorsen Technical Support Representative. Refer to the OEM Point of Contact (POC) information section in this document.

TABLE 7 - HALVORSEN BRACE KIT PARTS LIST ITEM

(8)

PART NO.

DESCRIPTION

QTY.

-

629-0480

K - BRACE

REF

1

107-0364

NUT, PTH A2 0.38-16 SS

8

2

107-1932

WASHER, FLAT NAR A2 0.38 SS

8

3

107-2360

SCREW, HHC GR8 0.38-16 X1.5 MG

2

4

110-0194

NUT, PTH GR5 TH 0.38-16 ZP

1

5

238-0704

WASHER, BEARING

1

6

628-7874

U-BOLT, 0.38-16 X1.5 X2P CLAMPING SS

2

7

628-9702

U-BOLT, 0.38-16 X1.5 X2P SQUARE BEND SS

2

8

629-0478

BRACKET, UPPER

1

9

629-0479

BRACKET, LOWER

1

10

629-0804

CLAMP, SADDLE SS

2

11

DWG-628-9907

BRACE KIT INSTALLATION PROCEDURE

REF

Tool List Common hand tools and general supplies listed in Table 8 are necessary for accomplishing this installation. Ensure that these tools and supplies are available before starting any work.

TABLE 8 - TOOLS LIST FOR INSTALLATION TOOLS AND SUPPLIES

3-2 Page 86 August 2017

QUANTITY

Open end-box combination wrench, 9/16 inches

1

Socket wrench

1

Socket, 9/16 inches

1

Torque wrench calibrated in N·m (or lbf-ft. or lbf-in.)

1

OVERHAUL

Halvorsen B.

LOADER PREPARATION (1)

Park the loader to be modified on a flat level surface.

(2)

Position the loader in a well illuminated work area.

(3)

Allow clear access for working on the right side of the loader.

(4)

Lower the deck until it is completely resting on the chassis (if not already lowered).

(5)

Apply the parking brake and shut down the engine.

(6)

Place chocks approximately 50 mm (2 in.) from the front and rear of any tire.

(7)

Turn the battery disconnect switch, located on the battery box, to the OFF position.

(8)

Place the part no. 623-6100 handrail and walk-deck assembly in the fully retracted position. Refer to Figure 92.

W-Handrail, RF P/N 623-6070 Brace kit will be installed here W-Handrail, Pivoting P/N 623-6918

W-Handrail, Telescoping P/N 623-6095

Handrail and W alkdeck Assembly P/N 623-6100

RETRACTED

HANDRAIL AND WALK-DECK FULLY RETRACTED Figure 92 HANDRAIL AND WALK-DECK ASSEMBLY (9)

Secure the part no. 623-6918 pivoting handrail weldment into its folded position.

(10)

Rotate the fully retracted part no. 623-6100 handrail and walk-deck assembly 90 degrees. The handrail should be suspended horizontally above the deck. Refer to Figure 93.

REMOVAL AND INSTALLATION

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Halvorsen Handrail horizontal above deck

Rotated walkdeck Install quick release pins

Pivoting handrail securely folded

Rotated guide rails HANDRAIL AND WALK-DECK TILTED 90º INWARDS Figure 93 HANDRAIL AND WALK-DECK ASSEMBLY (CONT.)

WARNING FULLY LOCK TELESCOPING WALK-DECK IN PLACE TO AVOID SERIOUS INJURY OR DEATH. (11)

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Install quick release pins to secure the part no. 623-6100 right front handrail and walk-deck assembly in this rotated position.

OVERHAUL

Halvorsen C.

INSTALLATION INSTRUCTIONS The part no. 629-0480, K-BRACE must be installed by fastening it to part no. 623-6070, W-HANDRAIL, RF. The location of the brace kit as it will be installed on the handrail is shown in Figure 96. NOTE:

IT IS NOT NECESSARY TO REMOVE THE HANDRAIL FROM THE WALK-DECK IN ORDER TO INSTALL THE BRACE KIT. THE TELESCOPING SLIDING HANDRAIL, WALK-DECK AND OTHER HANDRAIL PARTS ARE NOT SHOWN IN FIGURE 94 FOR CLARITY.

W-Handrail, RF P/N 623-6070

Vertical square rail

Brace kit P/N 629-0480

Lower channel

Upright round rail

Figure 94 BRACE KIT INSTALLED ON RIGHT FRONT HANDRAIL D.

ASSEMBLE BRACE (1)

Connect the upper and lower brackets.

(2)

Position the brackets side by side on a flat working surface.

REMOVAL AND INSTALLATION

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Halvorsen (3)

Align slots in part no. 629-0479, LOWER BRACKET (item number 9) with corresponding holes in part no. 629-0478, UPPER BRACKET (item number 8).

(4)

Insert part no. 107-2360, SCREW (item number 3) and part no. 238-0704, WASHER (item number 5) through each slot in the lower bracket. The screw heads must be on the side of the lower bracket. Refer to Figure 95.

Upper bracket

Lower bracket

INSTALL SCREWS AND WASHERS THROUGH SLOTS AND HOLES ON BRACKETS. Figure 95 PAIRING BRACKETS (5)

Thread a part no. 110-0194, NUT (item number 4) and part no. 238-0704, WASHER (item number 5) on each screw from the side of the upper bracket. Use a 9/16-inch socket and end-box combination wrench to thread nuts most of the way. Do not tighten them. Allow the connected brackets to move. Refer to Figure 96.

CONNECT BOTH BRACKET LOOSELY ALLOWING MOTION. Figure 96 LOOSELY CONNECTING BRACKETS

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OVERHAUL

Halvorsen E.

FIT THE BRACE ASSEMBLY (1)

Loosely attach brace assembly to the handrail.

(2)

Hold the connected brackets in position on the handrail. Place the part no. 629-0478, UPPER BRACKET (item number 8) on the vertical square rail and rest the part no. 629-0479, LOWER BRACKET (item number 9) on the upright round rail. Refer to Figure 97.

Upper bracket

Lower bracket

Handrail

HOLD CONNECTED BRACKETS IN POSITION ON HANDRAIL. Figure 97 ATTACHING BRACKETS TO HANDRAIL (3)

Insert two part no. 628-9702, SQUARE U-BOLT, (item number 7) from below to hold the upper bracket to the vertical square rail. Refer to Figure 98.

(4)

Thread a part no. 107-0364, NUT (item number 1) and part no. 107-1932, WASHER (item number 2) on the ends of each part no. 628-9702, SQUARE U-BOLT, (item number 7). Refer to Figure 98.

(5)

Use a socket wrench with a 9/16-inch socket to tighten the nuts evenly. However, leave them loose enough to allow the part no. 629-0478, UPPER BRACKET (item number 8) to slide on the vertical square rail.

CAUTION SECURE BRACE IN REQUIRED POSITION BEFORE TIGHTENING HARDWARE. DO NOT TORQUE UNTIL INSTRUCTED AT THE END OF THE INSTALLATION.

REMOVAL AND INSTALLATION

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Halvorsen

FIT THE UPPER BRACKET LOOSELY TO VERTICAL SQUARE RAIL. Figure 98 FITTING UPPER BRACKET TO VERTICAL RAIL (6)

Place two part no. 629-0804, SADDLE CLAMP (item number 10) between the part no. 629-0479, LOWER BRACKET (item number 9) and the upright round rail. Align holes in bracket with holes in part no. 629-0804, SADDLE CLAMP (item number 10). Refer to Figure 101.

(7)

Insert two part no. 628-7874, CLAMPING U-BOLT (item number 6) from below through each part no. 629-0804, SADDLE CLAMP (item number 10) and part no. 629-0479, LOWER BRACKET (item number 9) around the upright round rail. Refer to Figure 99.

Gap between Brackets

Saddle Clamps

Upright Round Rail

Square U-bolts Clamping U-bolts

ATTACH CLAMPING U-BOLTS ON LOWER BRACKET. Figure 99 ATTACHING CLAMPING U-BOLTS (8)

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Thread a part no. 107-0364, NUT (item number 1) and part no. 107-1932, WASHER (item number 2) on the ends of each part no. 628-7874, CLAMPING U-BOLT (item number 6).

OVERHAUL

Halvorsen (9)

F.

Use a socket wrench with a 9/16-inch socket to tighten the nuts evenly. However, leave them loose enough to allow the part no. 629-0479, LOWER BRACKET (item number 9) to slide on the upright round rail. Refer to Figure 99.

NOTE:

TO TIGHTEN NUTS EVENLY ON ALL U-BOLTS, MAKE SURE A SIMILAR NUMBER OF THREADS PROTRUDE PAST THE NUTS ON EACH THREADED END AT ALL TIMES.

(10)

Adjust the position of the brackets to maintain a uniform gap between brackets around the handrail channel. Be sure the channel is not in contact with any part of the brace assembly to prevent rubbing. Refer to Figure 99.

(11)

Securely tighten all fasteners to prevent any motion of the brace assembly. Tighten fasteners on the upper bracket first, then tighten the lower bracket and last tighten the connection between brackets. Do not over tighten.

TIGHTENING THE BRACE ASSEMBLY IN POSITION (1)

With all fasteners firmly in place apply the final torque using a torque wrench with a 9/16-inch socket. Refer to Figure 100.

(2)

Torque all nuts evenly per the sequence in the corresponding table in Chapter 2, Section 4, “Maintenance Specifications”. Refer to Figure 101.

TORQUE CONNECTING NUTS EVENLY. Figure 100 TIGHTENING TO TORQUE SPECIFICATIONS

REMOVAL AND INSTALLATION

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Halvorsen

TORQUE ALL OTHER NUTS EVENLY. Figure 101 TIGHTENING ALL OTHER FASTENERS

3-2 Page 94 August 2017

OVERHAUL

Halvorsen

Halvorsen Volume II

ILLUSTRATED PARTS LIST Original Instructions Version 1 Edition 3 This volume supersedes all editions and revisions prior to:

December 2015 English Language For use with equipment serial numbers AN14511 and subsequent This volume includes the following options: DIESEL TIER 3 ENGINE ALLISON 2100 TRANSMISSION

Refer to Volume I for Operation and Maintenance JBT, Ground Support Equipment John Bean Technologies Corporation 7300 Presidents Drive Orlando, Florida 32809 USA +1-407-851-3377 Telephone +1-407-850-4221 Fax

CONFIDENTIAL This technical manual contains unpublished work of John Bean Technologies Corporation. All information herein is confidential and proprietary and cannot be duplicated, used or disclosed in whole or in part, except with written permission from John Bean Technologies Corporation, Orlando, Florida USA. © 2011–2015 John Bean Technologies Corporation, all rights reserved.

i

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Halvorsen RECORD OF REVISIONS All pages in this issue are original. The following pages have had changes incorporated:

Change Date

Edition / Revision

List of Effective Pages

Change Description

Aug. 2011

Edition 1

Volume II

New edition.

June 2012

Edition 2

Volume II

Updated: chapters 4 and 5.

Mar. 2013

Edition 2 Revision 1

Volume II

Updated: chapters 4 and 5.

June 2014

Edition 2 Revision 1.1

Volume II

Updated: chapters 4 and 5.

Dec. 2015

Edition 3

Volume II

Updated: chapters 4 and 5.

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Halvorsen CHAPTER 4. ILLUSTRATED PARTS LIST

Section 1. Introduction 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.

HOW TO ORDER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.

PARTS RETURNED FOR CREDIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.

STANDARD WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5.

ITEMS JBT DOES NOT WARRANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 A.

NORMAL WEAR ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

B.

SHOP SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

C.

ROUTINE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Section 2. Manufacturer CAGE Codes 1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.

METHOD OF LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 3. Numerical Parts List 1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.

EXPLANATION OF COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.

NUMERICAL ARRANGEMENT SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.

SAMPLE APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 4. Explanation of Parts List Columns 1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.

PARTS LIST COLUMNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 A.

ITEM NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B.

PART NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

C.

PART DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

D.

QUANTITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4-Contents Page 1 December 2015

Halvorsen Section 5. Engine and Transmission Assembly ACTUATOR, STONE BENNET SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7300-006 . . . . . . . . . 2 ENGINE INSTALLATION, MLK25K3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9627 . . . . . . . . . . . . . 3 POWER MODULE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9583 . . . . . . . . . . . . 14 ENGINE AND TRANSMISSION WITH WINTERIZATION . . . . . . . . . . . . . . 627-9582 . . . . . . . . . . . . 21 DIPSTICK ASSEMBLY, 2100 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 624-8309 . . . . . . . . . . . . 24 SURGE OVERFLOW TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 627-4426 . . . . . . . . . . . . 25 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9581 . . . . . . . . . . . . 27

Section 6. Chassis Assembly CHASSIS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9676 . . . . . . . . . . . . . 2 BATTERY TRAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-6451 . . . . . . . . . . . . . 6 FUEL SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-3926 . . . . . . . . . . . . . 9 FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6157 . . . . . . . . . . . . 14 SHROUD AND SUPPORT ASSEMBLY, RADIATOR . . . . . . . . . . . . . . . . . 627-5618 . . . . . . . . . . . . 16 MAINTENANCE SUPPORT BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . 623-8468 . . . . . . . . . . . . 19 PLACARD INSTALLATION, CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-7183 . . . . . . . . . . . . 20

Section 7. Drive Train Assembly FRONT AXLE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8791 . . . . . . . . . . . . . 2 FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8792 . . . . . . . . . . . . . 4 DRIVE AND STEER AXLE - KESSLER LT41-PL58. . . . . . . . . . . . . . . . . . . 627-8476 . . . . . . . . . . . . . 7 DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9920 . . . . . . . . . . . . 10

Section 8. Rear Axle Assembly REAR AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1225 . . . . . . . . . . . . . 2 REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1226 . . . . . . . . . . . . . 4 HELPER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-1509 . . . . . . . . . . . . . 7 WALKBEAM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-5133 . . . . . . . . . . . . . 9 WALKBEAM MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1224 . . . . . . . . . . . . 10 HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1240 . . . . . . . . . . . . 12

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Halvorsen Section 9. Tires and Wheels TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1450. . . . . . . . . . . . . . 2 TIRE AND RIM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1451. . . . . . . . . . . . . . 3 TUBELESS BEAD SEAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-8708. . . . . . . . . . . . . . 4

Section 10. Scissors Assembly SCISSORS ASSEMBLY, INNER AND OUTER. . . . . . . . . . . . . . . . . . . . . . 627-9635. . . . . . . . . . . . . . 2 SCISSORS SUB-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-0300. . . . . . . . . . . . . . 5 SIDE SHIFT ASSEMBLY, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-4640. . . . . . . . . . . . . 11 ROLL CYLINDER ASSEMBLY, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6612. . . . . . . . . . . . . 13 PIVOT ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7421. . . . . . . . . . . . . 15 SIDE SHIFT ASSEMBLY, REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6220. . . . . . . . . . . . . 16 ROLL CYLINDER ASSEMBLY, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6613. . . . . . . . . . . . . 18 LINK / PIVOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7273. . . . . . . . . . . . . 20 LINK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7272. . . . . . . . . . . . . 23

Section 11. Deck Assembly DECK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9636. . . . . . . . . . . . . . 2 FOLDING WINGS / CAB AND ENGINE HATCH. . . . . . . . . . . . . . . . . . . . . 623-6920. . . . . . . . . . . . . . 6 FOLDING WING ASSEMBLY, LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . 624-6644. . . . . . . . . . . . . 11 FOLDING WING ASSEMBLY, RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . 623-6956. . . . . . . . . . . . . 13 SCISSOR TRACKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7214. . . . . . . . . . . . . 14 SCISSOR TRACKS INSTALLATION, REAR. . . . . . . . . . . . . . . . . . . . . . . . 623-7215. . . . . . . . . . . . . 17 TRACTION ROLLER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4020. . . . . . . . . . . . . 19 TRACTION ROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-4088. . . . . . . . . . . . . 21 BUMPERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1400. . . . . . . . . . . . . 24 CASTER AND ROLLER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 623-6900. . . . . . . . . . . . . 28 CASTER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3077. . . . . . . . . . . . . 30 ROLLER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3078. . . . . . . . . . . . . 32 IMPACT ROLLERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6895. . . . . . . . . . . . . 35 IMPACT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7250. . . . . . . . . . . . . 37 PALLET STOP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6911. . . . . . . . . . . . . 38 PALLET STOP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1211. . . . . . . . . . . . . 44 TINE WAY COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6820. . . . . . . . . . . . . 46 TINE WAY COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3075. . . . . . . . . . . . . 47

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Halvorsen TIE DOWN / LIFT PROVISION INSTALLATION, DECK . . . . . . . . . . . . . . . 624-3115 . . . . . . . . . . . . 48 MUD FLAP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-9632 . . . . . . . . . . . . 52 PLACARD INSTALLATION, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-7168 . . . . . . . . . . . . 54 CARGO TIE DOWN KIT, DECK PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . 628-1270 . . . . . . . . . . . . 56

Section 12. Walk-deck and Handrail Assembly HANDRAIL, WALKDECK AND GUIDE INSTALLATION . . . . . . . . . . . . . . . 623-6700 . . . . . . . . . . . . . 2 HANDRAIL AND WALKDECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 623-4705 . . . . . . . . . . . . 10 HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX . . . . . . . . . . . . . . . 623-6850 . . . . . . . . . . . . 12 HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR . . . . . . . . . . . . . . 623-6860 . . . . . . . . . . . . 14 HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX . . . . . . . . . . . . . . . 623-6880 . . . . . . . . . . . . 16 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR . . . . . . . . . . . . . 623-6890 . . . . . . . . . . . . 18 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT . . . . . . . . . . . . 623-6100 . . . . . . . . . . . . 20 HANDRAIL AND WALKDECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 623-8710 . . . . . . . . . . . . 25 GUIDE AND PALLET LOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7330 . . . . . . . . . . . . 27 PALLET LOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-4251 . . . . . . . . . . . . 29

Section 13. Ladder Assembly LADDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3125 . . . . . . . . . . . . . 2 LADDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3126 . . . . . . . . . . . . . 5 LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4190 . . . . . . . . . . . . . 8 SUPPORT ASSEMBLY, LOWER LADDER . . . . . . . . . . . . . . . . . . . . . . . . . 624-3127 . . . . . . . . . . . . 11

Section 14. Cab Assembly CAB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9637 . . . . . . . . . . . . . 2 SUPPORT BEAM ASSEMBLY, CAB FRONT . . . . . . . . . . . . . . . . . . . . . . . 624-4038 . . . . . . . . . . . . 10 SUPPORT BEAM ASSEMBLY, CAB REAR. . . . . . . . . . . . . . . . . . . . . . . . . 624-4039 . . . . . . . . . . . . 11 CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9639 . . . . . . . . . . . . 12 CAB SHELL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4753 . . . . . . . . . . . . 19 SIDE DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2994 . . . . . . . . . . . . 25 REAR DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2995 . . . . . . . . . . . . 28 HEATER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-1146 . . . . . . . . . . . . 30 HEATER ASSEMBLY, D4 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-5930 . . . . . . . . . . . . 32 HANDRAIL ASSEMBLY, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4041 . . . . . . . . . . . . 34 MIRROR ASSEMBLY, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6080 . . . . . . . . . . . . 36

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Halvorsen WIPER INSTALLATION, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3956. . . . . . . . . . . . . 38 ELECTRICAL PANEL ASSEMBLY, CONVEY . . . . . . . . . . . . . . . . . . . . . . 624-2915. . . . . . . . . . . . . 42 CAB INSULATION, THERMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3093. . . . . . . . . . . . . 46 CAB INSULATION INSTALLATION, ACOUSTIC . . . . . . . . . . . . . . . . . . . . 625-3967. . . . . . . . . . . . . 48 PANEL ASSEMBLY, FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3964. . . . . . . . . . . . . 50

Section 15. Hydraulic System CHASSIS HYDRAULIC INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669. . . . . . . . . . . . . . 2 HOSE ASSEMBLY KIT, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669-001 . . . . . . . . . 22 TUBE ASSEMBLY KIT, CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669-002 . . . . . . . . . 35 EMERGENCY PUMP HYDRAULIC ASSEMBLY . . . . . . . . . . . . . . . . . . . . 624-0330. . . . . . . . . . . . . 47 MANIFOLD ASSEMBLY, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5410. . . . . . . . . . . . . 49 MANIFOLD SUB-ASSEMBLY, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6681. . . . . . . . . . . . . 51 MANIFOLD, FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-8653. . . . . . . . . . . . . 54 HYDRAULIC RESERVOIR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5930. . . . . . . . . . . . . 55 SCISSOR HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9350. . . . . . . . . . . . . 58 HOSE ASSEMBLY KIT, SCISSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5945-003 . . . . . . . . . 75 TUBE ASSEMBLY KIT, SCISSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9350-002 . . . . . . . . . 86 MANIFOLD ASSEMBLY, REAR PITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5411. . . . . . . . . . . . . 97 MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS . . . . . . . . . . . . 623-5413. . . . . . . . . . . . . 99 DECK HYDRAULIC INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0452. . . . . . . . . . . . 101 HOSE ASSEMBLY KIT, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5952-003 . . . . . . . . 111 TUBE ASSEMBLY KIT, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-6080-002 . . . . . . . . 117 MANIFOLD ASSEMBLY, STOPS AND LIFT. . . . . . . . . . . . . . . . . . . . . . . . 623-5415. . . . . . . . . . . . 124 MANIFOLD ASSEMBLY, FIVE STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 623-5416. . . . . . . . . . . . 126 CAB HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5949. . . . . . . . . . . . 128 HOSE ASSEMBLY KIT, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5949-003 . . . . . . . . 132 HYDRAULIC INSTALLATION, FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . 623-7170. . . . . . . . . . . . 137 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT . . . . . . . . . . 623-7170-003 . . . . . . . . 141 VALVE BLOCK ASSEMBLY A/C MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 625-4073. . . . . . . . . . . . 146

Section 16. Electrical System CHASSIS ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9621-001 . . . . . . . . . . 2 WINTERIZATION ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . 624-3490. . . . . . . . . . . . . 23 ELECTRICAL INSTALLATION, POWER MODULE . . . . . . . . . . . . . . . . . . 628-5469. . . . . . . . . . . . . 34 ELECTRICAL ASSEMBLY, MAIN PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . 628-0554-001 . . . . . . . . . 44

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Halvorsen SCISSOR ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0414 . . . . . . . . . . . . 58 DECK ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3249 . . . . . . . . . . . . 67 DECK PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2911 . . . . . . . . . . . . 78 TAIL LIGHT ASSEMBLY, 24V LEFT TURN . . . . . . . . . . . . . . . . . . . . . . . . . 624-5754 . . . . . . . . . . . . 88 TAIL LIGHT ASSEMBLY, 24V RIGHT TURN. . . . . . . . . . . . . . . . . . . . . . . . 624-5756 . . . . . . . . . . . . 90 CAB ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0563-001 . . . . . . . . 92 DASH PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0600-001 . . . . . . . 103 WIPER PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 624-3258 . . . . . . . . . . . 109 CONVEY PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 624-2915 . . . . . . . . . . . 112 A/C CONNECTOR ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 627-7214 . . . . . . . . . . . 116 PROXIMITY SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . 622-6730 . . . . . . . . . . . 117 ACCELERATOR PEDAL ELECTRICAL ASSEMBLY. . . . . . . . . . . . . . . . . . 627-7150 . . . . . . . . . . . 118

Section 17. Identification IDENTIFICATION INSTALLATION, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . 623-5500-001 . . . . . . . . . 2 IDENTIFICATION INSTALLATION, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5500-002 . . . . . . . . . 7 IDENTIFICATION INSTALLATION, DECK. . . . . . . . . . . . . . . . . . . . . . . . . . 623-5500-003 . . . . . . . . 12 MAINTENANCE STANDARD DECAL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . 627-4879 . . . . . . . . . . . . 18

Section 18. Air Conditioning System AIR CONDITIONER CONDENSER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3088 . . . . . . . . . . . . . 2 AIR CONDITIONER COMPRESSOR MOTOR . . . . . . . . . . . . . . . . . . . . . . 625-3089-500 . . . . . . . . . 4 A/C EVAPORATOR, LOUVER BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3091 . . . . . . . . . . . . . 6 REFRIGERANT HOSES KIT, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4728 . . . . . . . . . . . . . 9 AIR CONDITIONING SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . 627-8134 . . . . . . . . . . . . 13 AIR CONDITIONING ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . 627-8136 . . . . . . . . . . . . 18 AIR CONDITIONING HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . 627-8135 . . . . . . . . . . . . 24 MANIFOLD, A/C MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4073 . . . . . . . . . . . . 32 DRIER ASSEMBLY, A/C RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3864 . . . . . . . . . . . . 35 AIR CONDITIONING SYSTEM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 625-4534 . . . . . . . . . . . . 36 A/C HYDRAULIC HOSE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8135-001 . . . . . . . . 39 A/C HYDRAULIC TUBE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8135-002 . . . . . . . . 48 A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . 625-4887 . . . . . . . . . . . . 54 A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . . 625-4132 . . . . . . . . . . . . 55 A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . 625-4130 . . . . . . . . . . . . 56

4-Contents Page 6 December 2015

Halvorsen CHAPTER 4. ILLUSTRATED PARTS LIST

Section 1. Introduction

1.

GENERAL Chapter 4 includes the parts lists and illustrations. Parts lists are grouped by function and subdivided by assembly. A table of contents lists the various assemblies and sub-assemblies of the equipment. Instructions for ordering and returning parts, and the standard JBT warranty, are included in this section. Review the warranty before ordering and/or returning parts. Manufacturer CAGE Codes, listed in alphabetical order in Section 2, are provided for items not modified by JBT. In addition, an explanation of columns assists in using the parts lists. For safety and reliability use only JBT replacement parts.

2.

HOW TO ORDER PARTS Orders will receive prompt attention and errors will be minimized if the customer follows the suggestions listed below: •

Write order legibly (preferably typewritten). Date the order and show a requested shipping date. Give the full name, address, and telephone number (if in the USA) of the person ordering the parts. Give the full name and address of the person who is to receive the parts.

NOTE:

GIVE THE BILLING ADDRESS IF DIFFERENT FROM THE SHIPPING ADDRESS.

•

Specify shipping mode, i.e., Air Freight, Motor Freight, United Parcel Service, Parcel Post, etc.

•

Indicate the quantity of each item required, starting with units of measure (“each,” “feet,” etc.) as required.

•

State the JBT part number, followed by a complete description. Check to be sure the part number and description agree. Parts not assigned a JBT part number should be ordered by manufacturer's name and part number.

•

If possible, include the model and serial number of the unit for which parts are required.

•

Assign a number to the order and sign it legibly.

•

Immediately confirm all fax and telephone orders with purchase orders.

•

Address orders as follows: JBT - Ground Support Equipment 7300 Presidents Drive Orlando, Florida 32809 USA

INTRODUCTION

4-1 Page 1 December 2015

Halvorsen 3.

4.

PARTS RETURNED FOR CREDIT •

Before returning any part, write a letter to JBT, Ground Support Equipment, Orlando, Florida USA requesting permission. Give an exact list, descriptions, and part numbers. Explain why you wish to return parts and what action is desired: repair, credit, or replacement. Include model and serial number of the unit from which the parts were removed.

•

If authority is granted, transportation charges must be prepaid, the sender's name must be marked on the outside of the container, and a return order must be enclosed with the returned parts.

•

Only parts purchased from JBT may be returned for credit consideration.

•

If a replacement part is desired before returning a defective part, a separate purchase order must accompany this request. When credit is approved, your account will be credited with the proper amount.

STANDARD WARRANTY John Bean Technologies Corporation, warrants that new equipment (product) of its own manufacture is of good workmanship and is free from mechanical defects, provided that (1) the equipment is operated in accordance with the printed instructions of JBT, (2) the equipment is used under the normal operating conditions for which it is designed, (3) the equipment is not subjected to misuse, negligence or accident, and (4) the equipment receives proper care, lubrication, protection, and maintenance in accordance with the printed instructions of JBT by qualified personnel. This warranty expires 12 months from time of commissioning of unit into service or 1000 hours, whichever first occurs. JBT obligations under this warranty being limited to the repair or replacement, at JBT election, of defective parts, provided that such defect is reported to JBT promptly or within 30 days after the defect is discovered, or by reasonable diligence should have been discovered by the customer. JBT will not be liable under this warranty for labor to remove or reinstall the defective part, for down time or for any other costs. Any parts replaced under this warranty shall become the property of and upon request be returned to and at the expense of JBT. Under this warranty JBT may, at its discretion, require the first user to purchase replacement components and make warranty coverage dependent upon a failure analysis.

5.

ITEMS JBT DOES NOT WARRANT Engines, engine components, transmissions, axles, commercial truck chassis, storage batteries, tires, equipment lighting, normal wear items (A.), shop supplies (B.), routine adjustments (C.), maintenance items, cleaning, preparation and towing. Many of the foregoing components are warranted directly by the non-JBT manufacturer to the first user and serviced by a worldwide network of distributors and others authorized to handle warranty claims. A first user's warranty claim should be presented directly to such an authorized service entity. In the event any component manufacturer will not deal directly with a first user then JBT will cooperate with the first user in the presentation of a claim to such non-JBT manufacturer. Under NO circumstances does JBT assume any liability for any warranty claims against or warranty work done by or in behalf of any non-JBT manufacturer of the foregoing components. JBT reserves the right to make changes in design and changes or improvements upon its products without any obligation upon itself to notify a first user or to install the same upon its products theretofore manufactured.

4-1 Page 2 December 2015

ILLUSTRATED PARTS LIST

Halvorsen A.

NORMAL WEAR ITEMS Tires, chains, sprockets, bearings, bushings, engine belts and hoses, brake pads and discs, lagged rollers and etc. are not covered for wear and tear. Should the first user suspect a manufacturing defect as the cause for failure of one of these components the first user may, after purchasing and installing a replacement component, return the failed component to JBT for warranty analysis. Should JBT or the component manufacturer determine the failure was due to a manufacturing defect the first user will receive warranty credit for the failure. Should JBT or the component manufacturer determine the component failed due to simple wear or abuse the first user will be liable for all service fees.

B.

SHOP SUPPLIES All lubricants, hydraulic system fluid, engine coolant and additives, all filters, and items used during normal maintenance of equipment are not covered under this warranty.

C.

ROUTINE ADJUSTMENTS Any hydraulic or mechanical adjustment made to enhance or continue the operation of a piece of equipment and having been made after 50 hours from time of commissioning of the unit into service.

THERE ARE NO UNDERSTANDINGS, REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS, IMPLIED, STATUTORY, OR OTHERWISE (INCLUDING, BUT WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE), NOT EXPRESSLY SET FORTH HEREIN. Except as expressly provided herein, JBT shall not be liable to buyer for damages of any kind or nature occasioned by or arising out of the installation, operation, use, misuse, non-use, repair, or replacement of said equipment, or out of the use of any method of process for which the same may be employed. In the event, notwithstanding the terms of this agreement, it is determined by a court of competent jurisdiction that an express warranty has been given by JBT to Buyer with respect to the speed, capacity, or other like performance characteristics of said equipment. JBT liability for breach of the same shall be limited to accepting return of such equipment f.o.b. plant of manufacture, refunding any amounts paid thereon by Buyer (less depreciation at the rate of 15% per year if Buyer has used equipment for more than 30 days) and canceling any balance still owing on the equipment. DISCLAIMER OF CONSEQUENTIAL DAMAGES. JBT IN NO EVENT SHALL BE LIABLE FOR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THIS AGREEMENT. CONSEQUENTIAL DAMAGES FOR PURPOSES HEREOF SHALL INCLUDE, WITHOUT LIMITATION, LOSS OF USE, INCOME OR PROFIT, OR LOSSES SUSTAINED AS THE RESULT OF INJURY (INCLUDING DEATH) TO ANY PERSON, OR LOSS OF OR DAMAGE TO PROPERTY (INCLUDING, WITHOUT LIMITATION, PROPERTY HANDLED OR PROCESSED BY THE USE OF SAID EQUIPMENT).

INTRODUCTION

4-1 Page 3 December 2015

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Halvorsen Section 2. Manufacturer CAGE Codes

1.

GENERAL The CAGE Code (Commercial And Government Entity Code) is assigned as a unique identifier for suppliers of goods and services to government defense agencies. A CAGE code identifies a specific supplier facility and its location. Many suppliers use the CAGE code as a prefix to their part numbers for identification of the item and its origin. CAGE Codes are used internationally as part of the NATO Codification System (NCS). CAGE codes are issued in the U.S. by the Defense Logistics Information Service (DLIS). Other countries, such as the United Kingdom and France, also issue CAGE codes.

2.

METHOD OF LISTING This list is arranged in alphabetic order by vendor, while the CAGE codes are shown at the right side of each manufacturer’s name. CAGE codes below correspond to the suppliers of the major components used to manufacture the equipment (refer to Manufacturers’ Appendices, Chapter 5). The Business Identification Number Crossreference System, or BINCS, at the Defense Logistics Information Service website was used as a reference for these CAGE codes. Additional information can be requested from the Defense Logistics Information Service, 74 Washington Ave. N STE 7, Battle Creek, MI 49017-3084.

MANUFACTURER CAGE CODES Eaton Mfg. Co. Reliance Div. Massillon, OH 44646

73330

General Motor Corp. Allison Transmission Division 4700 Www. 10th St. P.O. Box 894 Indianapolis, IN 46206-0894

73342

Sauer - Sundstrand Co. 2800 E. 13th St. Ames, IA 50010

14120

Dana Corp. Spicer Heavy Axle Div. 2100 W. State Blvd. P.O. Box 750 Fort Wayne, IN 46801

97271

Detroit Diesel Corp. 13400 Outer Drive West Detroit MI 48239-4001

72582

MANUFACTURER CAGE CODES

4-2 Page 1 December 2015

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Halvorsen Section 3. Numerical Parts List

1.

INTRODUCTION The numerical listing comprises part numbers of the equipment. Included in this list are references to Section, Figure, and Item numbers of the parts located in Chapter 4. When a part number is known and item description or illustration is desired, the number should be located in the numerical index. In this list, Section, Figure and Item number is shown for each part number. By consulting the respective parts list or illustration, the part can be located by reference to the corresponding item number.

2.

3.

EXPLANATION OF COLUMNS •

The first column contains the JBT part numbers. The part numbers are in numerical order.

•

The second column identifies the section.

•

The third column identifies the figure number which illustrates each item.

•

The fourth column identifies the item number.

NUMERICAL ARRANGEMENT SEQUENCE Part number arrangement begins at the extreme left-hand position and continues to the right, one position at a time. The first position arrangement of the part number is as follows: Numerals 0 through 9

4.

SAMPLE APPLICATION The following list of numbers is in correct numeric sequence: 102-0001 102-0020 102-0031 102-0035 102-0043 102-0059

NUMERICAL PARTS LIST

4-3 Page 1 December 2015

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Halvorsen Section 4. Explanation of Parts List Columns

1.

INTRODUCTION The parts listed in each section are organized in order of their numerical part number. The aids in locating parts via their part number. Electrical and hydraulic components are located in the section of the manual where the component resides on the product. In cases where multiple components comprise a system and that system resides throughout the product (i.e.,: fuel system, hydraulic system), then those components can be located in the section of the manual where the main component of that system resides on the product.

2.

PARTS LIST COLUMNS A.

ITEM NUMBER The first column provides a cross reference between the parts listed and the illustrations. To find a view of the part listed and its visual relationship to the assembly, locate the figure and item number in the list, then refer to the illustration and locate the part by item number. To find a part number and description in the parts list, locate the part on an illustration, note the item number, then refer to the parts list and locate the applicable part number and description.

B.

PART NUMBER The second column lists the part number necessary for reordering repair parts. Refer to the Description column for description and additional identifying information. Standard commercial hardware can be ordered from JBT or obtained locally. Vendor parts can be obtained from JBT or directly from the vendor.

C.

PART DESCRIPTION The third column lists the description of each item in the parts list. The identifying noun or key word is the first word in the description column. The remainder of this column contains the rest of the description to assist in completely identifying the item.

D.

QUANTITY The final column indicates the quantity of each part required to complete the next higher assembly. The abbreviation REF indicates that a part number is referenced to another list; this practice insures that the quantity shown on the list does not exceed the quantity used on the equipment.

EXPLANATION OF PARTS LIST COLUMNS

4-4 Page 1 December 2015

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Halvorsen Section 5. Engine and Transmission Assembly

Assembly

Assy. No.

Figure

Page

1.

ACTUATOR, STONE BENNET SHIFTER

623-7300-006

Figure 1

2

2.

ENGINE INSTALLATION, ML25K3P

627-9627

Figure 2 Sheet 1

3

3.

POWER MODULE ASSEMBLY

627-9583

Figure 3 Sheet 1

14

4.

ENGINE AND TRANSMISSION WITH WINTERIZATION

627-9582

Figure 4 Sheet 1

21

5.

DIPSTICK ASSEMBLY, 2100 TRANSMISSION

624-8309

Figure 5

24

6.

SURGE OVERFLOW TANK ASSEMBLY

627-4426

Figure 6

25

7.

ENGINE ASSEMBLY

627-9581

Figure 7 Sheet 1

27

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 1 December 2015

Halvorsen

Figure 1 ACTUATOR, STONE BENNET SHIFTER 623-7300-006 4-5 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL A BOTH SIDES

DETAIL C 35

1

36 38 DETAIL B

DETAIL F

109

DETAIL A

112

140 139

DETAIL C

Figure 2 Sheet 1 ENGINE INSTALLATION, MLK25K3P 627-9627

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 3 December 2015

Halvorsen 133 110 39

116

52 5 115 88 138

55

5

5 88 89

109

89 116

111 60

61 108 21 16 99

39

DETAIL B

Figure 2 Sheet 2 ENGINE INSTALLATION, MLK25K3P 627-9627 4-5 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

34

5

56 59

16 21 14 5 3 3

63 5

3 5 23 18 24

32 5 59 57 55 59 86

51

DETAIL F SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 3 ENGINE INSTALLATION, MLK25K3P 627-9627

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 5 December 2015

Halvorsen

133 64 62 106

110

61

5 116 103

102 SECTION H-H ROTATED 180 DEG.

135

45

Figure 2 Sheet 4 ENGINE INSTALLATION, MLK25K3P 627-9627 4-5 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 98 20 94 112 77

DETAIL

G

Figure 2 Sheet 5 ENGINE INSTALLATION, MLK25K3P 627-9627

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 7 December 2015

Halvorsen

100

22 113 SECTION E-E

82

84

83

DETAIL G

Figure 2 Sheet 6 ENGINE INSTALLATION, MLK25K3P 627-9627 4-5 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL L

137 136 133 64 1 42

26 30

7

4 45

1 135 64 132 24 23 125 86 33 18 23 24

20 93 122

39 124

64 1

2 137

54 39

SECTION J-J

SECTION K-K SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 7 ENGINE INSTALLATION, MLK25K3P 627-9627

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 9 December 2015

Halvorsen 106 109

15 19 97

117 89 44

77

89 94 98 20 16 21 DETAIL L

39

49

39 SECTION D-D SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 8 ENGINE INSTALLATION, MLK25K3P 627-9627 4-5 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE INSTALLATION, MLK25K3P 627-9627 ITEM

PART NO.

DESCRIPTION

QTY.

1

102-0512

BARB, HOSE 04 X 1/4 MNPT BR

3

2

102-1202

ELB. 1/4 NPT-BRASS WH3500X4

1

3

105-0014

CLAMP, MUFFLER 3.00 WITH SADDLE

5

4

105-0075

CLAMP, MUFFLER 2.00 WITH SADDLE

2

5

105-0091

CLAMP HOSE 54-44

7

105-1089

BARB, HOSE 10 X 1/2 MNPT BR

1

14

107-9081

SCREW. HHC-F 8.8 M10 X 1.5 X 35 MG

2

15

107-9258

NUT, PTH 8 M6 X 1.00 MG

8

16

107-9260

NUT, PTH 8 M10 X 1.50 MG

12

18

107-9262

NUT, PTH 8 M16 X 2.00 MG

10

19

107-9274

WASHER, FLAT STD. HD M6 MG

12

20

107-9275

WASHER, FLAT STD. HD M8 MG

9

21

107-9276

WASHER, FLAT STD. HD M10 MG

22

22

107-9278

WASHER, FLAT STD. HD M12 MG

2

23

107-9279

WASHER, FLAT STD. HD M16 MG

22

24

107-9340

SCREW, HHC 10.9 M16 X 2 X 55 MG

12

26

118-2678-002

CROSS - 1/4 NPT

1

30

620-1952

COCK, DRAIN 04 MNPT

1

32

627-1508

W-TRANSMISSION MOUNT

1

33

627-5709

W-ENGINE MOUNT

1

34

623-5392

MUFFLER, DONALDSON-M085207

1

35

627-9920

A-SHAFT, DRIVE

1

36

627-3926

I-FUEL SYSTEM, HEATED, ML44K

1

38

627-9583

A-POWER MOD, ML44K

1

39

623-7258

CLAMP, HOSE-CT-250L

10

42

627-5618

A-SHROUD / SUPPORT-RADIATOR

1

44

623-8706

ELBOW, RUBBER REDUCER 3.5/3.0

1

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

14

4-5 Page 11 December 2015

Halvorsen ENGINE INSTALLATION, MLK25K3P 627-9627 ITEM

PART NO.

DESCRIPTION

QTY.

45

623-9551

CLAMP, HOSE-SILICONE 0.625

2

49

623-9555

M-HOSE, STRAIGHT SILICONE 2.001

1

51

623-9639

BRACKET, EXHAUST PIPE-TURBO

1

52

624-0270

HOSE, ENGINE-PRESSURE

1

54

624-0276

HOSE, ELBOW SILICONE 2.00 I.D.

1

55

627-4273

W-EXHAUST PIPE TURBO

1

56

624-0281

EXHAUST PIPE, MUFFLER INLET

1

57

624-0282

EXHAUST PIPE, MUFFLER OUTLET

1

59

624-0314

WRAP, HIGH TEMP-CLOTH

2

60

627-9768

PIPE, AIR INTAKE

1

61

627-3395

W-TUBE RADIATOR OUTLET

1

62

627-3394

W-TUBE RADIATOR INLET

1

63

624-1409

EXHAUST SYSTEM BELLOW, NGSL

1

64

624-1447

CLAMP, HOSE-FUEL INJ. 0.25

4

77

627-9880

W-CAC CROSSBEAM

1

82

107-2281

SCREW, HHC GR8 0.5-20 X 1.5 MG

4

83

107-2283

NUT, PTHM GRC 0.5-20 MG

4

84

107-9455

WASHER, FLAT NAR HD 0.5 MG

4

86

624-8968

PLATE, SHIM ENGINE MOUNT

4

87

105-0103

CLAMP, HOSE 1.50-3.50 SS

1

88

105-0106

CLAMP, HOSE 0.88-2.75 SS

2

89

105-0117

CLAMP, HOSE 2.125-4.00 SS

1

90

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

4

93

107-9046

SCREW, HHC 8.8 M8 X 1.25 X 25 MG

1

94

107-9047

SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG

4

97

107-9168

SCREW, SFH-F 10.9 M6 X 1 X 20 MG

4

98

107-9259

NUT, PTH 8 M8 X 1.25 MG

4

99

107-9316

SCREW, HHC-F 10.9 M10 X 1.5 X 35 MG

4-5 Page 12 December 2015

8

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE INSTALLATION, MLK25K3P 627-9627 ITEM

PART NO.

DESCRIPTION

QTY.

100

107-9388

SCREW, HFLNG 10.9 M12 X 1.75 X 30 MG

2

102

REF-623-5384-014

HOUSING, AIR CLEANER

1

103

REF-623-5384-018

BANDS, AIR CLEANER MOUNT

2

106

623-8271

PRE-CLEANER, DONALDSON-H000821

1

108

627-0650

M-HOSE, 1.88 I.D. ELBOW

1

109

627-7214

AE-CAC

1

110

627-9766

W-TUBE, CAC RETURN

1

111

627-9764

TUBE, CAC INTAKE

1

112

627-9649

W-CAC BRACKET, NGSL

1

113

107-2181

NUT, PTH 10 M12 X 1.75 MG

2

115

627-5899

COUPLING, SILICONE ELBOW, TURBO

1

116

627-5901

COUPLING, SILICONE

3

117

627-9601

W-COUPLING, INTAKE ELBOW

1

118

628-5832

REDUCER, 2.50 X 3.00 DIA., SILICONE

1

119

627-6173

GASKET, CAC MOUNT

1

120

627-6174

GASKET, CAC MOUNT

2

122

239-8852-024

CLAMP, SUPPORT 2.62 NC

1

124

627-5218

TUBE, RAD. INLET, ML44K

1

125

627-6383

HOSE, RAD. INLET, RUBBER, ML44K

1

132

623-9552-032

HOSE, COOLANT 0.25 X 32 SAE 20R3

1

133

623-9552-122

HOSE, COOLANT 0.25 X 122 SAE 20R3

1

135

623-9553-052

HOSE, COOLANT 0.625 X 52 SAE 20R1

1

136

102-0701

ELBOW, ST 90 0.25 BR STD.

1

137

118-2658-003

NIPPLE, HEX 0.25 X 0.25

2

138

105-0135

CLAMP, HOSE 2.63-3.50 S.S.

1

139

107-2933

WASHER, LOCK M10 MG

4

140

107-9320

SCREW, HHC 10.9 M10 X 1.5 X 60 MG

4

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 13 December 2015

Halvorsen

29 11 22 58 62 64 61 49

60 68 66 67 57 11 22 72

76

51

93

70

Figure 3 Sheet 1 POWER MODULE ASSEMBLY 627-9583 4-5 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 78 78 96 94 69

10 21

75 98 84 88 86 88 86 83 61 62 81 63

97 73

59 62

43 100 89 21 82 70 88 86 83 50 87 99 21 10 51 92 91

85 88 86

Figure 3 Sheet 2 POWER MODULE ASSEMBLY 627-9583

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 15 December 2015

Halvorsen

70 77 35 25 24 41

84 34 41

43

28 HYDRAULIC PUMP

41 23

15 74 8 SOME ITEMS REMOVED FOR CLARITY

Figure 3 Sheet 3 POWER MODULE ASSEMBLY 627-9583 4-5 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

SECTION A-A SOME ITEMS REMOVED FOR CLARITY

93 80

95

79

94 73

96

74 93

57 67 66 68 60

71

SECTION B-B

Figure 3 Sheet 4 POWER MODULE ASSEMBLY 627-9583

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 17 December 2015

Halvorsen POWER MODULE ASSEMBLY 627-9583 ITEM

PART NO.

DESCRIPTION

QTY.

8

107-2182

NUT, PTH 10 M16 X 2.00 MG

2

10

107-9045

SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG

4

11

107-9078

SCREW, HHC-F 8.8 M10 X 1.5 X 20 MG

6

15

107-9117

SCREW, HHC 8.8 M16 X 2 X 60 MG

2

21

107-9275

WASHER, FLAT STD. HD M8 MG

4

22

107-9276

WASHER, FLAT STD HD M10 MG

9

23

107-9279

WASHER, FLAT HD M16 MG

2

24

107-9321

SCREW, HHC 10.9 M10 X 1.5 X 70 MG

6

25

107-9429

SCREW, SHCSLO 10.9 M8 X 1.25 X 20 MG

4

28

107-9458

SCREW, SFH-F 10.9 M14 X 2 X 40 MG

4

29

107-9388

SCREW, KFLNG 10.9 M12 X 1.75 X 30 MG

8

34

627-4872

MOUNT, LH PUMP BRACKET

1

35

627-4869

MOUNT, RH PUMP BRACKET

1

41

627-4853

COUPLING, CENTAFLEX CFA 50-2-S

1

43

627-7302

BRACKET, ALTERNATOR-UPPER, ML44K

1

49

627-7502

W-RH TRANS ADAPTER

1

50

627-7619

W-LH TRANS ADAPTER

1

51

627-9582

ENGINE/TRANS. W/WNTZ

1

57

107-2181

NUT, PTH 10 M12 X 1.75 MG

4

58

107-9014

SCREW, HHC-F 8.8 M6 X 1 X 10 MG

4

59

107-9038

SCREW, HHC 8.8 M6 X 1 X 90 MG

4

60

107-9093

SCREW, HHC-F 8.8 M12 X 1.75 X 45 MG

4

61

107-9258

NUT, PTH 8 M6 X 1.00 MG

6

62

107-9274

WASHER, FLAT STD HD M6 MG

63

620-7183

KIT, RADIATOR COOLANT OVERFLOW

1

64

623-6870

MOUNT, FLEX BOLT M6 X 1.0

4

65

624-0301

SPACER-SURGE TANK - HEAVY DUTY

4

4-5 Page 18 December 2015

16

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen POWER MODULE ASSEMBLY 627-9583 ITEM

PART NO.

DESCRIPTION

QTY.

66

624-5155

ISOLATOR, SURGE TANK - HEAVY DUTY

4

67

624-5157

PLATE, SPACER-SURGE ISOLATORS

2

68

624-5158

WASHER, MOUNT-SPACER

4

69

627-9820

W-OVERLOW BRACKET, TIER3

1

70

REF-627-3290-201

BELT, -35 TO 125 F

1

71

627-4422

W-MOUNT, SURGE TANK

1

72

627-4425

W-MOUNT, SURGE TANK

1

73

627-4426

A-TANK, SURGE-OVERFLOW

1

74

627-4876

M-HYD PUMP BRACKET

1

75

627-7307

W-MOUNT, ALTERNATOR

1

76

627-5955

PLATE, ECU MOUNT BRACKET

1

77

627-5448

SPACER, DAMPER PULLEY

1

78

102-0512

BARB. HOSE 04 X 1/4 MNPT BR

2

79

103-1719

ADAPTER, S90 1/2 FNPT X 1/2 MNPT BR

1

80

105-1089

BARB. HOSE 10 X 1/2 MNPT BR

1

81

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

2

82

107-9044

SCREW, HHC-F 8.8 M8 X 1.25 X 16 MG

1

83

107-9104

SCREW, HHC-F 8.8 M16 X 2 X 35 MG

2

84

107-9120

SCREW, HHC 8.8 M16 X 2 X 80 MG

1

85

107-9121

SCREW, HHC 8.8 M16 X 2 X 90 MG

1

86

107-9662

NUT, PTH 8 M16 X 2.00 MG

4

87

107-9267

NUT, HEX 8 M8 X 1.25 MG

1

88

107-9443

WASHER, FLAT STD HD M16 MG

6

89

239-8852-004

CLAMP, SUPPORT 1.00 NC

1

90

239-8852-005

CLAMP, SUPPORT 1.12 NC

1

91

REF-623-5384-060

ISOLATOR, ENGINE MOUNT

4

92

623-8221

FRONT, MOTOR MOUNT

1

93

623-9551

CLAMP, HOSE-SILICONE 0.625

2

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 19 December 2015

Halvorsen POWER MODULE ASSEMBLY 627-9583 ITEM

PART NO.

DESCRIPTION

QTY.

94

623-9552-026

HOSE, COOLANT 0.25 X 26 SAE 20R3

1

95

623-9553-016

HOSE, COOLANT 0.625 X 16 SAE 20R1

1

96

624-1447

CLAMP, HOSE-FUEL INJ. 0.25

2

97

624-8309

A-DIPSTICK 2100 TRANSMISSION

1

98

627-7151

SPACER, MOTOR MOUNT

1

99

239-8852-002

CLAMP, SUPPORT 0.75 NC

1

100

628-5713

NEOPRENE, 0.13 X 1.0 X 2.50

1

* NOT SHOWN

4-5 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

15

2

1

Figure 4 Sheet 1 ENGINE AND TRANSMISSION WITH WINTERIZATION 627-9582

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 21 December 2015

Halvorsen 8

8

3

7

10

6

ENGINE SIDE

REF 623-5384-103 FLYWHEEL W/RING

5

9 SECTION THRU COVER CONNECTING ENGINE WITH TRANSMISSION NOT TO SCALE

Figure 4 Sheet 2 ENGINE AND TRANSMISSION WITH WINTERIZATION 627-9582 4-5 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE AND TRANSMISSION WITH WINTERIZATION 627-9582 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-9581

ENGINE, VM D756IE3

1

2

627-8774

TRANSMISSION, ALLISON 2100SP

1

3

623-5386-001

FLEXPLATE, ALLISON TRANSMISSION

1

5

623-5386-003

PILOT ADAPTER - FLEXPLATE

1

6

623-5386-004

BOLT, PILOT ADAPTER

8

7

623-5386-005

RING, ATTACHING - FLEXPLATE

1

8

623-5386-007

KIT, BOLT ATTACHING RING

2

9

623-5386-008

COVER, HOUSING

2

10

623-5386-009

PLATE, SCUFF

1

14

623-5384-061

MOUNT, ENGINE FRONT LH

1

15

623-5386-015

BOLT, FLEXPLATE HOUSING COVER

4

17

625-5699

STARTER MOTOR, 24V ISKRA

1

18

625-5699-002

CAP SCREW

2

19

625-5699-003

WASHER, SPRING

2

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 23 December 2015

Halvorsen 1

2

Figure 5 DIPSTICK ASSEMBLY, 2100 TRANSMISSION 624-8309 DIPSTICK ASSEMBLY, 2100 TRANSMISSION 624-8309 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-8309-001

DIPSTICK, 2100 TRANSMISSION

1

2

624-8309-002

TUBE, TRANSMISSION DIPSTICK

1

4-5 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

1

4

2

3 5

7

6

Figure 6 SURGE OVERFLOW TANK ASSEMBLY 627-4426

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 25 December 2015

Halvorsen SURGE OVERFLOW TANK ASSEMBLY 627-4426 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-1482

NUT, PTH A2 #8-32 S.S.

1

2

111-5755

SCREW, PRND GR 2 #8-32 X 0.5 ZP

1

3

118-7293

WASHER, FLAT NARROW #8 ZP

1

4

623-8707

LANYARD - 20.00 WITH TAB

1

5

623-7159

M-CAP, RADIATOR 1 BAR

1

6

623-7338

SIGHT, WINDOW - LIQUID LEVEL

1

7

627-4397

W-TANK, SURGE / OVERFLOW

1

4-5 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 14 PLUG, CLAMP, AND FITTING SUPPLIED WITH ASSEMBLY

143

110

DETAIL A

95

88 105 113

121

144 SEE DETAIL A

26 104

155 158 162

89 154 159 157 152 33 159 156 161 160 124 138

139

Figure 7 Sheet 1 ENGINE ASSEMBLY 627-9581

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 27 December 2015

Halvorsen DETROIT DIESEL VM MOTORI VM MOTORI S.p.A. - 44042 CENTO (FE) via Ferrarese, 29 - Made in Italy -

MATRICOLA Serial

XXX/X-XXXXX

MOTORE TIPO Engine type MODELLO Engine Type VERSIONE Eng. Version

OMOLOGAZIONE Homologation

PESO Weight Kg

XXX

XXX/1 XXXXXXX XXX

POT MAX Max power Kw

XX.X

GIRI/MIN r.p.m.

XXXX

XX*XX/XXXX*XX/XXX*XXXX*XX XX

XX X - XXXXXX

SERIAL PLATE MUST BE ATTACHED HERE (SAMPLE PLATE SHOWN)

10 98 136

94

112 103

132

108

150 96

142

119 114 115 116 117 118 120 102

122

100 111

95

129 14

1 93 99

106 18

97

141

20 109

149 107

126

Figure 7 Sheet 2 ENGINE ASSEMBLY 627-9581 4-5 Page 28 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-3544

HEATER, TANK, COOL, 1000W, 120V

1

2

623-3548

HE-OIL PAN HEATER

1

3

623-5384-009

BANJO FITTING, BARB FUEL LINE

1

4

623-5384-011

WASHER, SEAL - BANJO BOLT

5

5

623-5384-013

FILTER, AIR CLEANER

1

6

623-5384-014

HOUSING, AIR CLEANER

1

7

623-5384-015

ELBOW, AIR INTAKE-TURBO

1

8

623-5384-016

CLAMP, AIR ELBOW SMALL - TURBO

1

9

623-5384-017

CLAMP, AIR ELBOW LARGE - TURBO

1

10

623-5384-018

BANDS, AIR CLEANER MOUNT

2

11

623-5384-019

INDICATOR, AIR RESTRICTION

1

12

623-5384-021

THERMOSTAT

1

13

623-5384-022

THERMOSTAT HOUSING

1

14

623-5384-025

PULLEY, WATER PUMP 1:1.56

1

15

623-5384-032

FITTING, BLEED - WATER MANIFOLD

1

16

623-5384-033

BANJO, WATER BLEED FITTING

7

17

623-5384-034

WASHER, SEALING - WATER FITTING

18

623-5384-035

OIL FILTER

1

19

623-5384-036

O-RING, OIL FILTER

2

20

623-5384-039

OIL COOLER ASSEMBLY

1

21

623-5384-045

CONNECTOR, INTAKE MANIFOLD

1

22

623-5384-046

FUEL INJECTION TIMER SWITCH

1

23

623-5384-047

SWITCH, WATER TEMP. SHUTDOWN

1

24

623-5384-048

CAP, OIL FILLER

2

26

627-9581-034

MANIFOLD, EXHAUST MIDDLE

1

28

623-5384-054

EXPANSION RINGS, EXHAUST MANIFOLD

4

29

623-5384-057

INTAKE, MANIFOLD, REAR

1

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

15

4-5 Page 29 December 2015

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

30

623-5384-060

ISOLATOR, ENGINE MOUNT

4

31

6232-5384-061

MOUNT, ENGINE FRONT, LEFT SIDE

1

32

623-5384-064

EJECTION VALVE, AIR FILTER

1

33

627-9581-091

TURBOCHARGER

1

36

623-5384-084

OIL SEPERATOR

1

37

623-5384-090

FUEL SOLENOID

1

38

623-5384-094

GASKET, EXHAUST

6

39

623-5384-095

GASKET, COOLANT

6

40

623-5384-096

GASKET, COOLANT CONNECTION

1

41

623-5384-099

LUBRICATION LINE, HEAD

1

42

623-5384-101

REPAIR KIT, FUEL INJECTOR

1

43

623-5384-102

RELAY-COLDSTART

1

45

623-5384-104

BLOCK-OUT PLATE, PUMP

1

46

623-5384-105

HOSE, FUEL-.3125

1

47

623-5384-106

GASKET, PUMP BLOCK - OFF PLATE

1

48

623-5384-108

BARB-STR 0.38 X 0.25 NPT

2

49

623-5384-109

EL 90 0.25 NPT-STREET

3

50

623-5384-110

ADAPTER 0.25 X 0.375 NPT

2

51

623-5384-111

COUPLING 0.25 NPT

1

52

623-5384-112

CLAMP, FUEL HOSE

4

53

623-5384-113

EL 90 0.25 NPT

1

54

623-5384-114

BARB-STR 0.3125H X 0.25 NPT

2

55

623-5384-115

HARNESS, ENGINE

1

56

623-5384-116

HARNESS, GLOW PLUGS

1

57

623-5384-117

HARNESS, KSB GLOW PLUGS

1

58

623-5384-118

SEALANT, OIL PAN

1

59

623-5384-121

GASKET, CRUSH DRAINBACK 706LTE

6

60

623-5384-124

SOLENOID, STARTER - NGSL

1

4-5 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

61

623-5384-125

KEY, FRONT PULLEY

1

62

623-5384-126

KEY, OIL PUMP GEAR

1

63

623-5384-127

O-RING

1

64

623-5384-128

FRONT SEAL

1

65

623-5384-129

NUT

1

66

623-5384-131

GASKET, EXHAUST

1

67

623-5384-132

GASKET SET

1

68

623-5384-133

TAPPET

1

69

623-5384-134

UNION, FUEL INJECTOR

6

70

623-5384-135

GASKET, TURBO MOUNTING

2

71

623-5384-136

GASKET SET, CYLINDER HEAD

1

72

623-5384-137

O-RING, REAR CAMSHAFT SEAL

2

73

623-5384-138

REAR MAIN BEARING W/CARRIER

1

74

623-5384-139

SEAL, REAR MAIN

1

75

623-5384-140

WASHER, THRUST

2

76

623-5384-141

O-RING

1

77

623-5384-142

BOLT, FLYWHEEL

78

623-5384-143

BOLT, BELL HOUSING

79

623-5384-144

BOLTS, TRANSMISSION

80

623-5384-145

STUD, CARRIER BEARING

6

81

623-5384-146

SCREW, HEAD

6

82

623-5384-147

SCREW, HEAD

6

83

623-5384-148

SCREW, HEAD

14

84

623-5384-152

O-RING, FLYWHEEL

2

85

623-5384-153

PLUG, TOP ROCKER COVER

8

86

623-5384-154

BOLT, ROCKER COVER

87

623-5384-155

PLUG, OIL BREATHER

3

88

623-5384-156

ELBOW, OIL BREATHER

1

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

12 9 11

27

4-5 Page 31 December 2015

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

89

623-5391-003

FITTING, WATER HEATER

1

90

623-5391-006

GLOW PLUGS

6

91

623-5391-007

CONTROLLER, GLOW PLUG

1

92

623-7312

HEATER, 150W, 120V IMMERSON

1

93

623-7369

BRACKET, HEATER

1

94

627-3290-004

TUBE ASSEMBLY, FUEL RETURN

1

95

627-3290-006

PUMP, WATER

1

96

627-3290-014

COVER, ROCKER ARM

2

97

627-3290-026

CRANKSHAFT PULLEY

1

98

627-3290-031

DIP STICK, OIL SUMP

1

99

627-3290-041

PIPE. OIL DRAIN

1

100

627-3290-045

HOSE, BYPASS

1

101

627-9581-049

NIPPLE, TURBO OIL

1

102

627-3290-051

TUBE, FUEL PUMP RETURN

1

103

627-3290-055

CLAMP, INJECTOR HOLD DOWN

6

104

627-3290-067

ADAPTER

1

105

627-3290-083

GASKET, INTAKE THROTTLE

1

106

627-3290-086

VIBRATION BALANCER

1

107

627-3290-089

PUMP, FUEL INJECTION KIT

1

108

627-3290-115

SCREW, INJECTOR HOLD DOWN

6

109

627-3290-131

BOLT, OIL PAN

110

627-3290-159

INJECTOR

6

111

627-3290-162

BLOCK, FUEL REFUSE

1

112

627-9581-058

MANIFOLD, FRONT INTAKE

1

113

627-3290-168

MANIFOLD, COOLANT, REAR

1

114

627-3290-169

PIPE, HIGH PRESSURE FUEL

1

115

627-3290-170

PIPE, HIGH PRESSURE FUEL

1

116

627-3290-171

PIPE, HIGH PRESSURE FUEL

1

4-5 Page 32 December 2015

43

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

117

627-3290-172

PIPE, HIGH PRESSURE FUEL

1

118

627-3290-173

PIPE, HIGH PRESSURE FUEL

1

119

627-3290-174

PIPE, HIGH PRESSURE FUEL

1

120

627-3290-175

PIPE, INJECTION

1

121

627-3290-176

MANIFOLD, COOLANT, FRONT

1

122

627-3290-178

HOSE, FUEL RAIL RETURN

1

124

627-9581-180

HOSE, OIL RETURN

1

125

627-3290-186

GASKET, ROCKER COVER

2

126

627-3290-199

M-OIL PAN, TIER3

1

127

627-3290-201

BELT, -35 TO 125 F

2

128

627-3290-202

K-CONNECTOR, VEHICLE, R756IE3, VM

1

129

627-3290-221

ECU, ENIGINE TIER3

1

130

627-3290-222

FILTER, FUEL AND HEATER

1

131

627-3290-223

FLANGE, EXHAUST 2.000, TIER3

1

132

627-3290-225

ELBOW, INLET

1

133

627-3290-226

PRIM FUEL FILTER, TIER3

2

134

627-3290-227

O-RING, OIL FILTER BASE

2

135

627-3290-228

GASKET, WATER PUMP

2

136

627-3290-229

TUBE, DIPSTICK, TIER3

1

137

627-3290-230

O-RING, DIPSTICK, TIER3

1

138

627-3290-231

CLAMP, HOSE

6

139

627-3290-234

PLUG, PIL PAN DRAIN

2

141

627-3290-236

WATER PIPE RETURN

1

142

627-3290-237

WATER RETURN PIPE

1

143

627-3290-238

CLAMP, SPRINGBAND

1

144

627-3290-246

GASKET, INTAKE MANIFOLD

6

145

627-3290-248

PUMP, OIL ASSEMBLY

1

146

627-3290-251

STUD, OIL FILTER

1

ENGINE AND TRANSMISSION ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-5 Page 33 December 2015

Halvorsen ENGINE ASSEMBLY 627-9581 ITEM

PART NO.

DESCRIPTION

QTY.

147

627-3290-252

GASKET, INJECTOR

6

148

627-3290-253

O-RING

6

149

627-3290-254

VALVE

1

150

627-3290-255

RAIL, FUEL ASSY.

1

151

627-7307

W-MOUNT, ALTERNATOR

1

152

627-9581-037

CONTROL FLANGE, TURBO

1

154

627-9581-079

GASKET, TURBO OUTLET

1

155

623-5384-166

STUD

8

156

627-3290-109

STUD

4

157

627-3290-110

STUD, M8 X 22

3

158

623-5384-165

NUT, M8

20

159

627-3290-129

NUT, M8

7

160

627-9581-167

FLANGE, TURBO OUTLET

1

161

627-9581-184

GASKET, TURBO OUTLET FLANGE

1

162

627-9581-197

ELBOW, TURBO RELOCATION

1

163*

627-3290-029

HUB, CRANKSHAFT

1

* NOT SHOWN

4-5 Page 34 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 6. Chassis Assembly

Assembly

Assy. No.

Figure

Page

1.

CHASSIS ASSEMBLY

627-9676

Figure 1 Sheet 1

2

2.

BATTERY TRAY INSTALLATION

627-6451

Figure 2 Sheet 1

6

3.

FUEL SYSTEM INSTALLATION

627-3926

Figure 3 Sheet 1

9

4.

FUEL TANK ASSEMBLY

623-6157

Figure 4

14

5.

SHROUD AND SUPPORT ASSEMBLY, RADIATOR

627-5618

Figure 5 Sheet 1

16

6.

MAINTENANCE SUPPORT BLOCK ASSEMBLY

623-8468

Figure 6

19

7.

PLACARD INSTALLATION, CHASSIS

624-7183

Figure 7

20

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 1 December 2015

Halvorsen

27

8

9

1 18

20

3

21 3 30

Figure 1 Sheet 1 CHASSIS ASSEMBLY 627-9676 4-6 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

26 3

7 12 25

13

14

15 17 11

6

2

28 5

16

Figure 1 Sheet 2 CHASSIS ASSEMBLY 627-9676

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 3 December 2015

Halvorsen

19

11

29 23 29 10

Figure 1 Sheet 3 CHASSIS ASSEMBLY 627-9676 4-6 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHASSIS ASSEMBLY 627-9676 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2231

SCREW, HHC 8.8 M12 X 1.75 X 20 MG

6

2

107-9014

SCREW, HHC-F 8.8 M6 X 1 X 10 MG

1

3

107-9045

SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG

7

5

107-9275

WASHER, FLAT STD HD M8 MG

1

6

107-9302

SCREW, HHC 10.9 M8 X 1.25 X 25 MG

1

7

107-9416

BOLT, HFLNG 8.8 M10 X 1.5 X 20 MG

24

8

107-9447

WASHER, FLAT NAR HD M12 MG

6

9

627-9626

W-CHASSIS ML24K3P

1

10

627-8791

I-FRONT AXLE, KESSLER LT41

1

11

623-8468

A-MAINTENANCE STAND

2

12

623-8469

PAD, RUBBER

6

13

628-1805

W-CLEVIS, AIR TRANSPORT

1

14

623-8692

W-PIN, AIRTRANSPORTABILITY

1

15

623-8695

PIN, QUICK RELEASE 5/8 IN.

1

16

623-8697

LANYARD-12.00 WITH SPLIT RING

1

17

623-8698

LANYARD-12.00 WITH TAB

1

18

623-8734

PAD, FRONT SUB FRAME

2

19

624-1225

I-REAR AXLE, NGSL

1

20

624-1450

I-TIRES, NGSL

1

21

624-3140

W-HYD. MANIFOLD COVER

1

23

627-6451

I-BATTERY BOX, ML44K

1

25

624-6070

SHIM, DECK REST THICK

4

26

624-6593

BUMPER, PLATFORM

2

27

624-7183

I-PLACARD, CHASSIS

1

28

624-8941

M-SHAFT COLLAR

1

29

627-9627

I-POWER MOD, ML25K3P

1

30

627-9669

IH-CHASSIS

1

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 5 December 2015

Halvorsen

10 8 17

2

Figure 2 Sheet 1 BATTERY TRAY INSTALLATION 627-6451 4-6 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

B

7

B

6

TOP VIEW SOME ITEMS REMOVED FOR CLARITY

8

17

15 16

15 16

11 SECTION

B-B

11

Figure 2 Sheet 2 BATTERY TRAY INSTALLATION 627-6451

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 7 December 2015

Halvorsen BATTERY TRAY INSTALLATION 627-6451 ITEM

PART NO.

DESCRIPTION

QTY.

2

107-9046

SCREW, HHC-F 8.8 M8 X 1.25 X 25 MG

2

6

107-9276

WASHER, FLAT STD HD M10 MG

6

7

107-9316

SCREW, HHC-F 10.9 M10 X 1.5 X 35 MG

6

8

627-1447

W-TRAY, BATTERY ML44K

1

10

627-1504

W-COVER, BATTERY ML44K

1

11

623-7289

THREADED SHAFT, M8 X 1.25

4

12

627-1505

BATTERY STRAP, HEAT SHRINK

2

15

107-9259

NUT, PTH 10 M8 X 1.25 MG

8

16

107-9275

WASHER, FLAT STD HD M8 MG

8

17

107-2185

NUT, INSERT, AVK-AHS7812579

2

4-6 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

46 43

45

INJECTOR 3 PUMP

4

44

SOME ITEMS REMOVED FOR CLARITY

15

TO FEED TUBE

42 4

4

3

FUEL BLOCK

16

14

28

Halvorsen

Figure 3 Sheet 1 FUEL SYSTEM INSTALLATION 627-3926

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 9 December 2015

Halvorsen 11 10 9

DETAIL C

8 17

DETAIL D

SOME ITEMS REMOVED FOR CLARITY FEED TUBE

DETAIL H

47 22

38 7 19

SECTION A-A ROTATED 90 DEG. CCW

44 43

SECTION B-B SOME ITEMS REMOVED FOR CLARITY

Figure 3 Sheet 2 FUEL SYSTEM INSTALLATION 627-3926 4-6 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 46

4 TIE WRAP HOSES

42

27” LONG

18 21 20

29 3 VENT LINE TO BOTTOM TANK

25 31 7

6

30

23

140” LONG

4

14” LONG

44

29 3

29 3

19 7 38

TO FUEL BLOCK

DETAIL C

4 33” LONG

29 3 TO FEED HOSE

4 48

80” LONG

29 3

16

TO INJECTOR PUMP

31 7

37 21 37

4 43

6

DETAIL D SOME ITEMS REMOVED FOR CLARITY

DETAIL H ROTATED 90 DEG. CCW

Figure 3 Sheet 3 FUEL SYSTEM INSTALLATION 627-3926

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 11 December 2015

Halvorsen FUEL SYSTEM INSTALLATION 627-3926 ITEM

PART NO.

DESCRIPTION

QTY.

3

105-1190

HOSE, FUEL 3/8 I.D. DSL / GAD, J1527

4

105-1262

CLAMP, HOSE 0.44-0.67 S.S.

9

6

107-2180

NUT, PTH 10 M10 X 1.50 MG

10

7

107-9276

WASHER, FLAT STD HD M10 MG

28

8

107-2858

SCREW, PPAN A2 #10-32 X 0.75 S.S.

5

9

231-5027-003

GASKET

1

10

231-5027-004

WASHER, FLAT SD 0.203 I.D. 0.38 O.D. X 0.06 NYLON

5

11

628-4434

M-SENDER, FUEL LEVEL

1

14

623-6157

A-FUEL TANK

1

15

623-6158

ISOLATOR STRIP, FUEL TANK

2

16

625-6640

W-STRAP, FUEL TANK - ASSEMBLY

2

17

DWG-514-6319

DWG-SENDING UNIT INSTALL INSTRUCTIONS

1

18

107-9310

SCREW, HHC-F 10.9 M8 X 1.25 X 65 MG

2

19

107-9081

SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG

4

20

107-9259

NUT, PYH 8 M8 X 1.25 MG

4

21

107-9275

WASHER, FLAT STD HD M8 MG

8

22

103-1714

PLUG, HEX CS 06 MNPT BR

1

23

105-1096

BARB, 90 06 X 06 MNPT BR

1

25

625-6695

W-FUEL TANK BRACKET, SUPPORT

2

28

625-6987

A-FUEL TANK BRACKET, SUPPORT

1

29

620-1317-004

FLEX-GARD, NYLON SLIT 5/8 IN.

30

625-9437

PLATE, SPACER, FUEL TANK

31

107-9084

SCREW, HHC 8.8 M10 X 1.5 X 50 MG

10

37

107-9062

SCREW, HHC 8.8 M8 X 1.25 X 40 MG

2

38

107-9260

NUT, PTH 8 M10 X 1.5 MG

4

42

519-7339-001

HEATED FUEL HOSE - 24VDC

1

43

REF-627-3290-222

FILTER, FUEL AND HEATER

0

4-6 Page 12 December 2015

24.5 ft.

24.5 ft. 2

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen FUEL SYSTEM INSTALLATION 627-3926 ITEM

PART NO.

DESCRIPTION

QTY.

44

627-3729

A-FILTER, FS20022, LUB.

1

45

105-1289

BARB, HOSE 0.31 I.D. HOSE X 6FNPT

1

46

102-1625

ADAPTER, STRAIGHT 10M SAE (45) X 3/8 IN. MNPT BR

2

47

627-5562

PLATE, FILTER

1

48

628-5890

K-BANJO FITTING M14

2

* NOT SHOWN

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 13 December 2015

Halvorsen

10

5 1

13 4 13

12 9

13

13

5 1

9

11

SECTION A-A

14

10

3

Figure 4 FUEL TANK ASSEMBLY 623-6157 4-6 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen FUEL TANK ASSEMBLY 623-6157 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-6157-001

CAP, FUEL TANK

1

2

624-8922

TUBE, RD 4.50 X 0.250 W AL

1

3

624-8923

FITTING, 0.500 X 0.375 NPTF AL

1

4

624-8924

FITTING, 0.500 X 0.500 NPTF AL

1

5

624-8926

VALVE, ROLLOVER

1

6

624-8927

CAP, SHIPPING 5 HOLE FLG

1

7

624-8928

CAP, SHIPPING PLASTIC

3

8

624-8929

CAP, SHIPPING VINYL

1

9

624-8939

SHELL, FRONT FUEL TANK NGSL

1

10

624-8931

SIDE, FUEL TANK NGSL

2

11

624-8932

SUPPORT, WITHDRAW NGSL

1

12

624-8933

FLANGE, GUAGE #10-32 NGSL

1

13

624-8934

A-WITHDRAW TUBE NGSL

2

14

624-8940

SHELL, REAR FUEL TANK NGSL

1

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 15 December 2015

15 SOME ITEMS REMOVED FOR CLARITY

DETAIL A 22 26

5

22

26

25

8

DETAIL B

3

14

2

5

12

EXPLODED VIEW

1

DETAIL B

DETAIL A

5

13

20 21

Halvorsen

Figure 5 Sheet 1 SHROUD AND SUPPORT ASSEMBLY, RADIATOR 627-5618 4-6 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 24 13 20

RADIATOR MOUNT

5 22 22 7 16

9

22 3 18 19

11 14

13

Figure 5 Sheet 2 SHROUD AND SUPPORT ASSEMBLY, RADIATOR 627-5618

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 17 December 2015

Halvorsen SHROUD AND SUPPORT ASSEMBLY, RADIATOR 627-5618 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2035

SCREW, SOCKET HEAD SET, M5 X 0.8 X 10 ZP

2

2

107-9078

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M10 X 1.50 X 20 MG

4

3

107-9080

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M10 X 1.50 X 30 MG

12

5

107-9260

NUT, PTH 8 M10 X 1.50 MG

18

7

107-9460

NUT, HEX GR 8 0.38 X 16 MG

4

*8

623-6774

MOTOR, HYDRAULIC F11-5

1

9

623-7129

ISOLATOR, LF 1.5 SERIES

4

11

623-8150

W-RADIATOR GRILL

1

12

628-1668

W-HOUSING, RADATOR FAN

1

13

624-3101

W-PLENUM, RADIATOR SUPPORT

1

14

623-8490

FAN, 20 IN. O.D. FLANGE 4Z-37.5/37.5

1

15

623-8493

HUB, ROTATING, FAN

1

16

627-5130

RADIATOR, ALUMINUM W/OIL COOL, ML44K

1

18

623-8581

GASKET, ADH FOAM RADIATOR

2

19

623-8582

GASKET, ADH FOAM RADIATOR

2

20

107-9047

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M8 X 1.25 X 30 MG

10

21

5150138

WASHER, FLAT 5/16 IN.

10

22

107-9276

WASHER, FLAT STD HARD M10 MG

28

24

107-2168

NUT, INSERT, AL, M8 X 1.25, GRIP 3.8

1

25

628-1667

W-MOUNT, RADIATOR FAN SHROUD

1

26

107-9081

SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG

6

4-6 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen (HANDLE) 4

1

2

(KEYRING) 3

Figure 6 MAINTENANCE SUPPORT BLOCK ASSEMBLY 623-8468

MAINTENANCE SUPPORT BLOCK ASSEMBLY 623-8468 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8461

MAINTENANCE STAND WELDMENT

1

2

623-8466

PIN, QUICK RELEASE L 7/16 IN.

1

3

623-8467

LANYARD-20.00 WITH SPLIT RING

1

4

627-8288

DE-MAINTENANCE STAND

1

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 19 December 2015

Halvorsen

Figure 7 PLACARD INSTALLATION, CHASSIS 624-7183 4-6 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen PLACARD INSTALLATION, CHASSIS 624-7183 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-7149

A-PLACARD, DOT FLIP HAZARD

1

2

107-9017

SCREW, HEX HEAD CAP-F 10.9 M6 X 1 X 20 MG

4

3

107-9450

WASHER, FENDER STD HARD M6 MG

4

4

624-7175

INSERT, GRIP M6 X 1.0 CS

4

CHASSIS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-6 Page 21 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 7. Drive Train Assembly

Assembly

Assy. No.

Figure

Page

1.

FRONT AXLE INSTALLATION

627-8791

Figure 1

2

2.

FRONT AXLE ASSEMBLY

627-8792

Figure 2 Sheet 1

4

3.

DRIVE AND STEER AXLE - KESSLER LT41-PL58

627-8476

Figure 3 Sheet 1

7

4.

DRIVE SHAFT ASSEMBLY

627-9920

Figure 4 Sheet 1

10

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-7 Page 1 December 2015

Halvorsen

4

1

3

REF: 627-8543

2 SECTION A-A

3

Figure 1 FRONT AXLE INSTALLATION 627-8791 4-7 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen FRONT AXLE INSTALLATION 627-8791 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2831

SCREW, HHC GR 8 0.75-16 X 14 MG

8

2

107-9501

NUT, PTH 0.75-16 UNC MG

8

3

107-9280

WASHER, FLAT STD HD M20 MG

4

627-8792

A-AXLE, FRONT, KESSLER

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

16 1

4-7 Page 3 December 2015

Halvorsen

11 13 15 14

4

5

6

10

5

6

8 7

2 DETAIL B

6

5

4

1

Figure 2 Sheet 1 FRONT AXLE ASSEMBLY 627-8792 4-7 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

SECTION A-A SOME ITEMS REMOVED FOR CLARITY

12

6

5

DETAIL B SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 2 FRONT AXLE ASSEMBLY 627-8792

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-7 Page 5 December 2015

Halvorsen FRONT AXLE ASSEMBLY 627-8792 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5427

CALIPER, PARKING BRAKE

1

2

625-8642

CALIPER, SERVICE BRAKE

1

4

107-9095

SCREW, HHC 8.8 M12 X 1.75 X 60 MG

6

5

107-2181

NUT, PTH 10 M12 X 1.75 MG

9

6

107-9447

WASHER, FLAT NAR HD M12 MG

7

628-5485

M-KESSLER AXLE LT41-PL58

1

8

107-9096

SCREW, HHC 8.8 M12 X 1.75 X 70 MG

2

10

107-2934

NUT, U, M6 X 1, 0.8-4 PLATE, MG

4

11

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

4

12

107-9094

SCREW, HHC-F 8.8 M12 X 1.75 X 50 MG

1

13

107-9274

WASHER, FLAT STD HD M6 MG

4

14

628-5319

W-AXLE LS CONTACT

1

15

628-5329

W-AXLE LIMIT SWITCH CONTACT MOUNT

1

4-7 Page 6 December 2015

18

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

3

2

4

1 4

1 7

Figure 3 Sheet 1 DRIVE AND STEER AXLE - KESSLER LT41-PL58 627-8476

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-7 Page 7 December 2015

Halvorsen DO NOT PAINT CHROME CYLINDER

4

DO NOT PAINT CHROME CYLINDER

4

7 2

3

1

4

3

SOME COMPONENTS REMOVED FOR CLARITY

Figure 3 Sheet 2 DRIVE AND STEER AXLE - KESSLER LT41-PL58 627-8476 4-7 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DRIVE AND STEER AXLE - KESSLER LT41-PL58 627-8476 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-8476-001

SPACER, WHEEL, KESSLER

2

2

627-8476-002

MOUNT, BRAKE CALIPER

1

3

627-8476-003

DISC, LARGE-WHEEL BRAKE, KESSLER

1

4

627-8476-004

STEERING CYLINDER

2

7

627-8476-070

CONNECTOR ROD ASSEMBLY, ML42K4P

1

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-7 Page 9 December 2015

Halvorsen DRIVE AXLE

TRANSMISSION

REV. D Figure 4 Sheet 1 DRIVE SHAFT ASSEMBLY 627-9920 4-7 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DRIVE AXLE

TRANSMISSION

Figure 4 Sheet 2 DRIVE SHAFT ASSEMBLY 627-9920

DRIVE TRAIN ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-7 Page 11 December 2015

Halvorsen DRIVE SHAFT ASSEMBLY 627-9920 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5447-001

FLANGE

2

2

623-5447-002

YOKE, SLIP

2

3

623-5447-003

STUB, SLIP

2

4

623-5447-004

BEARING, CENTER

1

5

623-5447-005

YOKE, TUBE

1

6

623-5447-006

YOKE, END

1

7

623-5447-007

SHAFT, TUBE

1

8

624-8966

UNIVERSAL JOINT, MAINTENANCE FREE

3

9

623-5447-009

FLANGE, DRIVE

1

10

623-5447-010

WASHER, SHAFT

1

11

623-5447-011

NUT, SHAFT

1

12*

623-5447-012

TUBE

1

13

623-5447-013

TUBE

1

14*

623-5447-014

WASHER, LOCK 0.50

4

15*

623-5447-015

BOLT, 0.50-20 X 1.75

4

16*

623-5447-016

NUT, HEX 0.50-20

4

17

624-4055

RETAINER, WASHER, DRIVE FLANGE

1

18*

623-5447-017

KIT, BEARING STRAP C3-70-38X

1

19

627-1994

A-TOOL, 3 PIN SPANNER WRENCH

1

*

107-9032

SCREW, HHC 8.8 M6 X 1 X 45 MG

6

*

107-9035

SCREW, HHC 8.8 M6 X 1 X 60 MG

2

* NOT SHOWN

4-7 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 8. Rear Axle Assembly

Assembly

Assy. No.

Figure

Page

1.

REAR AXLE INSTALLATION

624-1225

Figure 1

2

2.

REAR AXLE ASSEMBLY

624-1226

Figure 2 Sheet 1

4

3.

HELPER CYLINDER ASSEMBLY

628-1509

Figure 3

7

4.

WALKBEAM ASSEMBLY

624-5133

Figure 4

9

5.

WALKBEAM MODIFICATION

624-1224

Figure 5

10

6.

HUB ASSEMBLY

624-1240

Figure 6

12

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 1 December 2015

Halvorsen

REV. E

Figure 1 REAR AXLE INSTALLATION 624-1225 4-8 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen REAR AXLE INSTALLATION 624-1225 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9045

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M8 X 1.25 X 20 MG

16

2

107-9079

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M10 X 1.50 X 25 MG

2

3

107-2309

WASHER, FLAT NARROW HARD M8 MG

4

107-9276

WASHER, FLAT STD HARD M10 MG

2

5

623-5449

W-PIN, REAR AXLE

2

6

623-8732

TRAY, HOSE

2

7*

624-3246

CHASSIS, ELECTRICAL (REF. SEC. 4-16)

1

8

623-9637

SPACER, BRONZE, REAR AXLE

8

9**

624-1226

A-REAR AXLE, NGSL (REF. FIG. 2)

1

10

625-3193

GREASE FITTING, STRAIGHT. 5/16-24 SHORT

2

16

* NOT SHOWN **NOTE: Contact JBT for appropriate IUID label when replacing rear axle assembly 624-1225

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 3 December 2015

Halvorsen

REV. C Figure 2 Sheet 1 REAR AXLE ASSEMBLY 624-1226 4-8 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 Sheet 2 REAR AXLE ASSEMBLY 624-1226

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 5 December 2015

Halvorsen REAR AXLE ASSEMBLY 624-1226 ITEM

PART NO.

DESCRIPTION

QTY.

1

103-0744

PIN, COTTER 0.156 X 1.75 SS

4

2

107-2181

NUT, PTH 10 M12 X 1.75 MG

6

3*

107-2182

NUT, PTH 10 M16 X 2.00 MG

32

4

107-9263

NUT, PTH 8 M20 X 2.50 MG

2

5

107-9280

WASHER, FLAT NARROW HARD M20 MG

12

6

107-9348

SCREW, HEX HEAD CAP, 10.9 M16 X 2.00 X 130 MG

32

7

107-9373

SCREW, HEX HEAD CAP, 10.9 M20 X 2.50 X 190 MG

2

8

107-9396

SCREW, HEX FLANGE, 10.9 M12 X 1.75 X 120 MG

8

9

107-9443

WASHER, FLAT STD HARD M16 MG

10

107-9454

WASHER, FLAT THICK HARD M12 MG

8

11

628-1509

A-HELPER CYLINDER (REF. FIG. 4)

2

13

625-4019

BUSHING, REAR AXLE PIVOT

2

14

624-0268

SPACER, HELPER CYLINDER

2

15

624-0327

MACHINING, REAR AXLE

1

16

624-5133

A-WALKBEAM NGSL (REF. FIG. 5)

2

17

624-1240-

HUB ASSEMBLY (REF. FIG. 7)

4

18

624-3092

SPACER, WALKBEAM

2

19

624-3093

SPACER, WALKBEAM OUTER

2

20

624-3095

BRACKET WELDMENT, HELPER CYLINDER UPRIGHT

2

21

624-3098

ROD, HELPER CYLINDER SPRING

2

22

624-3099

SPRING, HELPER CYLINDER UPRIGHT

4

23

624-3100

COVER, SPRING, HELPER CYLINDER UPRIGHT

4

64

* NOT SHOWN

4-8 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 5

SEE DETAIL

B

3

5

2 1 2

1

SECTION

A-A

6

A

7

A

9

10

4 5

2

DETAIL

B

Figure 3 HELPER CYLINDER ASSEMBLY 628-1509

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 7 December 2015

Halvorsen HELPER CYLINDER ASSEMBLY 628-1509 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-4647

BRACKET, MOUNTING, HELPER CYLINDER WHEEL

1

2

623-6149

WHEEL ASSEMBLY, HELPER CYLINDER

2

3

625-3996

BUSHING, HELPER CYL WHEEL PIN

1

4

623-9568

BUSHING, HELPER CYLINDER FIBER BACKE

2

5

625-4508

W-BRACKET, HELPER CYLINDER WHEELS

1

6

624-0322

CIRCLIP, HELPER CYLINDER 0.625

2

7

624-0323

CIRCLIP, HELPER CYLINDER 1.00

1

9

628-1404

CYLINDER, HELPER

1

10

623-9560

FITTING, GREASE, STRAIGHT 0.25-28 SHORT ZP

1

NOTE:

4-8 Page 8 December 2015

CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING HELPER CYLINDER ASSEMBLY 628-1509.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 WALKBEAM ASSEMBLY 624-5133

WALKBEAM ASSEMBLY 624-5133 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-9568

BUSHING, HELPER CYLINDER PIVOT

2

2

624-1224

WALKBEAM MODIFICATION

1

3

623-9560

GREASE FITTING

1

NOTE:

CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING REAR AXLE.

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 9 December 2015

Halvorsen

REV. D

Figure 5 WALKBEAM MODIFICATION 624-1224 4-8 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen WALKBEAM MODIFICATION 624-1224 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-1221

WALKBEAM

1

2

624-1222

FLANGE, WALKBEAM, INNER

1

3

624-1223

FLANGE, WALKBEAM, OUTER

1

4

107-1030

SCREW, HEX HEAD CAP, GR 8 0.50 - 13 X 1.25 ZP

6

5

107-2171

SCREW, SOCKET FLAT HEAD, GR 8 0.50 -13 X 1.25 ZP

4

6

107-2172

PIN, DOWEL 0.625 X 1.25 51200

6

7

107-2173

PIN, DOWEL 0.625 X 1.75 51200

6

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 11 December 2015

Halvorsen

REV. H

Figure 6 HUB ASSEMBLY 624-1240 4-8 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HUB ASSEMBLY 624-1240 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2360

SCREW, HHC GR 8 0.38-16 X 1.5 MG

18

2

107-9014

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M6 X 1.00 X 10 MG

1

3

623-9560

FITTING, GREASE

1

4

624-0335

BEARING, TIMKEN 2.8125 BORE

1

5

624-0336

BEARING, 2.75 BORE

1

6

624-0337

SEAL, 3.25 SHAFT

1

7

624-0338

SNAP RING, 6.25 BORE

1

8

624-0339

O-RING, 6.102 O.D.

1

9

624-8970

BRAKE CALIPER, REAR

1

*

624-0341-001

SEAL

1

*

624-0341-002

OVERHAUL

1

*

624-0341-004

KIT, DISC BRAKE, REAR

1

*

624-8970-001

SERVICE KIT, SERVICE BRAKE, RR-LIN

1

*

624-8970-002

BACKING PLATE

1

*

624-8970-003

WASHER

1

*

624-8970-004

SLEEVE, AUSCO BRAKE

1

*

624-8970-005

SCREW, HEX HD, GR 8, 0.5-13 X 5.5

1

*

624-8970-006

NUT, PTHM, GR 8 0.5-13

1

10

624-0343

BRAKE DISC

1

11

624-0345

COVER

1

12

624-0352

NUT, 2.548-18

2

13

624-0353

WASHER, LOCK

1

14

624-0358

BOLT, WHEEL STUD

15

624-0360

SPINDLE WELDMENT, BRAKE MOUNT

1

16

624-0363

HUB, MACHINED

1

*

624-0362

HUB, CASTING

1

*

105-0351

LOCTITE, THREADLOCKER - 242, 10 ML

1

*

624-0362

HUB, CASTING

1

17

624-8564

BRACKET, HOSE NGSL

1

12

* NOT SHOWN

REAR AXLE ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-8 Page 13 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 9. Tires and Wheels

Assembly

Assy. No.

Figure

Page

1.

TIRES INSTALLATION

624-1450

Figure 1

2

2.

TIRE AND RIM ASSEMBLY

624-1451

Figure 2

3

3.

TUBELESS BEAD SEAL SYSTEM

623-8708

Figure 3

4

TIRES AND WHEELS The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-9 Page 1 December 2015

Halvorsen

REV. C Figure 1 TIRE INSTALLATION 624-1450

TIRES INSTALLATION 624-1450 ITEM

PART NO.

DESCRIPTION

1

624-1227

NUT, WHEEL

2

624-1451

A-TIRE AND RIM ASSEMBLY (REF. FIG. 2)

4-9 Page 2 December 2015

QTY. 48 6

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 TIRE AND RIM ASSEMBLY 624-1451

TIRE AND RIM ASSEMBLY 624-1451 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-0346

RIM, MODIFIED R15 (3 PIECE)

1

2

623-5388

TIRE, 355/65 R15 MICHELIN

1

4

624-1451-001

VALVE EXTENSION

1

TIRES AND WHEELS The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-9 Page 3 December 2015

Halvorsen

Figure 3 TUBELESS BEAD SEAL SYSTEM 623-8708

TUBELESS BEAD SEAL SYSTEM 623-8708 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8708-001

SEAL, TUBELESS BEAD 250TL15

1

2

623-8708-002

VALVE 2102, 52412

1

3

623-8708-003

PLUG 2110, 46701

1

4-9 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 10. Scissors Assembly

Assembly

Assy. No.

Figure

Page

1.

SCISSORS ASSEMBLY, INNER AND OUTER

627-9635

Figure 1 Sheet 1

2

2.

SCISSORS SUB-ASSEMBLY

624-0300

Figure 2 Sheet 1

5

3.

SIDE SHIFT ASSEMBLY, FRONT

623-4640

Figure 3

11

4.

ROLL CYLINDER ASSEMBLY, FRONT

624-6612

Figure 4

13

5.

PIVOT ARM ASSEMBLY

623-7421

Figure 5

15

6.

SIDE SHIFT ASSEMBLY, REAR

623-6220

Figure 6

16

7.

ROLL CYLINDER ASSEMBLY, REAR

624-6613

Figure 7

18

8.

LINK / PIVOT INSTALLATION

623-7273

Figure 8 Sheet 1

20

9.

LINK ASSEMBLY

623-7272

Figure 9

23

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 1 December 2015

Halvorsen

REV. U

Figure 1 Sheet 1 SCISSORS ASSEMBLY, INNER AND OUTER 627-9635 4-10 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 1 Sheet 2 SCISSORS ASSEMBLY, INNER AND OUTER 627-9635

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 3 December 2015

Halvorsen SCISSORS ASSEMBLY, INNER AND OUTER 627-9635 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9062

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 40 MG

4

2

107-9259

NUT, PTH 10 M8 X 1.25 MG

4

3

107-9275

WASHER, FLAT STD HARD M8 MG

4

4*

622-6913

BUMPER, PLATFORM

2

7

623-4640

SIDE SHIFT ASSEMBLY, FRONT

1

8

624-3248

SCISSORS ELECTRICAL (REF. SEC. 4-16)

1

9

625-9350

SCISSORS HYDRAULICS (REF. SEC. 4-15)

1

10

623-6220

A-BOGY (SIDE SHIFT) REAR (REF. FIG. 3-6)

1

11

107-2272

SCREW, SOCKET FLAT HEAD, GR 8 0.75 - 16 X 6 MG

12

624-0300-500

A-SUBASSEMBLY, SCISSORS (REF. FIG. 3-6)

13

107-2232

NUT, PTH LT THIN 0.75-16 MG

14

624-8917

SCREW, MOD., SOCKET FLAT HEAD, GR 8 0.75-16 X 5.75 MG

4

15

107-2348

SCREW, HEX HEAD CAP, 10.9 M8 X 1.25 X 14 MG

2

12 1 16

* NOT SHOWN

4-10 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. E

Figure 2 Sheet 1 SCISSORS SUB-ASSEMBLY 624-0300

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 5 December 2015

Halvorsen

Figure 2 Sheet 2 SCISSORS SUB-ASSEMBLY 624-0300 4-10 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 Sheet 3 SCISSORS SUB-ASSEMBLY 624-0300

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 7 December 2015

Halvorsen

Figure 2 Sheet 4 SCISSORS SUB-ASSEMBLY 624-0300

4-10 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen SCISSORS SUB-ASSEMBLY 624-0300 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-1050

SCREW, HEX HEAD CAP, 8.8 M10 X 1.50 X 35 ZP

2

2

107-1912

WASHER, LOCK M10 ZP

5

3

107-9091

SCREW, HEX HEAD CAP, 8.8 M12 X 1.75 X 30 MG

4

4

107-9313

SCREW, HEX HEAD CAP, FULL THREAD 10.9 M10 X 1.50 X 20 MG

5

5

624-6597

SPACER, SCISSOR PITCH CYLINDER

4

6*

625- 4519

SHAFT, LOWER REAR ROLLER PIVOT

2

7

623-4598

SPACER, LOWER PITCH CYLINDER

4

8

623-4622

PIVOT SHAFT, SCISSORS MAIN

2

9

623-4629

PIVOT SHAFT WELDMENT, UPPER SCISSOR CYLINDER

1

10

623-7422

A-ROLLER ASSEMBLY, LOWER SCISSOR

2

*

623-7367

ROLLER, FLANGED

1

*

625- 4012-001

BUSHING, LOWER ROLLER

1

11

623- 9560

FITTING, GREASE, STRAIGHT 0.25-28 SHORT

12

624-1403

BUSHING, LOWER FRONT

4

13

624-1404

BUSHING, MAIN CONNECTION

4

14

624-1405

BUSHING, PITCH ARM

4

15

624-1406

BUSHING, LOWER PITCH CYLINDER

2

16

624-1415

KEEPER PLATE

2

17

624-1453

TUBE, LIFT CYLINDER, SPACER

4

18

624-1454

TUBE, LIFT CYLINDER, SPACER

4

19

624-1997

SPACER, PITCH ARM

4

20

624-1998

SPACER, MAIN OUTER CONNECTION

2

21

624-1999

SPACER, MAIN INNER CONNECTION

2

22

624-2000

SCISSOR MOD., INNER

1

23

624-2001

WASHER, THRUST

2

24

624-2002

SPACER, SCISSORS

2

25

624-2003

PIVOT SHAFT WELDMENT, SCISSORS OUTER

2

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

10

4-10 Page 9 December 2015

Halvorsen SCISSORS SUB-ASSEMBLY 624-0300 ITEM

PART NO.

DESCRIPTION

QTY.

26

624-2005

PIVOT SHAFT WELDMENT, PITCH ARM UPPER

2

27

624-2008

PIVOT SHAFT WELDMENT, PITCH CYLINDER

2

28

624-2011

PIVOT SHAFT WELDMENT, PITCH ARM LOWER

2

29

625- 4519

SHAFT, LOWER REAR ROLLER PIVOT

2

30

624-2030-500

PITCH ARM MOD., OUTER SCISSOR

1

31

624-2031

WASHER, THRUST

2

32

624-2040

OUTER SCISSOR MOD., LEFT

1

33**

624-2050

OUTER SCISSOR MOD., RIGHT

1

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing this part. NOTE: Contact JBT for appropriate IUID label when replacing part 624-0300.

4-10 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. F

Figure 3 SIDE SHIFT ASSEMBLY, FRONT 623-4640

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 11 December 2015

Halvorsen SIDE SHIFT ASSEMBLY, FRONT 623-4640 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-1587

CIRCLIP, ROLLER, D1400-0500

2

5

623-4624

SPACER, SIDE SHIFT

2

6

623-5393-500

CYLINDER, FRONT SIDE SHIFT

1

*

623-5393-090

SEAL KIT

1

8

623-7421

PIVOT ARM ASSEMBLY (REF. FIG. 9)

2

9

623-8275

SUPPORT WELDMENT, CYLINDER SHORT

1

10

623-8282

SLEEVE, SIDE SHIFT CYLINDER

2

14

107-9419

SCREW, HEX FLANGE, 8.8 M10 X 1.50 X 35 MG

4

17

624-6612-500

ROLL CYLINDER ASSEMBLY, FRONT (REF. FIG. 8)

2

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing 623-4640.

4-10 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 4

6 2

A

3 1

5

7

SECTION

A

A-A

3-D REF VIEW Figure 4 ROLL CYLINDER ASSEMBLY, FRONT 624-6612

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 13 December 2015

Halvorsen ROLL CYLINDER ASSEMBLY, FRONT 624-6612 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-1589

CIRCLIP, ROLLER, D1400-1100-B

1

2

104-1590

CIRCLIP, ROLLER, D1300-1600-B

1

3

623-4623

BUSHING, SIDE SHIFT

1

4

623-6271

BEARING, SPHERICAL PLAIN 110 MM BORE

1

5

623-9560

FITTING, GREASE, STRAIGHT 0.25-28 SHORT ZP

2

6**

624-1991

ROLL CYLINDER, FRONT

1

*

624-1991-090

SEAL KIT

1

7

623-9561

ROD WIPER, 3.5 SHAFT DIAMETER

2

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing this part.

4-10 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. D Figure 5 PIVOT ARM ASSEMBLY 623-7421

PIVOT ARM ASSEMBLY 623-7421 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-4599

PIVOT ARM

1

2

623-4636

BEARING, SELF-LUBRICATING

1

3

623-6272

BEARING, SPHERICAL PLAIN 50 MM BORE

1

4

104-1583

CIRCLIP, ROLLER, D1300-0750-B

1

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 15 December 2015

Halvorsen

REV. E Figure 6 SIDE SHIFT ASSEMBLY, REAR 623-6220 4-10 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen SIDE SHIFT ASSEMBLY, REAR 623-6220 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-1588

CIRCLIP, ROLLER, D1400-0550

2

2*

107-9419

SCREW, HEX FLANGE, 8.8 M10 X 1.50 X 35 MG

4

6

623-4624

SPACER, SIDE SHIFT

2

7

623-4632

ROLLER, FLANGED

2

8

623-5394-500

CYLINDER, REAR SIDE SHIFT

1

*

623-5393-090

SEAL KIT

1

10

625- 4016

BEARING, SPHERE-ROL - WITH PHYMET

2

11

623-8279

SUPPORT WELDMENT, CYLINDER LONG

1

12

623-8282

SLEEVE, SIDE SHIFT CYLINDER

2

16

104-1584

CIRCLIP, ROLLER, D1300-1000

2

17

624-6613-500

ROLL CYLINDER ASSEMBLY, REAR (REF. FIG. 11)

2

* NOT SHOWN NOTE:

CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING SIDE SHIFT ASSEMBLY REAR 623-6220.

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 17 December 2015

Halvorsen 1 3

6

A

4

5

2

7

SECTION

A

A-A

3-D REF VIEW

Figure 7 ROLL CYLINDER ASSEMBLY, REAR 624-6613 4-10 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ROLL CYLINDER ASSEMBLY, REAR 624-6613 ITEM 1**

PART NO.

DESCRIPTION

QTY.

624-1992

ROLL CYLINDER, REAR

1

*

624-1991-090

SEAL KIT

1

2

623-9560

FITTING, GREASE, STRAIGHT 0.25-28 SHORT ZP

2

3

623-6271

BEARING, SPHERIC PLAIN 110 MM BORE

1

4

623-4623

BUSHING, SIDE SHIFT

1

5

104-1589

CIRCLIP, ROLLER, D1400-1100

1

6

104-1590

CIRCLIP, ROLLER, D1300-1600

1

7

623-9561

ROD WIPER, 3.5 SHAFT DIAMETER

2

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing 623-6220.

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 19 December 2015

Halvorsen

REV. F Figure 8 Sheet 1 LINK / PIVOT INSTALLATION 623-7273 4-10 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 8 Sheet 2 LINK / PIVOT INSTALLATION 623-7273

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 21 December 2015

Halvorsen LINK / PIVOT INSTALLATION 623-7273 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7272

LINK ASSEMBLY (REF. FIG. 14)

1

2

623-7265

PIPE

4

3

623-7271

PIN WELDMENT

2

7

623-4637

PIN WELDMENT, PIVOT

2

12

107-9418

SCREW, HEX FLANGE, 8.8 M10 X 1.50 X 30 MG

4

4-10 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B Figure 9 LINK ASSEMBLY 623-7272

LINK ASSEMBLY 623-7272 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7266

SNAP RING

2

2

623-7268

BEARING

2

3

623-7269

LINK WELDMENT

1

4

623-9560

GREASE FITTING

1

SCISSORS ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-10 Page 23 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 11. Deck Assembly

Assembly

Assy. No.

Figure

Page

1.

DECK ASSEMBLY

627-9636

Figure 1 Sheet 1

2

2.

FOLDING WINGS / CAB AND ENGINE HATCH

623-6920

Figure 2 Sheet 1

6

3.

FOLDING WING ASSEMBLY, LEFT SIDE

624-6644

Figure 3

11

4.

FOLDING WING ASSEMBLY, RIGHT SIDE

623-6956

Figure 4

13

5.

SCISSOR TRACKS INSTALLATION

623-7214

Figure 5 Sheet 1

14

6.

SCISSOR TRACKS INSTALLATION, REAR

623-7215

Figure 6

17

7.

TRACTION ROLLER INSTALLATION

624-4020

Figure 7

19

8.

TRACTION ROLLER ASSEMBLY

628-4088

Figure 8 Sheet 1

21

9.

BUMPERS INSTALLATION

624-1400

Figure 9 Sheet 1

24

10. CASTER AND ROLLER TRAY ASSEMBLY

623-6900

Figure 10

28

11. CASTER TRAY ASSEMBLY

624-3077

Figure 11

30

12. ROLLER TRAY ASSEMBLY

624-3078

Figure 12

32

13. IMPACT ROLLERS INSTALLATION

623-6895

Figure 13

35

14. IMPACT ROLLER ASSEMBLY

623-7250

Figure 14

37

15. PALLET STOP INSTALLATION

623-6911

Figure 15 Sheet 1

38

16. PALLET STOP ASSEMBLY

624-1211

Figure 16

44

17. TINE WAY COVERS INSTALLATION

623-6820

Figure 17

46

18. TINE WAY COVER ASSEMBLY

624-3075

Figure 18

47

19. TIE DOWN / LIFT PROVISION INSTALLATION, DECK

624-3115

Figure 19 Sheet 1

48

20. MUD FLAP ASSEMBLY

623-9632

Figure 20

52

21. PLACARD INSTALLATION, DECK

624-7168

Figure 21

54

22. CARGO TIE DOWN KIT, DECK PLATFORM

628-1270

Figure 22 Sheet 1

56

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 1 December 2015

31 27 28 29 34

33 33 13

14

15

DETAIL A

35

3

35

33

16

25

26 29

1

DETAIL A

26 29

30 27 28 29 34

2

17

Halvorsen

Figure 1 Sheet 1 DECK ASSEMBLY 627-9636 4-11 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

6 35

12

24

4

5

18

11

Halvorsen

Figure 1 Sheet 2 DECK ASSEMBLY 627-9636

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 3 December 2015

4-11 Page 4 December 2015

TOP VIEW

USE 624-8955

USE 624-8971

USE 624-8971

USE 624-8955

USE 624-8955

SOME COMPONENTS REMOVED FOR CLARITY REPLACEMENT HINGE DIAGRAM (SERVICE PARTS ONLY) REF: 624-8954 FOR INSTALLATION INSTRUCTIONS

USE 624-8955

USE 624-8971

USE 625-4459

USE 624-8971

USE 624-8955

USE 624-8955

USE 625-4459

USE 625-4258

USE 625-4258

Halvorsen

Figure 1 Sheet 3 DECK ASSEMBLY 627-9636

The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

ILLUSTRATED PARTS LIST

Halvorsen DECK ASSEMBLY 627-9636 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7350

W-DECK, PLATFORM

1

2

623-6820

I-TINE WAY COVER

1

3

623-6900

I-CASTER/ROLLER TRAY

1

4

107-9062

SCREW, HHC 8.8 M8 X 1.25 X 40 MG

4

5

107-9259

NUT, PTH 8 M8 X 1.25 MG

4

6

107-9275

WASHER, FLAT STD HARD M8 MG

8

11

624-1400

I-BUMPERS, NGSL

1

12

623-7214

I-SCISSOR TRACKS, ALUMINUM DECK

1

13

623-6920

I-FOLDING WINGS, CAB AND ENGINE HATCH

1

14

623-6911

I-PALLET STOP

1

15

624-4020

I-TRACTION ROLLER

1

16

623-6700

I-HANDRAIL / WALKDECK / GUIDE

1

17

623-6895

I-IMPACT ROLLERS

1

18

628-0452

IH-DECK

1

24

623-9632

A-MUD FLAP

2

25

624-3115

I-TIE DOWN / LIFT PROVISION, DECK

1

26

107-9092

SCREW, HHC-F 8.8 M12 X 1.75 X 35 MG

2

27

107-9095

SCREW, HHC 8.8 M12 X 1.75 X 60 MG

4

28

107-9261

NUT, PTH 8 M12 X 1.75 MG

4

29

107-9278

WASHER, FLAT STD HD M12 MG

6

30

624-5162

W-PLATE, TINEWAY GUARD, RIGHT

1

31

624-5163

W-PLATE, TINEWAY GUARD, LEFT

1

32

624-6065

GASKET, TINEWAY GUARD

2

33

624-7168

I-PLACARD, DECK

1

34

107-9447

WASHER, FLAT NARROW HD M12 MG

4

35

628-1512

PLATE, DECK BUMPER OUTER DOUBLER

1

36

628-1516

PLATE, DECK BUMPER INNER DOUBLER

1

37

107-9214

SCREW, SFH-F 10.9 M12 X 1.75 X 50 MG

4

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 5 December 2015

Halvorsen

REV. N Figure 2 Sheet 1 FOLDING WINGS / CAB AND ENGINE HATCH 623-6920 4-11 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 Sheet 2 FOLDING WINGS / CAB AND ENGINE HATCH 623-6920

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 7 December 2015

Halvorsen

28

Figure 2 Sheet 3 FOLDING WINGS / CAB AND ENGINE HATCH 623-6920 4-11 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 Sheet 4 FOLDING WINGS / CAB AND ENGINE HATCH 623-6920

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 9 December 2015

Halvorsen FOLDING WINGS / CAB AND ENGINE HATCH 623-6920 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-6644

FOLDING WING ASSEMBLY, LEFT (REF. FIG. 7)

1

2

623-6956

FOLDING WING ASSEMBLY, RIGHT (REF. FIG. 8)

1

3

623-8466

PIN, QUICK RELEASE L-HANDLE, 7/16 IN.

1

4

623-8697

GASKET, TIE DOWN

1

5

624-6056

PIN WELDMENT, FOLDING WING

1

6

623-7164

SPRING, LEFT SIDE WING

1

7

623-7161

PIN, SQUARE

1

8

623-6616

GUIDE, SPRING TUBE

1

9

624-3130

DECK WELDMENT, HINGED

1

10

107-9062

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 40 MG

4

11

107-9180

SCREW, SOCKET FLAT HEAD, 10.9 M8 X 1.25 X 30 MG

4

12

107-9259

NUT, PTH 10 M8 X 1.25 MG

13

623-8212

GASKET, HINGE

14

107-9275

WASHER, FLAT STD HARD M8 MG

15

624-4026

HINGE, SS

4

18

623-7344

ENGINE HATCH

1

19

623-7104

TOP WELDMENT, LOCK

2

623-7104-001

KIT, TOP LOCK

21

623-7121

SPRING, LOCK

2

22

107-9276

WASHER, FLAT STD HARD M10 MG

2

26

HFS0178

NUT, JAM GR 5 0.50 -13 SS

2

27

624-4182

HANDLE, CAB LOCKDOWN

1

28

624-4185

LOCKDOWN, CAB LOCATOR

1

29

624-4186

ROD, THREADED

1

30

624-4187

RAM, CAB LOCKDOWN

1

31

107-9410

SCREW, HEX FLANGE, 8.8 M8 X 1.25 X 25 MG

3

32

107-9303

SCREW, HEX HEAD CAP, 10.9 M8 X 1.25 X 30 MG

8

33

107-9047

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M8 X 1.25 X 30 MG

4

*

18 8 34

* NOT SHOWN

4-11 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. C

Figure 3 FOLDING WING ASSEMBLY, LEFT SIDE 624-6644

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 11 December 2015

Halvorsen FOLDING WING ASSEMBLY, LEFT SIDE 624-6644 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9181

SCREW, HH C, 8.8 M8 X 1.25 X 35 MG

2

2

107-9069

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 80 MG

2

3

107-2168

NUT, INSERT, ALUMINUM, M8 X 1.25 GRIP 3.8

4

4

107-9275

WASHER, FLAT STD HARD M8 MG

3

5

623-4350

W-WING, LEFT

1

6

624-6643

SKID PLATE, LEFT SIDE FOLDING WING

1

7

107-9259

NUT, PTH 10 M8 X 1.25 MG

1

8

107-9276

WASHER, FLAT STD HARD M10 MG

1

9

623-7104

WELDMENT, TOP, LOCK

1

10

623-7121

SPRING, LOCK

1

4-11 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. F

Figure 4 FOLDING WING ASSEMBLY, RIGHT SIDE 623-6956

FOLDING WING ASSEMBLY, RIGHT SIDE 623-6956 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7158

FOLDING WING, MACHINED

1

2

623-4368

BAR, ROUND RETRACT PIN

1

3

623-4369

BAR, ROUND RETRACT PIN HANDLE

1

4

107-9034

SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 55 MG

1

5

107-9258

NUT, PTH 8 M6 X 1.00 MG

1

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 13 December 2015

Halvorsen DECK WELDMENT REF

1 3

SECTION A-A

Figure 5 Sheet 1 SCISSOR TRACKS INSTALLATION 623-7214 4-11 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL C 5

3 1 5 DETAIL C

SECTION B-B

Figure 5 Sheet 2 SCISSOR TRACKS INSTALLATION 623-7214

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 15 December 2015

Halvorsen SCISSOR TRACKS INSTALLATION 623-7214 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7195

TRACK, ROLLER RAIL, LONG

2

3

623-7197

TRACK, ROLLER RAIL, SHORT

2

5

107-9193

SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M10 X 1.5 X 25 MG

4-11 Page 16 December 2015

50

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. D

Figure 6 SCISSOR TRACKS INSTALLATION, REAR 623-7215

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 17 December 2015

Halvorsen SCISSOR TRACKS INSTALLATION, REAR 623-7215 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8562

TRACK, ROLLER RAIL, REAR

2

2

623-8561

PLATE, REAR ROLLER TRACK

2

4

107-9334

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 100 MG

20

5

107-2181

NUT, PTH 10 M12 X 1.75 MG

20

6

107-9447

WASHER, FLAT NARROW HARD M12 MG

20

4-11 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A

Figure 7 TRACTION ROLLER INSTALLATION 624-4020

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 19 December 2015

Halvorsen TRACTION ROLLER INSTALLATION 624-4020 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9259

NUT, PTH 10 M8 X 1.25 MG

36

2

107-9275

WASHER, FLAT STD HARD M8 MG

72

3

107-9303

SCREW, HEX HEAD CAP, 10.9 M8 X 1.25 X 30 MG

36

4

623-4088

TRACTION ROLLER ASSEMBLY (REF. FIG. 13)

4-11 Page 20 December 2015

9

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 1 21

22 14

17

8

3 24

10 22 9 SOME COMPONENTS REMOVED FOR CLARITY

14

15 14 18 19

Figure 8 Sheet 1 TRACTION ROLLER ASSEMBLY 628-4088

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 21 December 2015

Halvorsen

1 12 16 6 4 20 12

5

2

13 11 7 8

23

5 25 13

Figure 8 Sheet 2 TRACTION ROLLER ASSEMBLY 628-4088 4-11 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen TRACTION ROLLER ASSEMBLY 628-4088 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-6557

W-HOUSING, TRACTION ROLLER

1

2

628-4060

TRACTION ROLLER, GROOVED

1

3

623-6562

SPRING, LIMITER

1

4

107-9278

WASHER, FLAT STD HD M12 MG

2

5

620-0085

BEARING, 30 MM SELF ALIGNING

2

6

620-1591

SPROCKET, 12T 1.00 IN. BORE SINGLE

1

7

622-0463

SHIM, MOTOR MOUNT

1

8

107-9276

WASHER, FLAT STD HD M10 MG

8

9

623-6593

W-ARM, ADJUSTING, TRACTION ROLLER

1

10

623-6559

PLATE, MOUNTING

2

11

107-9260

NUT, PTH 8 M10 X 1.50 MG

4

12

107-9196

SCREW, SFH-F 10.9 M10 X 1.5 X 40 MG

4

13

107-9329

SCREW, HHC 10.9 M12 X 1.75 X 50 MG

2

14

107-9275

WASHER, FLAT STD HD M8 MG

15

624-4026

HINGE, STAINLESS STEEL

2

16

107-2181

NUT, PTH 10 M12 X 1.75 MG

2

17

107-9079

SCREW, HHC-F 8.8 M10 X 1.5 X 25 MG

4

18

107-9259

NUT, PTH 8 M8 X 1.25 MG

4

19

107-9303

SCREW, HHC 10.9 M8 X 1.25 X 30 MG

4

20

623-5473

A-CONVEY CHAIN, LOW STRETCH

1

21

107-2081

PIN, ROLL 302 0.5 X 3 STAINLESS STEEL

1

22

107-9267

NUT, HEX 8 M8 X 1.25 MG

2

23

104-0977

RING, SNAP EXT 1.00 SHAFT

1

24

624-6073

W-LIMITER, TRACTION ROLLER

1

25

620-1428

MOTOR, HYDRAULIC

1

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

10

4-11 Page 23 December 2015

Halvorsen 15

7 15

2

12

6

7

6

1

2

3

15

15 5

3 5 2

1

1 8

2

8 FRONT VIEW OF DECK

W-DECK (REF)

15

3

12 5

2

13

REAR VIEW OF DECK

Figure 9 Sheet 1 BUMPERS INSTALLATION 624-1400 4-11 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

15

6

8

7

2

SECTION A-A

Figure 9 Sheet 2 BUMPERS INSTALLATION 624-1400

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 25 December 2015

Halvorsen

BOTTOM VIEW

10

11

Figure 9 Sheet 3 BUMPERS INSTALLATION 624-1400 4-11 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen BUMPERS INSTALLATION 624-1400 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9095

SCREW, HEX HEAD CAP, 8.8 M12 X 1.75 X 60 MG

11

2

107-2181

NUT, PTH 10 M12 X 1.75 MG

18

3

107-9278

WASHER, FLAT STD. HARD M12 MG

30

5

623-5488

BUMPER, RUBBER

6

6

623-7192

BUMPER, FRONT

6

7

624-3136

SPACER, BUMPER

6

8

107-9331

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 70 MG

2

10

624-5173

STRIP, DECK, RUB

4

11

107-2233

SCREW, SOCKET FLAT HEAD, #8-32 X 0.38 S.S.

12

107-9098

SCREW, HEX HEAD CAP, 8.8 M12 X 1.75 X 90 MG

4

13

624-7192

EXTENSION, REAR BUMPER

2

15

107-9447

WASHER, FLAT NARROW HARD M12 MG

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

16

18

4-11 Page 27 December 2015

Halvorsen

REV. G

Figure 10 CASTER AND ROLLER TRAY ASSEMBLY 623-6900 4-11 Page 28 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CASTER AND ROLLER TRAY ASSEMBLY 623-6900 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-3077

CASTER TRAY ASSEMBLY

1

2

624-3078

ROLLER TRAY ASSEMBLY

1

3

623-7104

TOP WELDMENT, LOCK

*

623-7104-001

KIT, TOP LOCK

4

623-7121

SPRING, LOCK

31

5

107-9276

WASHER, FLAT STD HARD M10 MG

31

6

107-9275

WASHER, FLAT STD HARD M6 MG

31

7

107-9259

NUT, PTH 10 M8 X 1.25 MG

31

31

* NOT SHOWN

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 29 December 2015

Halvorsen

Figure 11 CASTER TRAY ASSEMBLY 624-3077 4-11 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CASTER TRAY ASSEMBLY 624-3077 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2310

SCREW, SOCKET FLAT HEAD, A2 M5 X 0.08 X 25 S.S.

144

2

107-1975

WASHER, FLAT STD A2 M5 S.S.

144

3

107-1976

NUT, PTH A2 M5 X 0.80 S.S.

144

4

624-8299

CASTER, LOW PROFILE

36

6

624-3080

TRAY, 31.50 IN., CASTER

3

7

624-3081

TRAY, 27.80 IN., CASTER

3

8

624-3082

TRAY, 19.34 IN., CASTER

3

*

624-3077-003

TRAY WITH CASTERS - 3082 (3 CASTERS)

1

*

624-3077-004

TRAY WITH CASTERS - 3081 (4 CASTERS)

1

*

624-3077-005

TRAY WITH CASTERS - 3080 (5 CASTERS)

1

* NOT SHOWN NOTE:

PART NO. 623-8460, SPACER, CASTER, USED UNDER ORIGINAL SPLIT-ROLLER CASTER IS OBSOLETE. DO NOT USE UNDER SINGLE-ROLLER LOW PROFILE CASTER, PART NO. 624-8299 (ITEM 4).

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 31 December 2015

Halvorsen

REV. B

Figure 12 ROLLER TRAY ASSEMBLY 624-3078 4-11 Page 32 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ROLLER TRAY ASSEMBLY 624-3078 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2310

SCREW, SOCKET FLAT HEAD, A2 M5 X 0.8 X 25 S.S.

48

2

107-1975

WASHER, FLAT STD A2 M5 S.S.

48

3

107-1976

NUT, PTH GR A2 M5 X 0.8 S.S.

48

4

624-6626

NUT, RETAINING GR 8 STEEL, 7/16-20

5

624-8299

CASTER, LOW PROFILE

7

624-3079

TRAY, 27.74 IN., CABIN HATCH

1

8

624-3083

TRAY, 37.92 IN., COMBINED

4

9

624-3084

TRAY, 37.92 IN., ROLLER

6

10

624-3085

TRAY, 29.29 IN., ROLLER

6

11

624-3086

TRAY, 24.29 IN., ROLLER

1

12

624-3087

TRAY, 30.42 IN., ROLLER

1

13

624-3088

TRAY, 15.30 IN., ROLLER

2

14

624-3089

TRAY, 10.30 IN., LEFT WING

1

15

624-3090

TRAY, 37.92 IN., KNUCKLE

2

16

624-4021

WASHER, GRAVITY ROLLER

220

17

624-4022

SHAFT, GRAVITY ROLLER

110

18

624-4025

TUBE ASSEMBLY, GRAVITY ROLLER

110

*

624-4023

BEARING, GRAVITY ROLLER

2

*

624-4024

TUBE, GRAVITY ROLLER

1

*

624-8964

K-RETAINER, TRAYS FULL DECK

1

*

107-9450

WASHER, FENDER STD HARD M6 MG

4

*

624-8899

K-RETAINER, TRAYS

1

*

107-9450

WASHER, FENDER STD HARD M6 MG

4

*

624-3078-002

TRAY WITH ROLLERS - 3089 (2 ROLLERS)

1

*

624-3078-003

TRAY WITH ROLLERS - 3088 (3 ROLLERS)

1

*

624-3078-004

TRAY WITH ROLLERS - 3086 (4 ROLLERS)

1

*

624-3078-006

TRAY WITH ROLLERS - 3084 (6 ROLLERS)

1

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

220 12

4-11 Page 33 December 2015

Halvorsen ROLLER TRAY ASSEMBLY 624-3078 ITEM

PART NO.

DESCRIPTION

QTY.

*

624-3078-033

TRAY WITH ROLLERS AND CASTERS - 3083 (3 CASTERS AND ROLLERS)

1

*

624-3078-105

TRAY WITH ROLLERS - 3079 (5 ROLLERS)

1

*

624-3078-205

TRAY WITH ROLLERS - 3085 (5 ROLLERS)

1

*

624-3078-305

TRAY WITH ROLLERS - 3090 (5 ROLLERS)

1

*

624-3078-405

TRAY WITH ROLLERS - 3087 (5 ROLLERS)

1

* NOT SHOWN NOTE:

4-11 Page 34 December 2015

PART NO. 623-8460, SPACER, CASTER, USED UNDER ORIGINAL SPLIT-ROLLER CASTER IS OBSOLETE. DO NOT USE UNDER SINGLE-ROLLER LOW PROFILE CASTER, PART NO. 624-8299 (ITEM 5).

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 13 IMPACT ROLLERS INSTALLATION 623-6895

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 35 December 2015

Halvorsen IMPACT ROLLERS INSTALLATION 623-6895 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2082

SCREW, HEX HEAD CAP, 8.8 M12 X 1.75 X 220 MG

3

2

107-9261

NUT, PTH 8 M12 X 1.75 MG

7

3

107-2149

SCREW, SOCKET FLAT HEAD, 10.9 M12 X 1.75 X 210 MG

4

4

623-7250

A-IMPACT ROLLER (REF. FIG. 20)

7

5

107-9447

WASHER, FLAT NARROW HARD M12 MG

7

4-11 Page 36 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 5

1

6

2 4

3

3-D REF VIEW

Figure 14 IMPACT ROLLER ASSEMBLY 623-7250

IMPACT ROLLER ASSEMBLY 623-7250 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2084

SCREW, SOCKET HEAD SET, C 45H M6 X 1.00 X 6 ZP

2

2

112-1555

NUT, JAM HEX 5/8-11 CP

2

3

624-8967

SPRING PLUNGER

2

4

623-7239

BAR, ROLLER SHAFT

1

5

625-4504

A- ROLLER

1

6

623-7246

SUPPORT WELDMENT, #1 IMPACT ROLLER

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

1

4-11 Page 37 December 2015

Halvorsen

REV. H

Figure 15 Sheet 1 PALLET STOP INSTALLATION 623-6911 4-11 Page 38 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 15 Sheet 2 PALLET STOP INSTALLATION 623-6911

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 39 December 2015

Halvorsen

Figure 15 Sheet 3 PALLET STOP INSTALLATION 623-6911 4-11 Page 40 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 15 Sheet 4 PALLET STOP INSTALLATION 623-6911

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 41 December 2015

Halvorsen

Figure 15 Sheet 5 PALLET STOP INSTALLATION 623-6911 4-11 Page 42 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen PALLET STOP INSTALLATION 623-6911 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-1211

A -PALLET STOP (REF. FIG. 26)

2

2

107-9331

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 70 MG

34

3

107-2181

NUT, PTH 10 M12 X 1.75 MG

40

4

107-9447

WASHER, FLAT NARROW HARD M12 MG

74

5

107-9018

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M6 X 1.00 X 25 MG

6

6

107-9258

NUT, PTH 8 M6 X 1.00 MG

8

7

623-6957

HOUSING WELDMENT, HEADLIGHT

2

8

623-7285

GASKET, HEADLIGHT

1

9

623-7286

GASKET, HEADLIGHT

1

10

107-9221

SCREW, SOCKET FLAT HEAD, 10.9 M12 X 1.75 X 70 MG

6

12*

107-9019

SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 30 MG

2

13

624-8307

SHIM, PALLET STOP

4

* NOT SHOWN

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 43 December 2015

Halvorsen REF: HYD. CYL. GUIDE/STOP

REV. B

Figure 16 PALLET STOP ASSEMBLY 624-1211 4-11 Page 44 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen PALLET STOP ASSEMBLY 624-1211 ITEM

PART NO.

DESCRIPTION

QTY.

1

103-0751

PIN, CLEVIS 0.50 X 1.75 PL

3

2

107-9263

NUT, PTH 8 M20 X 2.50 MG

3

3

107-9366

SCREW, HEX HEAD CAP, 10.9 M20 X 2.50 X 120 MG

3

4

110-0350

PIN, COTTER 0.13 X 1.00 ZP

3

5

623-7172

BRACKET, LINK PALLET STOP, MACHINED

1

6

624-1216

BRACKET WELDMENT, PALLET STOP

1

7

624-1219

STOP, PALLET, MACHINED

3

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 45 December 2015

Halvorsen

REV. D

Figure 17 TINE WAY COVERS INSTALLATION 623-6820

TINE WAY COVERS INSTALLATION 623-6820 ITEM 1

4-11 Page 46 December 2015

PART NO. 624-3075

DESCRIPTION COVER ASSEMBLY, TINE WAY (REF. FIG. 28)

QTY. 1

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. C

Figure 18 TINE WAY COVER ASSEMBLY 624-3075

TINE WAY COVER ASSEMBLY 624-3075 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2315

SCREW, SOCKET HEAD SET, 12.9 12/M 10 X 20 MG

8

2

624-3070

COVER ASSY, TINE WAY, LARGE

3

3

624-3071

COVER ASSY, TINE WAY, MEDIUM

1

4

624-3072

COVER ASSY, TINE WAY, SMALL

1

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 47 December 2015

Halvorsen 3 4

33 8

16 9 12

DETAIL B DETAIL K DETAIL B

DETAIL A

DETAIL A

8

30

9

32 31

DETAIL K

Figure 19 Sheet 1 TIE DOWN / LIFT PROVISION INSTALLATION, DECK 624-3115 4-11 Page 48 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 22 19

16 34 17

7

7

26

17

DETAIL C BOTH SIDES

DETAIL F BOTH SIDES

DETAIL E BOTH SIDES FRONT AND REAR

DETAIL J

DETAIL D DETAIL N DETAIL H DETAIL C

DETAIL E

32 31

DETAIL F

DETAIL G 17

7

31 32

REFER TO I-AC OPTION DETAIL D SOME COMPONENTS REMOVED FOR CLARITY 33

Figure 19 Sheet 2 TIE DOWN / LIFT PROVISION INSTALLATION, DECK 624-3115

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 49 December 2015

Halvorsen 20 16

REFER TO I-AC OPTION

32 31

33

26

DETAIL J BOTH SIDES DETAIL N SOME COMPONENTS REMOVED FOR CLARITY

27

7

21

18 19

16 17

17 7 25

7

17

DETAIL H BOTH SIDES SOME COMPONENTS REMOVED FOR CLARITY

DETAIL G BOTH SIDES

Figure 19 Sheet 3 TIE DOWN / LIFT PROVISION INSTALLATION, DECK 624-3115 4-11 Page 50 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen TIE DOWN / LIFT PROVISION INSTALLATION, DECK 624-3115 ITEM

PART NO.

DESCRIPTION

QTY.

3

107-2186

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 200 MG

8

4

107-2187

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 170 MG

8

7

107-9278

WASHER, FLAT STD HARD M12 MG

36

8

623-6818

BRACKET, TIE DOWN RING

26

9

623-6937

D-RING

26

12

624-3105

PROVISION, LIFT-DECK

16

107-9447

WASHER, FLAT NARROW HARD M12 MG

24

17

107-2181

NUT, PTH 10 M12 X 1.75 MG

30

18

107-2183

NUT, PTH 10 M20 X 2.50 MG

8

19

107-9280

WASHER, FLAT NARROW HARD M20 MG

20

107-9333

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 90 MG

8

21

107-2264

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 110 MG

6

22

107-9361

SCREW, HEX HEAD CAP, 10.9 M20 X 2.5 X 70 MG

8

25

624-7152

PLATE, BACKING, DECK TIE DOWN

2

26

624-7155

RESTRAINT, 25K TIE DOWN

2

27

624-7157

ADAPTER, RESTRAINT, 25K TIE DOWN

4

30

107-2880

SCREW, SHC, 12.9 M10 X 1.5 X 45 MG

4

31

107-9456

WASHR, FLAT NARROW HARD M10 MG

52

32

107-9260

NUT, PTH 8 M10 X 1.50 MG

52

33

107-2899

SCREW, SHC 12.9 M10 X 1.5 X 190 MG

48

34

107-9331

SCREW, HHC 10.9 M12 X 1.75 X 70 MG

8

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4

16

4-11 Page 51 December 2015

Halvorsen

Figure 20 MUD FLAP ASSEMBLY 623-9632 4-11 Page 52 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen MUD FLAP ASSEMBLY 623-9632 ITEM

PART NO.

DESCRIPTION

QTY.

2

623-9634

CLAMP, MUD FLAP

2

3

623-9635

MUD FLAP

1

4

107-9381

SCREW, HEX FLANGE, 10.9 M8 X 1.25 X 30 MG

5

5

107-9259

NUT, PTH 10 M8 X 1.25 MG

6

6

107-9275

WASHER, FLAT STD HARD M8 MG

12

7

624-4197

SUPPORT WELDMENT, MUD FLAP

1

8

107-9410

SCREW, HEX FLANGE, 8.8 M8 X 1.25 X 25 MG

1

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 53 December 2015

Halvorsen REF - WALKDECK/HANDRAILS

1

2

3

4

REF - WALKDECK/HANDRAILS 1

2

3

4 REF - DECK WELDMENT

6

VIEW A 1

2

5

6

VIEW A VIEW FROM REAR NOTE ORIENTATION OF ITEM 6 ITEMS REMOVED FOR CLARITY

Figure 21 PLACARD INSTALLATION, DECK 624-7168 4-11 Page 54 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen PLACARD INSTALLATION, DECK 624-7168 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-7149

A-PLACARD, DOT FLIP HAZARD

3

2

107-9450

WASHER, FENDER STD HARD M6 MG

1

3

107-9258

NUT, PTH 8 M6 X 1.00 MG

5

4

107-9168

SCREW, SFH-F 10.9 M6 X 1 X 20 MG

6

5

107-9018

SCREW, HHC-F 10.9 M6 X 1 X 25 MG

12

6

624-7156

SPACER, DOT FLIP HAZARD

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

1

4-11 Page 55 December 2015

A

A

B

B

Halvorsen

Figure 22 Sheet 1 CARGO TIE DOWN KIT, DECK PLATFORM 628-1270 4-11 Page 56 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 22 Sheet 2 CARGO TIE DOWN KIT, DECK PLATFORM 628-1270

DECK ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-11 Page 57 December 2015

Halvorsen CARGO TIE DOWN KIT, DECK PLATFORM 628-1270 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2880

SCREW, SHC 12.9 M10 X 1.5 X 45 MG

2

2

623-6818

BRACKET, D-RING CARGO TIE DOWN

1

3

107-9456

WASHER, FLAT NARROW HARD M10 MG

2

4

107-9260

NUT, PTH 8 M10 X 1.50 MG

2

5

623-6937

D-RING, CARGO TIE DOWN 10,000 LB

1

6

105-0327-901

LOCTITE 242 (24205) 0.5 ML

1

7

107-2899

SCREW, SHC 12.9 M10 X 1.5 X 190 MG

2

8

DWG-628-1270

K-CARGO TIE DOWN, DECK PLATFORM

1

4-11 Page 58 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 12. Walk-deck and Handrail Assembly

Assembly 1.

Assy. No.

Figure

Page

HANDRAIL, WALKDECK AND GUIDE INSTALLATION

623-6700

Figure 1 Sheet 1

2.

HANDRAIL AND WALKDECK ASSEMBLY

623-4705

Figure 2

10

3.

HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX

623-6850

Figure 3

12

HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR

623-6860

Figure 4

14

HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX

623-6880

Figure 5

16

HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR

623-6890

Figure 6

18

HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT

623-6100

Figure 7 Sheet 1

20

8.

HANDRAIL AND WALKDECK ASSEMBLY

623-8710

Figure 8

25

9.

GUIDE AND PALLET LOCK ASSEMBLY

623-7330

Figure 9

27

623-4251

Figure 10

29

4. 5. 6. 7.

10. PALLET LOCK ASSEMBLY

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

2

4-12 Page 1 December 2015

Halvorsen

REF - DECK WELDMENT

REV. H

Figure 1 Sheet 1 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700 4-12 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 1 Sheet 2 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 3 December 2015

Halvorsen

Figure 1 Sheet 3 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700 4-12 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 1 Sheet 4 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 5 December 2015

Halvorsen

Figure 1 Sheet 5 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700 4-12 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

6

Figure 1 Sheet 6 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 7 December 2015

Halvorsen

Figure 1 Sheet 7 HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700 4-12 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL, WALKDECK AND GUIDE INSTALLATION 623-6700 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2217

NUT, PTH GR 8 0.88-9 MG

8

2

107-2216

NUT, PTH GR 8 0.63-11 MG

46

3

107-9279

WASHER, FLAT HARD M16 MG

30

4*

107-9450

WASHER, FENDER STD HARD M6 MG

4

5

623-4705

HANDRAIL AND WALKDECK ASSEMBLY (REF. FIG. 8)

1

6

624-5028

SHAFT, WALKDECK PIN

6

7

624-5027

SHAFT, WALKDECK PIN

13

8

624-5029

SHAFT, WALKDECK PIN

4

9

624-5026

SHAFT, WALKDECK PIN

4

10

623-7330

GUIDE AND PALLET LOCK ASSEMBLY (REF. FIG. 17)

1

11

623-8591

PIN, QUICK RELEASE L 7/8 IN.

4

12

623-8592

PIN, QUICK RELEASE L 5/8 IN.

6

13

623-8593

PIN, QUICK RELEASE L 5/8 IN.

13

14

623-8707

LANYARD, 20 WITH TAB

25

15*

107-9019

SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 30 MG

17

16*

107-9258

NUT, PTH 8 M6 X 1.00 MG

19

17*

107-9450

WASHER, FENDER STD HARD M6 MG

19

18

107-2250

WASHER, FLAT NARROW HARD M24 MG

8

22*

107-9018

SCREW, HEX HEAD CAP, FULL THREAD 10.9 M6 X 1 X 25 MG

3

23*

107-9259

NUT, PTH 10 M8 X 1.25 MG

2

24*

107-9046

SCREW, HEX HEAD CAP, FULL THREAD 10.9 M8 X 1.25 X 25 MG

2

25*

107-9275

WASHER, FLAT STD HARD M8 MG

4

26

624-8893

TUBE, SS 1.0 IN. X 0.049 X 1.00

2

27

624-8895

TUBE, SS 0.75 IN. X 0.049 X 2.00

4

28

624-8894

TUBE, SS 0.75 IN. X 0.049 X 1.00

2

*

624-7401

KIT-FIELD FIX, NGSL

1

*

625-4258

K-HINGE REAR NGSL

1

*

625-4459

K-HINGE SUPPORT, REAR GUIDE RAIL

1

* NOT SHOWN

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 9 December 2015

Halvorsen

REV. D

Figure 2 HANDRAIL AND WALKDECK ASSEMBLY 623-4705 4-12 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY 623-4705 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-6850

HANDRAIL AND WALKDECK, TOOL BOX

1

2

623-6860

HANDRAIL AND WALKDECK, LEFT REAR

1

4

623-6880

HANDRAIL AND WALKDECK, TOOL BOX

1

5

623-6890

HANDRAIL AND WALKDECK, RIGHT REAR

1

6

623-6100

HANDRAIL AND WALKDECK, RIGHT FRONT

1

7

623-8710

HANDRAIL AND WALKDECK

1

8*

104-1607

LINK, CONNECTING PAIR 0.25 S.S.

4

9

627-6439

CHAIN, STRAIGHT LINK

10

107-2780

BOLT, EYE SH 0.75-0.38-16 X 2.5 S.S.

4

11

107-2456

WASHER, FLAT STD A2 M10 S.S.

4

12

107-2763

NUT, PTH A2 TH 0.38-16 S.S.

4

13

623-7275

HOOK, SLIDE BOLT / SWIVEL SNAP S.S.

2

2 ft.

* NOT SHOWN

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 11 December 2015

Halvorsen

REV. D

Figure 3 HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX 623-6850 4-12 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX 623-6850 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

4

4

107-2308

NUT, PTH A2 M6 X 1.00 S.S.

4

5

107-1782

SCREW, HEX HEAD CAP, FULL THREAD A2 M6 X 1.00 X 25 S.S.

4

6

620-6376

LANYARD

4

7

623-6851

WALK DECK WELDMENT, FRONT LEFT

1

8

623-6852

HANDRAIL WELDMENT, CENTER

1

9

623-6855

HANDRAIL WELDMENT, FRONT LEFT

1

11

623-8592

PIN, QUICK RELEASE L 5/8 IN.

1

12

623-8593

PIN, QUICK RELEASE L 5/8 IN.

3

14

624-2047

LATCH, DECK

1

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 13 December 2015

Halvorsen

Figure 4 HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR 623-6860 4-12 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR 623-6860 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

3

2

620-6376

LANYARD

3

3

623-6856

HANDRAIL WELDMENT, REAR

1

4

623-6861

WALK DECK WELDMENT

1

5

623-6875

HANDRAIL WELDMENT, CENTER

1

6

623-8592

PIN, QUICK RELEASE L-HANDLE, 5/8 IN.

1

7

623-8593

PIN, QUICK RELEASE L, 5/8 IN.

2

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 15 December 2015

Halvorsen

REV. D

Figure 5 HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX 623-6880 4-12 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX 623-6880 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

3

2

107-2308

NUT, PTH A2 M6 X 1.00 S.S.

8

3

107-1782

SCREW, HEX HEAD CAP, FULL THREAD A2 M6 X 1.00 X 25 S.S.

8

4

620-6376

LANYARD

3

5

623-6852

HANDRAIL WELDMENT, CENTER

2

6

623-6881

WALK DECK WELDMENT, RIGHT CENTER

1

7

623-8592

PIN, QUICK RELEASE L-HANDLE, 5/8 IN.

1

8

623-8593

PIN, QUICK RELEASE L, 5/8 IN.

2

9

624-2047

LATCH, DECK

2

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 17 December 2015

Halvorsen

Figure 6 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR 623-6890 4-12 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR 623-6890 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

3

2

620-6376

LANYARD

3

3

623-6852

HANDRAIL WELDMENT, CENTER

1

4

623-6856

HANDRAIL WELDMENT, REAR

1

5

623-6916

WALK DECK WELDMENT, REAR

1

6

623-8592

PIN, QUICK RELEASE L-HANDLE, 5/8 IN.

1

7

623-8593

PIN, QUICK RELEASE L, 5/8 IN.

2

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 19 December 2015

Halvorsen

REV. K

Figure 7 Sheet 1 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT 623-6100 4-12 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

16

Halvorsen

Figure 7 Sheet 2 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT 623-6100

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 21 December 2015

Halvorsen

Figure 7 Sheet 3 HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT 623-6100 4-12 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT 623-6100 ITEM

PART NO.

DESCRIPTION

QTY.

1*

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

3

3

107-1747

PIN, COTTER 18-8 5/32 DIAMETER S.S.

1

4

107-1748

PIN, ROLL A2 M4 X 26 S.S.

1

5

107-9193

SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M10 X 1.50 X 25 MG

16

6

107-9194

SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M10 X 1.50 X 30 MG

2

7

107-9195

SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M10 X 1.50 X 35 MG

2

9

107-9260

NUT, PTH 8 M10 X 1.50 MG

12

107-9276

WASHER, FLAT STD HARD M10 MG

6

13

107-9418

SCREW, HEX FLANGE 8.8 M10 X 1.50 X 30 MG

2

14

107-9421

SCREW, HEX FLANGE 8.8 M10 X 1.50 X 50 MG

4

15

107-9446

NUT, ACORN 6 M10 X 1.50 MG

16

107-9447

WASHER, FLAT NARROW HARD M12 MG

2

18

107-9452

SCREW, HEX HEAD CAP, 8.8 M12 X 1.75 X 160 MG

1

19

107-9453

NUT, JAM 4 M12 X 1.75 MG

2

21

107-9455

WASHER, FLAT NARROW HARD 0.50 MG

5

22

107-9456

WASHER, FLAT NARROW HARD M10 MG

2

23

107-9500

NUT, JAM 4 M10 X 1.50 MG

18

24

107-2274

NUT, JAM GR 8 0.75-16 MG

12

25

107-2728

WASHER, DIN 125A - TP200 M20 MG

24

26

515-1889

KNOB, HANDRAIL LOCK

1

28

623-6070

HANDRAIL WELDMENT, RIGHT FRONT

1

29

623-6095

HANDRAIL WELDMENT, TELESCOPING

1

30

623-6101

ROLLER, TRACK

6

31

623-6217

WALKDECK WELDMENT, TELESCOPING

1

32

623-6218

BUMPER, HANDRAIL

3

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

11

16

4-12 Page 23 December 2015

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT 623-6100 ITEM

PART NO.

DESCRIPTION

QTY.

33

623-6235

PIN, HANDRAIL LOCK

1

34

623-6237

SPRING, COMPRESSION

1

35

623-6241

ROLLER, PLASTIC GROOVED 3 IN. O.D.

1

36

623-6244

ROLLER ASSEMBLY, CUBE

3

RETAINER CLIP

1

* 37

623-6918

HANDRAIL WELDMENT, PIVOTING

1

38

623-6921

STRIP, WEAR

4

39

623-7006

WELDMENT, KICKPLATE AND HANDRAIL MOUNT

1

40

623-7404

STRIP, BUMPER MOUNT

3

41

623-7405

WELDMENT, WALKDECK AND KICKPLATE

1

42

623-7406

STRIP, WEAR

1

45

620-6376

LANYARD

3

46

623-8593

PIN, QUICK RELEASE L, 5/8 IN.

3

47

107-9317

SCREW, HEX HEAD CAP, 10.9 M10 X 1.50 X 40 MG

1

48

623-6868

STOP, SLEEVE

1

49

623-8707

LANYARD, 20 WITH TAB

1

50

624-5747

SPACER, HANDRAIL PIN

1

51

624-6052

PIN, YELLOW, QUICK RELEASE 5/8 IN.

1

52

107-2255

PIN, CLEVIS, 0.50 X 1.75 S.S.

1

53

107-1554

SCREW, HEX HEAD TAP B, C1 #10-16 X 0.5 S.S.

1

* NOT SHOWN

4-12 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 8 HANDRAIL AND WALKDECK ASSEMBLY 623-8710

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 25 December 2015

Halvorsen HANDRAIL AND WALKDECK ASSEMBLY 623-8710 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-0815

LINK, CONNECTING WIDE 0.13 S.S.

2

4

620-6376

LANYARD

2

5

623-8593

PIN, QUICK RELEASE L, 5/8 IN.

2

6

624-2025

WALK DECK WELDMENT, LEFT

1

7

624-2044

HANDRAIL WELDMENT, CAB

1

4-12 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. D

Figure 9 GUIDE AND PALLET LOCK ASSEMBLY 623-7330

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 27 December 2015

Halvorsen GUIDE AND PALLET LOCK ASSEMBLY 623-7330 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-4251

PALLET LOCK ASSEMBLY

2

624-2052

GUIDE WELDMENT, FIRST RIGHT

1

3

624-2053

GUIDE WELDMENT, FIRST LEFT

1

4

624-2054

GUIDE WELDMENT, SECOND LEFT

1

5

624-2055

GUIDE WELDMENT, SECOND RIGHT

1

6

624-2056

GUIDE WELDMENT, THIRD LEFT

1

7

623-8591

PIN, QUICK RELEASE L, 7/8 IN.

2

8

624-4744

GUIDE WELDMENT, FRONT LEFT

1

9

624-4745

GUIDE WELDMENT, FRONT RIGHT

1

4-12 Page 28 December 2015

12

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 10 PALLET LOCK ASSEMBLY 623-4251

WALK-DECK AND HANDRAIL ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-12 Page 29 December 2015

Halvorsen PALLET LOCK ASSEMBLY 623-4251 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-4248

HANDLE WELDMENT, PALLET LOCK

1

2

623-4249

FRAME WELDMENT, PALLET LOCK

1

3

623-6843

SPRING

1

4

623-6844

PIN, ROLL

1

5

623-6848

BLOCK, PALLET LOCK PISTON

1

6

623-8667

PIN ASSEMBLY

1

-

623-7233

LANYARD, PALLET LOCK PINS

1

* NOT SHOWN

4-12 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 13. Ladder Assembly

Assembly

Assy. No.

Figure

1.

LADDER INSTALLATION

624-3125

Figure 1 Sheet 1

2

2.

LADDER ASSEMBLY

624-3126

Figure 2 Sheet 1

5

3.

LADDER

624-4190

Figure 3 Sheet 1

8

4.

SUPPORT ASSEMBLY, LOWER LADDER

624-3127

Figure 4

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Page

11

4-13 Page 1 December 2015

Halvorsen

Figure 1 Sheet 1 LADDER INSTALLATION 624-3125 4-13 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 1 Sheet 2 LADDER INSTALLATION 624-3125

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-13 Page 3 December 2015

Halvorsen LADDER INSTALLATION 624-3125 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9017

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M6 X 1 X 20 MG

2

2

107-9258

NUT, PTH 8 M6 X 1.00 MG

2

3

107-9274

WASHER, FLAT STD HARD M6 MG

4

4

623-8697

GAKET, TIE DOWN

2

5

624-0308

PIN, HITCH 0.75 X 4.0

2

6

624-0309

PIN, LYNCH WIRE LOCK 0.38 X 2.5

2

7

624-3126

LADDER ASSEMBLY

1

8

624-3127

SUPPORT ASSEMBLY, LOWER LADDER

1

9

624-5019

LANYARD, 9.00 WITH TAB AND KEY RING

2

4-13 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. C Figure 2 Sheet 1 LADDER ASSEMBLY 624-3126

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-13 Page 5 December 2015

Halvorsen

Figure 2 Sheet 2 LADDER ASSEMBLY 624-3126 4-13 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen LADDER ASSEMBLY 624-3126 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9018

SCREW, HEX HEAD CAP, FULL THREAD 8.8 M6 X 1.00 X 25 MG

8

2

107-9260

NUT, PTH 8 M10 X 1.50 MG

2

3

107-9258

NUT, PTH 8 M6 X 1.00 MG

8

4

107-9274

WASHER, FLAT STD HARD M6 MG

16

5

107-9276

WASHER, FLAT STD HARD M10 MG

4

6

107-9322

SCREW, HEX HEAD CAP, 10.9 M8 X 1.25 X 80 MG

2

7

624-5743

WELDMENT, CHANNEL, LADDER ATTACH

2

8

623-9618

COUPLER, LADDER

1

10

624-4190

LADDER

1

11

624-5753

COUPLER, LADDER UPPER

1

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-13 Page 7 December 2015

Halvorsen

REV. E

Figure 3 Sheet 1 LADDER 624-4190 4-13 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 3 Sheet 2 LADDER 624-4190

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-13 Page 9 December 2015

Halvorsen LADDER 624-4190 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-5755

LADDER SLIDE, DOUBLE C

16

2

624-3104

RIVETS, LADDER

64

3

624-4169

BLOCKS, STOP, LADDER

16

4

624-4193

LADDER, SECTION

5

624-6053

RIVETS, 1/4 LADDER

64

6

624-7439

END CAP, LADDER, BLACK

10

7

624-7439-001

RIVET, FLAT, 0.188 X 0.375, ALUMINUM 41027

20

4-13 Page 10 December 2015

5

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 SUPPORT ASSEMBLY, LOWER LADDER 624-3127

SUPPORT ASSEMBLY, LOWER LADDER 624-3127 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-4191

WELDMENT, SUPPORT, LOWER LADDER

1

2

624-0310

BUSHING, LADDER

1

LADDER ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-13 Page 11 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 14. Cab Assembly

Assembly

Assy. No.

Figure

Page

1.

CAB INSTALLATION

627-9637

Figure 1 Sheet 1

2.

SUPPORT BEAM ASSEMBLY, CAB FRONT

624-4038

Figure 2

10

3.

SUPPORT BEAM ASSEMBLY, CAB REAR

624-4039

Figure 3

11

4.

CAB ASSEMBLY

627-9639

Figure 4 Sheet 1

12

5.

CAB SHELL ASSEMBLY

625-4753

Figure 5 Sheet 1

19

6.

SIDE DOOR ASSEMBLY

624-2994

Figure 6 Sheet 1

25

7.

REAR DOOR ASSEMBLY

624-2995

Figure 7

28

8.

HEATER INSTALLATION

627-1146

Figure 8

30

9.

HEATER ASSEMBLY, D4 CAB

627-5930

Figure 9

32

10. HANDRAIL ASSEMBLY, CAB

624-4041

Figure 10

34

11. MIRROR ASSEMBLY, CAB

624-6080

Figure 11

36

12. WIPER INSTALLATION, CAB

625-3956

Figure 12 Sheet 1

38

13. ELECTRICAL PANEL ASSEMBLY, CONVEY

624-2915

Figure 13 Sheet 1

42

14. CAB INSULATION, THERMAL

625-3093

Figure 14

46

15. CAB INSULATION INSTALLATION, ACOUSTIC

625-3967

Figure 15

48

16. PANEL ASSEMBLY, FLOOR MAT

625-3964

Figure 16

50

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

2

4-14 Page 1 December 2015

SOME COMPONENTS REMOVED FOR CLARITY

29

24

23

11

15

DETAIL A

CAB BEAM INSTALLATION VIEW

Halvorsen

Figure 1 Sheet 1 CAB INSTALLATION 627-9637 4-14 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

41

44

4

26 39

6 43 45

52

3

40

49 50

51 DETAIL A SOME COMPONENTS NEED REMOVED FOR CLARITY

Figure 1 Sheet 2 CAB INSTALLATION 627-9637

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 3 December 2015

Halvorsen 17

DETAIL B

13

19

DETAIL C

CAB SUB-ASSEMBLY VIEW SOME COMPONENTS REMOVED FOR CLARITY

19

DETAIL C

Figure 1 Sheet 3 CAB INSTALLATION 627-9637 4-14 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 26 10 30

53

22 2

5

32 10

3 20 21 14 9 25 DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

Figure 1 Sheet 4 CAB INSTALLATION 627-9637

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 5 December 2015

Halvorsen 1

8

17

34

18 4

8

33 12 5 CAB INSTALLATION VIEW

Figure 1 Sheet 5 CAB INSTALLATION 627-9637 4-14 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL D

CAB INSTALLATION VIEW

3

28

27 24

41

51 49 50

DETAIL D SOME COMPONENTS REMOVED

Figure 1 Sheet 6 CAB INSTALLATION 627-9637

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 7 December 2015

Halvorsen CAB INSTALLATION 627-9637 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9071

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 100 MG

6

2

107-2258

SCREW, SOCKET FLAT HEAD, FULL THREAD GR8 0.5-13 X 3.50 MG

2

3

107-9261

NUT, PTH 8 M12 X 1.75 MG

9

4

107-9031

SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 40 MG

1

5

107-9259

NUT, PTH 10 M8 X 1.25 MG

13

6

107-9266

NUT, HEX 8 M6 X 1.00 MG

1

8

107-9275

WASHER, FLAT STD. HARD M8 MG

9

107-1746

PIN, CLEVIS 18-8 1/2 DIA. SS

2

10

107-9278

WASHER, FLAT STD. HARD M12 MG

8

11

107-9260

NUT, PTH 8 M10 X 1.50 MG

1

12

107-9177

SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M8 X 1.25 X 16 MG

4

13

107-9381

SCREW, HEX FLANGE, 10.9 M8 X 1.25 X 30 MG

7

14

107-2336

PIN, COTTER 0.125 X 1 SS

2

15

107-2214

SCREW, HEX HEAD CAP, 10.9 M10 X 1.50 X 160 MG

1

17

627-9639

A-CAB

1

18

623-6987

PIN WELDMENT, CAB

1

19

624-6055

HINGE WELDMENT, 0.5 IN. PIN

1

20

624-1402

SHOCK

2

21

624-4028

SPACER, SHOCK

4

22

624-4029

BACKING PLATE, CAB

1

23

624-4038

A-SUPPORT BEAM ASSY, CAB FRONT

1

24

624-4039

A-SUPPORT BEAM ASSY, CAB REAR

1

25

624-6598

CLEVIS

2

26

107-9094

SCREW, HHC-F 8.8 M12 X 1.75 X 50 MG

8

27

107-2264

SCREW, HEX HEAD CAP, 10.9 M12 X 1.75 X 110 MG

1

28

107-9453

NUT, JAM 4 M12 X 1.75 MG

1

4-14 Page 8 December 2015

12

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB INSTALLATION 627-9637 ITEM

PART NO.

DESCRIPTION

QTY.

29

624-6596

BUSHING, CAB BEAM SLEEVE

2

30

624-6594

W-PLATE, CAB REAR BEAM

2

32

107-2257

NUT, PTH GR5 TH 0.5-13 MG

2

33

623-8707

LANYARD, 20 W/TAB

1

34

624-7419

PLATE, BACKING

2

39

107-1930

WASHER, FLAT STD. A2 M8 SS

1

40

107-1780

SCREW, HEX HEAD CAP, FULL THD. A2 M8 X 1.25 X 30 SS

1

41

624-7431

SHIM, CAB

1

43

624-7442

WELDMENT, PLATE, SHIM ADJUSTER

1

44

624-7445

WELDMENT, PLATE, SHIM

1

45

3616479

WASHER, LOCK M8 SS

1

49

107-2296

NUT, JAM A270 M20 X 2.5 SS

1

50

107-2293

SCREW, HHC-F, A270 M20 X 2.5 X 90 SS

1

51

625-3185

LANYARD, 12 W/TAB AND KEYRING

1

52

107-9447

WASHER, FLAT NARROW HARD M12 MG

4

53*

625-4873

CAP, SHOCK TOWER

2

* NOT SHOWN

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 9 December 2015

Halvorsen

REV. A

Figure 2 SUPPORT BEAM ASSEMBLY, CAB FRONT 624-4038

SUPPORT BEAM ASSEMBLY, CAB FRONT 624-4038 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-1591

CIRCLIP, ROLLER

3

2

624-4031

ROLLER ASSY, CAB

3

-

623-4607

BEARING, CAB ROLLER

1

-

624-4027

ROLLER, CAB

1

3

624-4036

SUPPORT BEAM WELDMENT, FRONT CAB

1

* NOT SHOWN

4-14 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A Figure 3 SUPPORT BEAM ASSEMBLY, CAB REAR 624-4039

SUPPORT BEAM ASSEMBLY, CAB REAR 624-4039 ITEM

PART NO.

DESCRIPTION

QTY.

1

104-1591

CIRCLIP, ROLLER

4

2

624-4031

ROLLER ASSY, CAB

4

*

623-4607

BEARING, CAB ROLLER

1

*

624-4027

ROLLER, CAB

1

3

624-4037

SUPPORT BEAM WELDMENT, REAR CAB

1

* NOT SHOWN

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 11 December 2015

Halvorsen

REV. L

Figure 4 Sheet 1 CAB ASSEMBLY 627-9639 4-14 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

12

Figure 4 Sheet 2 CAB ASSEMBLY 627-9639

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 13 December 2015

Halvorsen

Figure 4 Sheet 3 CAB ASSEMBLY 627-9639 4-14 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 Sheet 4 CAB ASSEMBLY 627-9639

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 15 December 2015

Halvorsen

Figure 4 Sheet 5 CAB ASSEMBLY 627-9639 4-14 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB ASSEMBLY 627-9639 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9080

SCREW, HEX HEAD CAP, FULL THREAD 10.9 M10 X 1.5 X 30 MG

4

2

107-9045

SCREW, HEX HEAD CAP, FULL THREAD 8.8

6

3

107-9259

NUT, PTH 10 M8 X 1.25 MG

4

4

107-9275

WASHER, FLAT STD. HARD M8 MG

5

107-9303

SCREW, HEX HEAD CAP, 10.9 M8 X 1.25 X 30 MG

4

6

110-9456

WASHER, FLAT NARROW HARD M10 MG

4

7

622-5108

CLAMP, MUFFLER 3.50 HEAVY DUTY

1

8

622-5153

COLUMN, STEERING 10 IN.

1

9

623-2675

WHEEL HUB, STEERING, 7/8-16 SPLINES

1

10

623-2676

HORN BUTTON

1

12

624-5738

SEAT, T1

1

*

624-5738-001

SEAT COVER

1

*

624-5738-002

SEAT CUSHION

1

*

624-5738-003

BACK COVER

1

*

624-5738-004

BACK CUSHION

1

*

624-5738-005

SEAT BELT

1

14*

624-2980-500

A-CAB SHELL

1

15

624-4040

I-HEATER

1

16

624-4175

FIRE EXTINGUISHER ASSY

1

*

624-4176

FIRE EXTINGUISHER

1

*

624-4177

BRACKET, FIRE EXTINGUISHER

1

17

624-4041

HANDRAIL ASSY

1

20*

623-5949

CAB HYDRAULICS

1

21*

624-3250

IE-CAB (REF. SEC. 4-16)

1

23

624-4061

FAN, CAB

1

24

624-4062

DOME LIGHT, CAB

1

25

624-6080

MIRROR ASSY

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

20

4-14 Page 17 December 2015

Halvorsen CAB ASSEMBLY 627-9639 ITEM

PART NO.

DESCRIPTION

QTY.

26

107-9034

SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 55 MG

2

27

107-9258

NUT, PTH 8 M6 X 1.00 MG

3

28

107-9274

WASHER, FLAT STD. HARD M6 MG

29

624-5751

STOP, HANDRAIL

1

30

107-9017

SCREW, HEX HEAD CAP, FULL THD. 10.9 M6 X 1.00 X 20 MG

1

31

519-0198

TRIM, QUICKEDGE

32

623-8707

LANYARD, 20 W/TAB

1

33

624-6052

PIN, YELLOW, QUICK RELEASE 5/8 IN.

1

34

624-4060

WIPER INSTALLATION, CAB

1

35

107-0808

RIVET, FLAT GR30 44 PL

6

36

623-9636*

PLACARD, LOADER/TRANSPORTER, DATA PLATE

1

37

624-5208

MOUNTING PLATE, PLACARD

1

38

624-5209*

DECAL, TRANS. SHIFT NOTE

1

39

107-9046

SCREW, HEX HEAD CAP, FULL THD. 8.8 M8 X 1.25 X 25 MG

6

12

2 ft.

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing this part.

4-14 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 20 36 37 40

23

43 33

DETAIL H

15 24

34 25 46 DETAIL G 44 39 DETAIL H 26 38

4

45

2

10 25 26 10

DETAIL G

2

45

4

47

Figure 5 Sheet 1 CAB SHELL ASSEMBLY 625-4753

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 19 December 2015

Halvorsen 4

27

10

10

4

2

27

4 10

10

2

4

27

27 DETAIL B

DETAIL A 21

DETAIL B

3 DETAIL A

9

6

11

3

DETAIL E 28 4

10

2

17 2 4 18

2

10

10

2

4

SOME ITEMS REMOVED FOR CLARITY

Figure 5 Sheet 2 CAB SHELL ASSEMBLY 625-4753 4-14 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 27 4

2

10

27 4

10 DETAIL C 27 27

4 4

10

2

10 DETAIL D

1

DETAIL E SOME ITEMS REMOVED FOR CLARITY

Figure 5 Sheet 3 CAB SHELL ASSEMBLY 625-4753

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 21 December 2015

Halvorsen 1

11

8

7

11 35

21

1 DETAIL C 48 22

49 DETAIL F

50

31

DETAIL D

2

10

DETAIL F

4 10

41 2

4 29

32 1

11

6

1

14

5

13

13

5

14 12

30

16 7

9

11

Figure 5 Sheet 4 CAB SHELL ASSEMBLY 625-4753 4-14 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB SHELL ASSEMBLY 625-4753 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2168

NUT, INSERT, AL, M8 X 1.25, GRIP 3.8

18

2

107-2175

NUT, INSERT, AL, M6 X 1.0, GRIP 4.2

37

3

107-2176

NUT, INSERT, AL, M4 X 0.7, GRIP 3.3

16

4

107-9017

SCREW, HHC-F 8.8 M6 X 1 X 20 MG

43

5

107-2180

NUT, PTH 10 M10 X 1.50 MG

4

6

107-9045

SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG

6

7

107-9047

SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG

5

8

107-9066

SCREW, HHC 8.8 M8 X 1.25 X 60 MG

4

9

107-9259

NUT, PTH 8 M8 X 1.25 MG

5

10

107-9274

WASHER, FLAT STD HD M6 MG

43

11

107-9275

WASHER, FLAT STD HD M8 MG

18

12

107-9276

WASHER, FLAT STD HD M10 MG

1

13

107-9321

SCREW, HHC 10.9 M10 X 1.5 X 70 MG

4

14

107-9456

WASHER, FLAT NAR. HD M10 MG

8

15

623-7338

SIGHT, WINDOW-LIQUID LEVEL

1

16

623-9610

W-STEP, CAB

1

17

624-1231

PLATE, FLOOR

1

18

624-1232

PLATE, FLOOR

1

19

624-2980-002

WINDOW, LEFT SIDE SKYLIGHT

1

20

624-2980-003

WINDOW, FRONT

1

21

624-2980-004

WINDOW, SKYLIGHT

1

22

624-2987

GRATE, TIE DOWN

4

23

624-2990

W-CAB

1

24

624-2991

W-FUEL TANK

1

25

624-2994

A-SIDE DOOR

1

26

624-2995

A-REAR DOOR

1

27

624-3003

MOUNT, DOOR STRAP

8

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 23 December 2015

Halvorsen CAB SHELL ASSEMBLY 625-4753 ITEM

PART NO.

DESCRIPTION

QTY.

28

624-3004

W-FOOT REST

1

29

627-1146

I-HEATER, D4 CAB

1

30

624-4050

BULKHEAD, CAB

1

31

624-4061

FAN, CAB

1

32

624-4062

DOME LIGHT, CAB

1

33

624-4063

CAP, FUEL TANK, HEATER

1

34

624-4068

GASKET, SIDE DOOR

1

35

624-5730

W-GRATE

1

36

624-5873-001

GASKET, FRONT WINDSHIELD

1

37

624-5873-003

GASKET, RH SLIDING WINDOW

1

38

624-6604

GASKET, REAR DOOR

1

39

624-7176

A-VENTILATOR, CAB

1

40

624-7181

SLIDING WINDOW, RIGHT SIDE

1

41

628-1156

A-PANEL, SIDE CONSOLE

1

42

625-3922

I-INSULATION, AC CAB

1

43

625-3956

I-WIPER, AC CAB

1

44

HFS0058

RIVET, BLIND 0.188 X 0.38 ALUMINUM

12

45

107-2466

WASHER, LCKINT A2 M6 S.S.

10

46

627-6923

K-PLATE, STRIKER REAR DOOR

1

47

627-6917

K-PLATE, STRIKER SIDE DOOR

1

48

107-2846

WASHER, FLAT NARROW #8 S.S.

4

49

107-2845

NUT, PTH GR 5 #8-32 S.S.

4

50

107-2844

SCREW, PRND GR 2 #8-32 X 0.75 S.S.

4

4-14 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. D

Figure 6 Sheet 1 SIDE DOOR ASSEMBLY 624-2994

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 25 December 2015

Halvorsen

Figure 6 Sheet 2 SIDE DOOR ASSEMBLY 624-2994 4-14 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen SIDE DOOR ASSEMBLY 624-2994 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2175

NUT, INSERT, ALUMINUM, M6 X 1.00, GRIP 4.2

20

2

107-9017

SCREW, HEX HEAD CAP, FULL THD. 8.8 M6 X 1.00 X 20 MG

30

3

107-9258

NUT, PTH 8 M6 X 1.00 MG

14

4

107-9274

WASHER, FLAT STD. HARD M6 MG

30

8

624-2992

WELDMENT, SIDE DOOR

1

9

624-2994-002

WELDMENT, COVER

1

10

624-2994-005

POCKET, DOOR

1

11

624-2996

LATCH, SIDE DOOR

2

12

624-7182

SLIDING WINDOW, SIDE DOOR, ASSY.

1

*

624-7181-001

HANDLE, SLIDING WINDOW

1

*

624-5873

GASKET, RUBBER

**

13

624-2994-001

HINGE, SIDE DOOR

1

15

624-5024

HANDLE, DOOR GRAB

1

16

107-2809

NUT, INSERT, ALS4, M8 X 1.25, GRIP 3.8

6

18

624-6627

LATCH, INSIDE, SIDE DOOR

1

19

624-6628

ROD, LATCH, SIDE DOOR

1

20

107-2466

WASHER, LCKINT A2 M6 SS

5

* NOT SHOWN **AS REQUIRED

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 27 December 2015

Halvorsen 11

8

6

1 4 2

DE

TAI

LA

1 1

2

5 3

1

2 1

7

3

12

DETAIL A

Figure 7 REAR DOOR ASSEMBLY 624-2995 4-14 Page 28 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen REAR DOOR ASSEMBLY 624-2995 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-2175

NUT, INSERT, ALUMINUM, M6 X 1.00 GRIP 4.2

17

2

107-9017

SCREW, HEX HEAD CAP, FULL THD. 8.8 M6 X 1.00 X 20 MG

13

3

107-9274

WASHER, FLAT STD. HARD M6 MG

11

4

624-2982

LATCH, OUTSIDE, REAR DOOR

1

5

624-2983

LATCH, INSIDE, REAR DOOR

1

6

624-2993

WELDMENT, REAR DOOR

1

7

624-2995-001

HINGE, REAR DOOR

1

8

624-2998

WINDOW, REAR DOOR

1

11

624-5873-002

GASKET, REAR DOOR WINDOW

1

12

107-2466

WASHER, LOCK INT A2 M6 S.S.

5

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 29 December 2015

Halvorsen

Figure 8 HEATER INSTALLATION 627-1146 4-14 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HEATER INSTALLATION 627-1146 ITEM

PART NO.

DESCRIPTION

QTY.

4

107-1975

WASHER, FLAT STD. A2 M5 MG

5

107-1976

NUT, PTH 8 M5 X 0.80 SS

9

6

107-2170

SCREW, HEX HEAD CAP, A2 M5 X 0.08 X 20 SS

9

7

107-9274

WASHER, FLAT STD. HARD M6 MG

4

8

237-1382-004

NUT, PTH GR 5 #6-32 ZP

4

11

239-9076-010

CLAMP, P 1.625 STEEL CUSHIONED

1

12

627-5930

A-HEATER, D4 CAB

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

18

4-14 Page 31 December 2015

Halvorsen

Figure 9 HEATER ASSEMBLY, D4 CAB 627-5930 4-14 Page 32 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HEATER ASSEMBLY, D4 CAB 627-5930 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-1234-001

CLAMP, P 1.00 STEEL CUSHIONED

7

3

624-1234-003

CLAMP, HOSE 59 MM–83 MM

2

4

624-1234-004

NUT, INSERT, AL M4 X 0.7, GRIP 3.3

1

6

624-1234-006

FLEXI EXHAUST 24 MM-50 IN.

1

7

624-1234-007

CLAMP, HOSE 0.55-1.25 SS

2

8

624-1234-008

COMBUSTION AIR HOSE - 13 IN.

1

10

624-1234-010

11MM FUEL CLAMPS

2

11

624-1234-011

THERMOSTAT, HEATER 24V

1

13

624-1234-013

HOSE, FUEL 3.5MM I.D. 7 IN.

1

14

624-1234-014

HOSE, FUEL 5.0MM I.D.-7 IN.

1

23

624-1234-023

M6 WASHER

4

24

624-1234-024

M6 NUT PTH

4

25

624-1234-025

DUCT, 90 DEG. X 75 MM

1

26

624-1234-026

CLAMP, FUEL 9 MM

2

27

624-1234-027

CAP, HOSE INTAKE

1

28

624-1234-028

CAP, HOSE EXHAUST

1

29

627-5930-001

HEATER, D4 24 VOLT WITH PUMP

1

*

627-5930-004

D4 FUEL PUMP

1

30

627-5930-002

HE-HEATER, D4 CUSTOM

1

31

627-5930-003

HOOD, D4 75 MM 90 DEGREE BEND

1

33

624-8942-004

TUBING, SHRINK

1

34

239-3650-001

TERMINAL SLIP-ON FEMALE 14-AWG INS

1

35

239-3650-002

TERMINAL SLIP-ON FEMALE 10-AWG INS

1

36*

624-8951

DIAGNOSTIC UNIT, ESPAR HEATER

1

* NOT SHOWN

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 33 December 2015

Halvorsen

VIEW A

REV. D

Figure 10 HANDRAIL ASSEMBLY, CAB 624-4041

4-14 Page 34 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HANDRAIL ASSEMBLY, CAB 624-4041 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-1748

PIN, ROLL A2 M4 X 26 SS

1

2

107-9260

NUT, PTH 8 M10 X 1.50 MG

2

3

107-9322

SCREW, HEX HEAD CAP, 10.9 M10 X 1.50 X 80 MG

2

4

107-9447

WASHER, FLAT NARROW HARD M12 MG

2

5

107-9456

WASHER, FLAT NARROW HARD M10 MG

2

6

515-1899

KNOB, PLASTIC

1

7

623-6218

BUMPER, HANDRAIL

1

8

623-6237

SPRING, COMPRESSION

1

9

623-7404

STRIP, BUMPER MOUNT

1

10

624-4042

HANDRAIL WELDMENT, CAB

1

11

624-4051

PIN, HANDRAIL, CAB

1

12

107-0806

RIVET, BLIND, WEAR, HANDRAIL, CAB, PRO GR41 64 SS

13

624-4047

STRIP, WEAR, HANDRAIL, CAB

2

14

624-4048

STRIP, WEAR, HANDRAIL, CAB

1

15

624-5747

SPACER, HANDRAIL PIN

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

33

4-14 Page 35 December 2015

Halvorsen

REV. A

Figure 11 MIRROR ASSEMBLY, CAB 624-6080 4-14 Page 36 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen MIRROR ASSEMBLY, CAB 624-6080 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9061

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 35 MG

3

2

107-9259

NUT, PTH 10 M8 X 1.25 MG

3

3

107-9275

WASHER, FLAT STD. HARD M8 MG

6

4

624-6076

WELDMENT, MIRROR MOUNT

3

5

624-6079

WELDMENT, MIRROR BRACKET

1

6

624-6081

MIRROR, HEAD

1

7

107-1492

NUT, ACORN 6 M8 X 1.25 ZP

2

8

107-2262

WASHER, CONICAL SPRING, M8 MG

3

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 37 December 2015

Halvorsen 6

10 13

8 16 3

13

9

ISO VIEW

Figure 12 Sheet 1 WIPER INSTALLATION, CAB 625-3956 4-14 Page 38 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

12

18 15

3

1

21

11

4

Figure 12 Sheet 2 WIPER INSTALLATION, CAB 625-3956

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 39 December 2015

Halvorsen 1

2

3

19

SEE DETAIL

A 20 21

12

14

22

17 20 18

7 DETAIL

A

Figure 12 Sheet 3 WIPER INSTALLATION, CAB 625-3956 4-14 Page 40 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen WIPER INSTALLATION, CAB 625-3956 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9275

WASHER, FLAT STD HD M8 MG

6

2

107-9284

NUT, HEX 10 M8 X 1.25 MG

4

3

107-9409

SCREW, HFLING 8.8 M8 X 1.25 X 20 MG

6

4

237-2308-002

GROMMET, 0.688 ID X 0.188 GW

1

6

622-0746-009

WIPER BLADE, REAR

1

7

624-1252

MOTOR, WIPER FRONT

1

8

624-1253

AE-MOTOR, WIPER REAR

1

9

624-4060-001

DRY ARM, FRONT

1

10

624-4060-002

DRY ARM, REAR

1

11

624-4060-003

ELBOW

1

12

624-4060-005

TUBING, WIPER ARM

2 ft.

13

624-4060-008

WET ARM KIT, WIPER

2

14

624-0746-006

SHAFT, PIVOT

1

15

624-5023

FILL CAP

1

16

624-5030

WIPER BLADE, FRONT

1

17

624-6082

SPACER WIPER

3

18

622-1035-011

FITTING COWL

2

19

625-3954

A- RESERVOIR, WIPER

1

20

624-4060-006

TUBING, 1.8 ID X 1/16 W X 20 FT.

1

21

624-4060-007

TUBING, FILL 4 FT. LONG

1

22

622-0746-007

WIPER ADAPTER KIT-UTA48519

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 41 December 2015

Halvorsen

Figure 13 Sheet 1 ELECTRICAL PANEL ASSEMBLY, CONVEY 624-2915 4-14 Page 42 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 13 Sheet 2 ELECTRICAL PANEL ASSEMBLY, CONVEY 624-2915

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 43 December 2015

Halvorsen ELECTRICAL PANEL ASSEMBLY, CONVEY 624-2915 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-2917

JOYSTICK AND CARD, CONVEY

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

12

3

622-2967-011

CONNECTOR, RECP 12 POS (MALE)

1

4

622-2967-027

CONNECTOR, WEDGE 12 POS RECP

1

5

624-3245

DE-CONVEY PANEL

1

6

DWG-623-9526

ELECT FABRICATION PRACTICES

1

7

620-0764

LAMP, 24V

6

8

519-2207

AE-LIGHT, PANEL ILLUMINATOR 1/2 X 1/2

1

9

620-0763-001

LIGHT, PILOT, BASE

5

10

620-0763-003

LIGHT, PILOT, LENS, GREEN

3

11

620-0763-002

LIGHT, PILOT, LENS, RED

2

12

111-7576

NUT, PTH GR 5 #10-24 ZP

2

13

107-0730

SCREW, SBIND GR 2 #10-24X.75 ZP

2

14

238-6221

SWITCH, TOGGLE SPDT

4

15

237-5490

SWITCH, TOGGLE DPDT

1

16

515-3065

SWITCH, TOGGLE SPST

1

17

622-2967-017

CONNECTOR, WEDGE 2 POS RECP

1

18

622-2962-009

CONNECTOR, SEALING PLUG

1

19

239-3646-001

TERMINAL, RING #4 14-AWG

5

20

620-1240-001

TERMINAL, RING #4 18-AWG

6

21

239-3646-008

TERMINAL, RING #6 10-AWG

6

22

239-3646-002

TERMINAL, RING #6 14-AWG

5

23

620-1240-002

TERMINAL, RING #6 18-AWG

4

24

621-5215-001

TUBING, HEAT SHRINK 0.12/0.25

25

620-3900-018

WIRE STRANDED YELLOW 18 GA GXL

26

110-3959

WASHER, FLAT NARROW #10 ZP

2

27

624-2914

PE-PANEL CONVEY

1

4-14 Page 44 December 2015

1

3 ft. 18 ft.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ELECTRICAL PANEL ASSEMBLY, CONVEY 624-2915 ITEM

PART NO.

DESCRIPTION

QTY.

28

622-7278-001

SPLICE, PARALLEL (14-12 AWG)

1

29

622-2967-014

CONNECTOR, PIN 14-16 AWG SOLID

1

30

622-2967-001

CONNECTOR, RECEPTACLE 2 POS (MALE)

1

33

624-2920

CONNECTOR, 9 POS (FEMALE)

1

34

624-2921

CONNECTOR, PIN (FEMALE)

9

35

624-6609

VARISTOR, METAL OXID 31 VDC

1

36

622-6481

SWITCH, TOGGLE GUARD

5

37

620-3900-014

WIRE, 14-AWG, GXL, YELLOW

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4 ft.

4-14 Page 45 December 2015

Halvorsen

Figure 14 CAB INSULATION, THERMAL 625-3093 4-14 Page 46 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB INSULATION, THERMAL 625-3093 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3093-001

PANEL, THERMAL INSULATION

1

2

625-3093-002

PANEL, THERMAL INSULATION

1

3

625-3093-003

PANEL, THERMAL INSULATION

1

4

625-3093-004

PANEL, THERMAL INSULATION

1

5

625-3093-005

PANEL, THERMAL INSULATION

1

6

625-3093-006

PANEL, THERMAL INSULATION

1

7

625-3093-008

PANEL, THERMAL INSULATION

1

8

625-3093-009

PANEL, THERMAL INSULATION

1

9

625-3093-010

PANEL, THERMAL INSULATION

1

10

625-3093-011

PANEL, THERMAL INSULATION

1

11

625-3093-012

PANEL, THERMAL INSULATION

1

12

625-3093-013

PANEL, THERMAL INSULATION

1

13

625-3093-014

PANEL, THERMAL INSULATION

6

14

625-3093-015

PANEL, THERMAL INSULATION

1

15

625-3093-016

PANEL, THERMAL INSULATION

1

16

625-3093-017

PANEL, THERMAL INSULATION

1

18

625-3093-020

PANEL, THERMAL INSULATION

1

19

625-3093-021

PANEL, THERMAL INSULATION

1

20

625-3093-022

PANEL, THERMAL INSULATION

1

21

625-3093-023

PANEL, THERMAL INSULATION

1

22

625-3093-024

PANEL, THERMAL INSULATION

1

23

625-3093-025

PANEL, THERMAL INSULATION

1

24

625-3093-026

PANEL, THERMAL INSULATION

1

25

625-3093-027

PANEL, THERMAL INSULATION

1

26

625-3093-028

PANEL, THERMAL INSULATION

1

27

625-3093-029

PANEL, THERMAL INSULATION

1

28

625-3093-030

PANEL, THERMAL INSULATION

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 47 December 2015

Halvorsen

Figure 15 CAB INSULATION INSTALLATION, ACOUSTIC 625-3967 4-14 Page 48 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB INSULATION INSTALLATION, ACOUSTIC 625-3967 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3967-001

PANEL, ACOUSTIC INSULATION

1

2

625-3967-002

PANEL, ACOUSTIC INSULATION

1

3

625-3967-003

PANEL, ACOUSTIC INSULATION

1

4

625-3967-004

PANEL, ACOUSTIC INSULATION

1

5

625-3967-005

PANEL, ACOUSTIC INSULATION

1

6

625-3967-006

PANEL, ACOUSTIC INSULATION

1

7

625-3967-007

PANEL, ACOUSTIC INSULATION

1

8

625-3967-008

PANEL, ACOUSTIC INSULATION

1

10

625-3967-012

PANEL, ACOUSTIC INSULATION

1

12

625-3967-014

PANEL, ACOUSTIC INSULATION

1

13

625-3967-015

PANEL, ACOUSTIC INSULATION

1

14

625-3967-016

PANEL, ACOUSTIC INSULATION

1

15

625-3967-017

PANEL, ACOUSTIC INSULATION

1

16

625-3967-018

PANEL, ACOUSTIC INSULATION

1

17

625-3967-019

PANEL, ACOUSTIC INSULATION

1

18

625-3967-020

PANEL, ACOUSTIC INSULATION

1

19

625-3967-021

PANEL, ACOUSTIC INSULATION

1

20

625-3967-020

PANEL, ACOUSTIC INSULATION

1

21

625-3967-021

PANEL, ACOUSTIC INSULATION

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 49 December 2015

Halvorsen

Figure 16 PANEL ASSEMBLY, FLOOR MAT 625-3964 4-14 Page 50 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen PANEL ASSEMBLY, FLOOR MAT 625-3964 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3964-001

PANEL, FLOOR MAT

1

2

625-3964-002

PANEL, FLOOR MAT

1

3

625-3984-003

PANEL, FLOOR MAT

1

CAB ASSEMBLY The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-14 Page 51 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 15. Hydraulic System

Assembly

Assy. No.

Figure

1.

CHASSIS HYDRAULIC INSTALLATION

627-9669

Figure 1 Sheet 1

2

2.

HOSE ASSEMBLY KIT, CHASSIS

627-9669-001

Figure 2 Sheet 1

22

3.

TUBE ASSEMBLY KIT, CHASSIS

627-9669-002

Figure 3 Sheet 1

35

4.

EMERGENCY PUMP HYDRAULIC ASSEMBLY

624-0330

Figure 4

47

5.

MANIFOLD ASSEMBLY, CHASSIS

623-5410

Figure 5

49

6.

MANIFOLD SUB-ASSEMBLY, CHASSIS

623-6681

Figure 6 Sheet 1

51

7.

MANIFOLD, FAN DRIVE

623-8653

Figure 7

54

8.

HYDRAULIC RESERVOIR ASSEMBLY

623-5930

Figure 8 Sheet 1

55

9.

SCISSOR HYDRAULIC INSTALLATION

625-9350

Figure 9 Sheet 1

58

10. HOSE ASSEMBLY KIT, SCISSOR

623-5945-003

Figure 10 Sheet 1

75

11. TUBE ASSEMBLY KIT, SCISSOR

625-9350-002

Figure 11 Sheet 1

86

12. MANIFOLD ASSEMBLY, REAR PITCH

623-5411

Figure 12

97

13. MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS

623-5413

Figure 13

99

14. DECK HYDRAULIC INSTALLATION

628-0452

Figure 14 Sheet 1

101

15. HOSE ASSEMBLY KIT, DECK

623-5952-003

Figure 15 Sheet 1

117

16. TUBE ASSEMBLY KIT, DECK

627-6080-002

Figure 16 Sheet 1

117

17. MANIFOLD ASSEMBLY, STOPS AND LIFT

623-5415

Figure 17

124

18. MANIFOLD ASSEMBLY, FIVE STATIONS

623-5416

Figure 18

126

19. CAB HYDRAULIC INSTALLATION

623-5949

Figure 19 Sheet 1

128

20. HOSE ASSEMBLY KIT, CAB

623-5949-003

Figure 20 Sheet 1

132

21. HYDRAULIC INSTALLATION, FINAL ASSEMBLY

623-7170

Figure 21 Sheet 1

137

22. HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT

623-7170-003

Figure 22 Sheet 1

141

23. VALVE BLOCK ASSEMBLY A/C MANIFOLD

625-4073

Figure 23

146

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Page

4-15 Page 1 December 2015

Halvorsen

SEE DETAIL

A

135

93 80 83

SEE DETAIL

E

SEE DETAIL

D

91 R

34

SEE DETAIL

U

SEE DETAIL

91

B

34 135 93

SEE DETAIL

C

DETAIL U SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 1 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 57

31 20

31

8 21 60

56 TP2 11 PB 3 108

59 G 60 TP1 56 H 60 P 17

12 LS

40 16

8

DETAIL E SOME ITEMS REMOVED FOR CLARITY

146 74 83

134

135

82 71 150

66

135 144 84 102

139 84 136

79 111

DETAIL D SOME ITEMS REMOVED FOR CLARITY

142 83

Figure 1 Sheet 2 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 3 December 2015

Halvorsen 94 83 73

123 136

94 83 73 61

135 61

29

100 68

31

C SOME ITEMS REMOVED FOR CLARITY (BOTH SIDES) DETAIL

135

31

113

112 99 96

B SOME ITEMS REMOVED FOR CLARITY DETAIL

Figure 1 Sheet 3 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

93 83 80 151

151

36

135

36 DETAIL A SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 4 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 5 December 2015

Halvorsen 9 135

DETAIL T SOME ITEMS REMOVED FOR CLARITY

34

91

SEE DETAIL J

SEE DETAIL H 34

91 SEE DETAIL K SEE DETAIL L 80 83 93

SEE DETAIL G SEE DETAIL M SEE DETAIL T

SEE DETAIL N

SEE DETAIL F

116 135

80 83

83 DETAIL F SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 5 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 81 84 81 77 84

120

138 115 28 28

48

125 129

126

50

128 48 DETAIL J BOTH SIDES

DETAIL G SOME PARTS REMOVED FOR CLARITY

62 37 24

102 35 62 36 R 15 M 15

2 29

118 135 96 99 T 15

15 P

12 LSO

DETAIL K SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 6 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 7 December 2015

Halvorsen 54 22 22 53 47 40 39

136

DETAIL H SOME ITEMS REMOVED FOR CLARITY (BOTH SIDES)

135 45 39

146 19

34

131 80 83 75

10 35

PORT 2 35 PORT 1 64 PORT 3 10

135 42

DETAIL L SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 7 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 135

45 136 121

52 45 45 46 46

109 DETAIL M

122

145 144 84

90 76

145 74 83 ADL 137

LSF 26 135 114 101 89

135 35 56 LS1 119

56 TP3 14 P3

80 83 86

14 P4

38 15 P1

T 17 P2 133

12 P5

DETAIL N SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 8 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 9 December 2015

Halvorsen 48 52

135

34 55 SEE DETAIL R

48 DETAIL P SOME ITEMS REMOVED FOR CLARITY

49

SEE DETAIL SEE DETAIL

P

Y

SEE DETAIL AC

SEE DETAIL W

SEE DETAIL AB

9

SEE DETAIL AD

146

135

ACTUATOR JAM NUT CLEVIS SELECTOR ARM

DETAIL

R

LINKAGE DETAIL

W Figure 1 Sheet 9 CHASSIS HYDRAULIC INSTALLATION 627-9669

4-15 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

115

SECTION AA-AA SOME ITEMS REMOVED FOR CLARITY

48

51

67

132 92 63 80 88 83 36

63

98 83 70

63 135

92

132

SECTION AB SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 10 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 11 December 2015

Halvorsen 35 97 LS

117

7 L

5 P

65

T 6

104 67

DETAIL AC SOME ITEMS REMOVED FOR CLARITY

4

79 82 141 122

82 79 71 111

136 149 122 140 82 79 122

147

122

111

122 DETAIL

AD

111

Figure 1 Sheet 11 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 41

DETAIL Y SOME ITEMS REMOVED FOR CLARITY

152 83 80

153 153 135

DETAIL V-V SOME ITEMS REMOVED FOR CLARITY

Figure 1 Sheet 12 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 13 December 2015

Halvorsen

SEE DETAIL

SEE DETAIL

X

AG

SEE DETAIL

AE

Figure 1 Sheet 13 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 31 OUTLET

DRAIN 26

119

60 INLET DETAIL X SOME ITEMS REMOVED FOR CLARITY

83 73

34

120 123 34

72 79 82

103

DETAIL AE BOTH SIDES

Figure 1 Sheet 14 CHASSIS HYDRAULIC INSTALLATION 627-9669

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 15 December 2015

Halvorsen 18

38

38

78 85 69

38

124

121

114 33 LFT

95

DETAIL AG SOME ITEMS REMOVED FOR CLARITY

127

135 102

32

32

134

SECTION AF-AF

Figure 1 Sheet 15 CHASSIS HYDRAULIC INSTALLATION 627-9669 4-15 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHASSIS HYDRAULIC INSTALLATION 627-9669 ITEM

PART NO.

DESCRIPTION

QTY.

2

102-0193

O-RING CONNECTOR 90

1

3

102-1071

FITTING SWIVEL 04 SAEF X 04 FNPT

1

4

102-1757

ADAPTER, 90 -32BARB X -24FLG CD61

1

5

102-1758

ADAPTER, KIT -12FLG CD62

1

6

102-1759

ADAPTER, KIT -24FLG CD61

1

7

102-1761

ADAPTER, 90 M22 X 1.5 X -08MJIC

1

8

102-1774-1616

ADAPTER, STRAIGHT -16MJIC X -16MJIC

2

9

102-1775-0404

ADAPTER, STRAIGHT -04MORB X -04MJIC

2

10

102-1775-0406

ADAPTER, STRAIGHT -04MORB X -06MJIC

2

11

102-1775-0604

ADAPTER, STRAIGHT -06MORB X -04MJIC

1

12

102-1775-0606

ADAPTER, STRAIGHT -06MORB X -06MJIC

3

14

102-1775-0808

ADAPTER, STRAIGHT -08MORB X -08MJIC

2

15

102-1775-1008

ADAPTER, STRAIGHT -10MORB X -08MJIC

4

16

102-1775-1208

ADAPTER, STRAIGHT -12MORB X -08MJIC

1

17

102-1775-2016

ADAPTER, STRAIGHT -20MORB X -16MJIC

2

18

102-1775-2416

ADAPTER, STRAIGHT -24MORB X -16MJIC

2

19

102-1776-0604

ADAPTER, REDUCER 06MJIC X 04FJIC

1

20

102-1776-0806

ADAPTER, REDUCER 08FJIC X 06MJIC

1

21

102-1776-1206

ADAPTER, REDUCER 06MJIC X 04FJIC

1

22

102-1776-1208

ADAPTER, REDUCER 06MJIC X 04FJIC

2

24

102-1777-0406

ADAPTER, 90 -04MORB X -06MJIC

1

26

102-1777-0606

ADAPTER, 90 -06MORB X -06MJIC

3

27

102-1777-0608

ADAPTER, 90 -06MORB X -08MJIC

2

28

102-1777-0806

ADAPTER, 90 -08MORB X -06MJIC

2

29

102-1777-0808

ADAPTER, 90 -08MORB X -08MJIC

3

30

102-1777-1008

ADAPTER, 90 -10MORB X -08MJIC

1

31

102-1777-1208

ADAPTER, 90 -12MORB X -08MJIC

5

32

102-1777-1212

ADAPTER, 90 -12MORB X -12MJIC

2

33

102-1777-2016

ADAPTER, 90 -20MORB X -16MJIC

1

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 17 December 2015

Halvorsen CHASSIS HYDRAULIC INSTALLATION 627-9669 ITEM

PART NO.

DESCRIPTION

QTY.

34

102-1778-0404

ADAPTER, 90 -06FJIC X -06MJIC

35

102-1778-0606

ADAPTER, 90 SW -06FJIC X -06MJIC

4

36

102-1778-0808

ADAPTER, 90 SW -08FJIC X -08MJIC

6

37

102-1778-1212

ADAPTER, 90 SW -12FJIC X -12MJIC

1

35

102-1778-1616

ADAPTER, 90 SW -16FJIC X -16MJIC

4

39

102-1779-0404

ADAPTER, 45 -04FJIC X -04MJIC

4

40

102-1779-0808

ADAPTER, 45 -08FJIC X -08MJIC

3

41

102-1780-0008

ADAPTER, TEE UNION -08JIC

1

42

102-1782-0006

ADAPTER, 90 SW -06FJIC X -06MJIC

1

43

102-1782-0008

ADAPTER, 90 SW -06FJIC X -06MJIC

2

45

102-1783-0404

ADAPTER, BH -04MJIC X -04MJIC

7

46

102-1783-0606

ADAPTER, BH -06MJIC X -06MJIC

2

47

102-1783-0808

ADAPTER, BH -08MJIC X -08MJIC

2

48

102-1784-0004

ADAPTER, BH 90 -02MJIC

8

49

102-1784-0006

ADAPTER, BH 90 -02MJIC

2

50

102-1784-0008

ADAPTER, BH 90 -02MJIC

2

51

102-1784-0012

ADAPTER, BH 90 -12MJIC

1

52

102-1785-0016

ADAPTER, BH 45 -XXMJIC

2

53

102-1786-0004

ADAPTER, BH RN -02MJIC

2

54

102-1786-0012

ADAPTER, BH RN -02MJIC

1

55

102-1787-0004

ADAPTER, BH BR -02MJIC

1

56

102-1788-0004

ADAPTER, PLUG -04ORB

3

57

102-1788-0012

ADAPTER, PLUG -12ORB

1

59

102-1790-0404

ADAPTER, 45 04MORB X 04MJIC

1

60

102-1790-1212

ADAPTER, 45 12MORB X 12MJIC

4

61

102-1796-0404

ADAPTER, 90 UNION -04JIC

4

62

102-1801-1212

ADAPTER, STRAIGHT -12MNPT X -12MJIC

2

63

102-1802-1208

ADAPTER, 90 -12MNPT X -08MJIC

4

64

102-1808-0404

ADAPTER, 90 -04MORB X -04MJIC

1

4-15 Page 18 December 2015

10

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHASSIS HYDRAULIC INSTALLATION 627-9669 ITEM

PART NO.

DESCRIPTION

QTY.

65

102-1816

ADAPTER, 90 -16MJIC X -12FLG CD62

1

66

102-1871-1212

ADAPTER, TEE RN-12MJIC X 12FNPT

1

67

105-0136-004

CLAMP, T-BOLT FOR 2.00 I.D. HOSE

2

68

107-1922

WASHER, LOCK A4 0.25 S.S.

2

69

107-2181

NUT, PYH 10 M12 X 1.75 MG

2

70

107-2314

BOLT, CARRIAGE GR 6.8 M8 X 1.25 X 65 MG

4

71

107-9024

SCREW, HHC-F 8.8 M6 X 1 X 60 MG

4

72

107-9036

SCREW, HHC 8.8 M6 X 1 X 70 MG

4

73

107-9042

SCREW, HHC-F 8.8 M8 X 1.25 X 10 MG

8

74

107-9044

SCREW, HHC-F 8.8 M8 X 1.25 X 16 MG

2

75

107-9063

SCREW, HHC 8.8 M8 X 1.25 X 45 MG

1

76

110-1617

SCREW, HHC GR 5 0.44-14 X 1 ZP

4

77

107-9086

SCREW, HHC 8.8 M10 X 1.5 X 70 MG

2

78

107-9092

SCREW, HHC-F 8.8 M12 X 1.75 X 35 MG

2

79

107-9258

NUT, PTH 8 M6 X 1.00 MG

11

80

107-9259

NUT, PTH 8 M8 X 1.25 MG

16

81

107-9260

NUT, PTH 8 M10 X 1.50 MG

4

82

107-9274

WASHER, FLAT STD HARD M6 MG

22

83

107-9275

WASHER, FLAT STD HARD M8 MG

41

84

107-9276

WASHER, FLAT STD HARD M10 MG

7

85

107-9278

WASHER, FLAT STD HARD M12 MG

2

86

107-9302

SCREW, HHC 10.9 M8 X 1.25 X 25 MG

4

87

107-9303

SCREW, HHC 10.9 M8 X 1.25 X 30 MG

2

88

107-9310

SCREW, HHC-F 10.9 M8 X 1.25 X 65 MG

4

89

107-9455

WASHER, FLAT NARROW HARD 0.5 MG

4

90

110-0244

WASHER, LOCK, 44 ZP

4

91

118-2679-003

ADAPTER, STRAIGHT -02MNPT X -04MJIC

4

92

232-7645

HEAT EXCHANGER

2

93

239-8852-004

CLAMP, SUPPORT 1.00 NC

4

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 19 December 2015

Halvorsen CHASSIS HYDRAULIC INSTALLATION 627-9669 ITEM

PART NO.

DESCRIPTION

QTY.

94

239-8852-017

CLAMP, SUPPORT 0.25 NC

4

95

514-8244

FILTER, HIGH PRESSURE 100 GPM

1

96

5150007

WASHER, FLAT STD 0.31 MG

2

97

519-4529-001

ADAPTER, STRAIGHT M14 X 1.5 X -06MJIC

1

98

5250185

NUT GR 5 5/16-18 HEX NYLON LOCK MG

4

99

600681

SCREW, HHC GR 5 0.31-18 X 0.75 MG

2

100

600682

SCREW, HHC GR 5 0.25-20 X 0.75 MG

2

101

600756

SCREW, HHC GR 5 0.5-13 X 1 MG

4

102

620-0925

ADAPTER, 45 -12FJIC X -12MJIC

2

103

620-0927

ADAPTER, 90 08MJIC X 08FJIC SW HP

2

104

620-0929

ADAPTER, 90 16MJIC X 16FJIC SW HP

1

105

620-1317-002

FLEX-GARD, NYLON SLIT 3/8 IN.

106

620-1317-006

FLEX-GARD, NYLON SLIT 1 IN.

107

620-1317-009

FLEX-GARD, NYLON SLIT 1/4 IN.

108

620-2565

GAUGE, PRESSURE

1

109

620-4440

CLAMP, TWIN TUBE 3/8 IN.

1

111

620-4447

CLAMP, SINGLE TUBE 3/4 IN.

4

112

621-5556

SPIN ON FILTER ASSEMBLY

1

113

621-5556-001

GAUGE, INDICATOR

1

114

623-5410

MANIFOLD, CHASSIS

1

115

623-5930

AH-RESERVOIR

1

116

623-6744

PLATE, COVER

1

117

623-8652

PUMP, HYDRAULIC

1

118

623-8653

MANIFOLD, FAN DRIVE

1

119

624-0330

AH-E-PUMP NGSL

1

120

624-1228

BULKHEAD, WALKBEAM

2

121

624-3128

TUBE CLAMP SINGLE 1.00

2

122

624-3129

TUBE CLAMP DOUBLE 1/4 IN.

7

123

624-5171

PAD, WALKING BEAM - NGSL

2

4-15 Page 20 December 2015

29 6 20

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHASSIS HYDRAULIC INSTALLATION 627-9669 ITEM

PART NO.

DESCRIPTION

QTY.

124

624-5719

BRACE, HYDRAULIC TANK ASSEMBLY

1

125

624-5722

TOP BAR, HYDRAULIC TANK ASSEMBLY

2

126

624-5725

STRAP, HYDRAULIC TANK ASSEMBLY

2

127

624-5726

PAD, HYDRAULIC TANK

2

128

624-5727

PAD, BOTTOM, HYDRAULIC TANK

2

129

624-5728

PAD, TOP, HYDRAULIC TANK

2

131

624-8907

VALVE, PRESUURE REDUCER

1

132

624-8908

ISOLATOR, HEAT EXCHANGER NGSL

8

133

625-4428

VALVE, CHECK IN-LINE 1908F

1

134

627-9652

BRKT, TRANSMISSION HYDRAULIC TUBE

1

135

627-9669-001

IH-CHASSIS HOSE ASSEMBLY KIT

1

136

627-9669-002

IH-CHASSIS TUBE ASSEMBLY KIT

1

137

102-1788-0006

ADAPTER, PLUG -06ORB

1

138

102-1788-0008

ADAPTER, PLUG -08ORB

1

139

107-2180

NUT, PTH 10 M10 X 1.50 MG

1

140

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

2

141

107-9031

SCREW, HHC 8.8 M6 X 1 X 40 MG

1

142

107-9045

SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG

1

143

107-9078

SCREW, HHC-F 8.8 M10 X 1.5 X 20 MG

1

144

107-9080

SCREW, HHC-F 8.8 M10 X 1.5 X 30 MG

2

145

239-8852-006

CLAMP, SUPPORT 1.25 NC

2

146

623-7300-006

ACTUATOR, STONE BENNETT SHIFTER

1

147

627-9912

BRKT, CAC CROSSBEAM

1

148

102-1775-0608

ADAPTER, STRAIGHT -06MORB X -08MJIC

2

149

102-1951

ADAPTER, 90 UNION 12JIC X 12JIC

1

150

118-2659-008

ADAPTER, BUSHING 3/4 MNPT X 3/8 FNPT

1

151

102-1786-0008

ADAPTER, BH RN -02MJIC

2

152

107-9047

SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG

2

153

102-1189

CLAMP COATED 11/16 I.D. SUPPORT

4

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 21 December 2015

Halvorsen 26 27 SEE DETAIL AD

53

A

K

2 3

U

R

K

DETAIL

42 43 53 SEE DETAIL H

U

R

14

SEE DETAIL J DETAIL

B

SEE DETAIL V

SEE DETAIL A

SEE DETAIL B

SEE DETAIL N

Figure 2 Sheet 1 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 4-15 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

35

12

12

35 48 24

24

47

DETAIL AD BOTH SIDES

47 48

11

11 36

36

24

47

SECTION D-D

48

Figure 2 Sheet 2 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 23 December 2015

Halvorsen PORT 2 8

PORT 3 46 PORT 1 23

7

LS

PORT 3 6 22

L

DETAIL J

T

34

34

P

SECTION K-K SOME ITEMS REMOVED FOR CLARITY

49 31 49

50

SECTION M-M

Figure 2 Sheet 3 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 4-15 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 42

43

37

3 2

SECTION C-C SOME ITEMS REMOVED FOR CLARITY

54 54

53

SECTION N SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 4 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 25 December 2015

Halvorsen

41 54 37

41

54

DETAIL P

Figure 2 Sheet 5 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 4-15 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 10

21

M 21

T 21 P 28 51

SECTION U-U SOME ITEMS REMOVED FOR CLARITY

15

16

29

14 25

SECTION R-R SOME ITEMS REMOVED FOR CLARITY

13

Figure 2 Sheet 6 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 27 December 2015

Halvorsen

13

R 16

LSO 9

22

DETAIL H SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 7 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 4-15 Page 28 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

33

30 INLET

9 LSF

45 TP2

31 H

34 32

DRAIN 1

P3 26

P1 27

P4 28

LS1 4

DETAIL V SOME ITEMS REMOVED FOR CLARITY

32

Figure 2 Sheet 8 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 29 December 2015

Halvorsen

5

6

29

10

1

30

SECTION W-W SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 9 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

4-15 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 19

14

25 DETAIL Y SOME ITEMS REMOVED FOR CLARITY

21 DETAIL X

DETAIL AB

DETAIL Y

51 DETAIL P

DETAIL AB SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 10 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 31 December 2015

Halvorsen 46

40 DETAIL AA-AA SOME ITEMS REMOVED OR CLARITY

P5 8

19 T1

LS 7

DETAIL X SOME ITEMS REMOVED OR CLARITY

Figure 2 Sheet 11 HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 4-15 Page 32 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

519-0196-048-S

HOSE, ASSEMBLY FJIC SW-06 X 48 SLVD

1

2

519-0196-056-S

HOSE, ASSEMBLY FJIC SW-06 X 56 SLVD

1

3

519-0196-057-S

HOSE, ASSEMBLY FJIC SW-06 X 57 SLVD

1

4

519-0196-068-S

HOSE, ASSEMBLY FJIC SW-06 X 68 SLVD

1

5

519-0196-102-S

HOSE, ASSEMBLY FJIC SW-06 X 102 SLVD

1

6

519-0196-110

HOSE, ASSEMBLY FJIC SW-06 X 110 LG

1

7

519-0196-124-S

HOSE, ASSEMBLY FJIC SW-06 X 124 SLVD

1

8

519-0196-100

HOSE, ASSEMBLY FJIC SW-06 X 100 LG

1

9

519-0196-175-S

HOSE, ASSEMBLY FJIC SW-06 X 175 SLVD

1

10

519-0196-223-S

HOSE, ASSEMBLY FJIC SW-06 X 223 SLVD

1

11

519-0197-014

HOSE, ASSEMBLY FJIC SW-08 X 14 LG

1

12

519-0197-030-S

HOSE, ASSEMBLY FJIC SW-08 X 30 SLVD

2

13

519-0197-033-S

HOSE, ASSEMBLY FJIC SW-06 X 33 SLVD

1

14

519-0197-038-S

HOSE, ASSEMBLY FJIC SW-08 X 38 SLVD

2

15

519-0197-040

HOSE, ASSEMBLY FJIX SW-08 X 40 LG

1

16

519-0197-041

HOSE, ASSEMBLY FJIX SW-08 X 41 LG

1

19

519-0197-054-S

HOSE, ASSEMBLY FJIC SW-08 X 54 SLVD

1

21

627-9713-096

HOSE, ASSEMBLY FJIC SW-12 X 96

1

22

519-0197-074-S

HOSE, ASSEMBLY FJIC SW-08 X 74 SLVD

1

24

519-0197-086-S

HOSE, ASSEMBLY FJIC SW-08 X 86 SLVD

2

25

519-0197-157-S

HOSE, ASSEMBLY FJIC SW-08 X 157 SLVD

1

26

519-0197-160-S

HOSE, ASSEMBLY FJIC SW-08 X 160 SLVD

1

27

519-0197-165-S

HOSE, ASSEMBLY FJIC SW-08 X 165 SLVD

1

28

519-0197-196-S

HOSE, ASSEMBLY FJIX SW-08 X 196 LG

11

29

519-0197-232-S

HOSE, ASSEMBLY FJIX SW-08 X 232 LG

1

30

620-1847-042-S

HOSE, ASSEMBLY FJIC SW-12 X 42 SLVD

1

31

620-1847-077-S

HOSE, ASSEMBLY FJIC SW-12 X 77 SLVD

1

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 33 December 2015

Halvorsen HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 ITEM

PART NO.

DESCRIPTION

QTY.

32

620-1848-028

HOSE, ASSEMBLY -16 X 28 LG 100R12

1

33

620-1848-049

HOSE, ASSEMBLY -16 X 49 LG 100R12

1

34

620-1848-087-S

HOSE, ASSEMBLY FJIC SW-16 X 87 SLVD

1

35

620-2013-008

HOSE, ASSEMBLY FJIC SW-04 X 8 LG

4

36

620-2013-015

HOSE, ASSEMBLY FJIC SW-04 X 15 LG

2

37

620-2013-026-S

HOSE, ASSEMBLY FJIC SW-04 X 26 SLVD

1

40

620-2013-051

HOSE, ASSEMBLY FJIC SW-04 X 51 LG

1

41

620-2013-054-S

HOSE, ASSEMBLY FJIC SW-04 X 54 SLVD

1

42

620-2013-059-S

HOSE, ASSEMBLY FJIC SW-04 X 59 SLVD

1

43

620-2013-060-S

HOSE, ASSEMBLY FJIC SW-04 X 60 SLVD

1

45

620-2013-067-S

HOSE, ASSEMBLY FJIC SW-04 X 67 SLVD

1

46

620-2013-024

HOSE, ASSEMBLY FJIC SW-04 X 24 LG

1

47

620-2013-081-S

HOSE, ASSEMBLY FJIC SW-04 X 81 SLVD

2

48

620-2013-085-S

HOSE, ASSEMBLY FJIC SW-04 X 85 SLVD

2

49

620-2013-140-S

HOSE, ASSEMBLY FJIC SW-04 X 140 SLV

2

50

623-0419-032

HOSE, SUCTION 2.00 ID X 32.00

1

51

627-9713-038

HOSE, ASSEMBLY FJIC SW-12 X 38

1

53

519-0197-092

HOSE, ASSEMBLY FJIC SW-08 X 92 LG

2

54

620-1850-020

A-HOSE, -06 ORFS TO -08 JIC, 20

4

4-15 Page 34 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL B

Figure 3 Sheet 1 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 35 December 2015

Halvorsen 3

5 5

4

DETAIL H

SECTION A-A

2

4

1

DETAIL H SOME ITEMS REMOVED FOR CLARITY

17 17

DETAIL B BOTH SIDES

17 17

Figure 3 Sheet 2 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 4-15 Page 36 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL D

DETAIL F

DETAIL G

DETAIL C

Figure 3 Sheet 3 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 37 December 2015

Halvorsen

18 11

10 6 9 2

8

DETAIL C

1 20

20

1

19

DETAIL D

DETAIL G

19

Figure 3 Sheet 4 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 4-15 Page 38 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 6

SECTION E-E

8

18

9

10

11

12 LFT

P 13

15

P2 14

T 15

OUTLET 14

13

12

DETAIL F SOME ITEMS REMOVED FOR CLARITY

Figure 3 Sheet 5 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 39 December 2015

Halvorsen 12 15

14 15

13

14

17

12

13 DETAIL F SOME ITEMS REMOVED FOR CLARITY 17

19 16

16

19 DETAIL B

DETAIL G SOME ITEMS REMOVED FOR CLARITY

Figure 3 Sheet 6 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 4-15 Page 40 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 17

16

DETAIL H

DETAIL G

DETAIL K

DETAIL G

DETAIL V DETAIL J 5

4

4

DETAIL H

Figure 3 Sheet 7 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 41 December 2015

Halvorsen 8

6

9

10

11 18

DETAIL J

16 17

DETAIL K SOME COMPONENTS REMOVED FOR CLARITY

Figure 3 Sheet 8 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 4-15 Page 42 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL L

20 1 REF 2

20 3

DETAIL L SOME COMPONENTS REMOVED FOR CLARITY

Figure 3 Sheet 9 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 43 December 2015

Halvorsen

DETAIL U

DETAIL S

19

“TO COOLER” PORT ON TRANSMISSION DETAIL S

Figure 3 Sheet 10 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 4-15 Page 44 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 13

12

15

14

DETAIL V SOME COMPONENTS REMOVED FOR CLARITY

8 6

9

10

11 18

DETAIL U SOME COMPONENTS REMOVED FOR CLARITY

Figure 3 Sheet 11 TUBE ASSEMBLY KIT, CHASSIS 627-9669-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 45 December 2015

Halvorsen TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-9696

A-TUBE, 0.25 SST

1

2

627-9697

A-TUBE, 0.25 SST

1

3

627-9695

A-TUBE, 0.75 SST

1

4

623-6723

A-TUBE, 0.25 SST

2

5

623-6725

A-TUBE, 0.50 SST

1

6

623-6731

A-TUBE, 1.00 SST

1

8

623-6733

A-TUBE, 0.25 SST

1

9

623-6734

A-TUBE, 0.25 SST

1

10

623-6735

A-TUBE, 0.25 SST

1

11

623-6736

A-TUBE, 0.375 SST

1

12

623-8175

A-TUBE, 1.00 SST

1

13

623-8176

A-TUBE, 1.00 SST

1

14

623-8177

A-TUBE, 0.50 SST

1

15

624-3137

A-TUBE, 0.375 SST

1

16

624-6059

A-TUBE, 0.25 SST

2

17

624-6060

A-TUBE, 0.25 SST

2

18

623-6737

A-TUBE, 0.375 SST

1

19

627-9668

A-TUBE, 0.75 SST

1

20

628-4630

A-TUBE, 0.75 SST

1

4-15 Page 46 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 4 EMERGENCY PUMP HYDRAULIC ASSEMBLY 624-0330

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 47 December 2015

Halvorsen EMERGENCY PUMP HYDRAULIC ASSEMBLY 624-0330 ITEM

PART NO.

DESCRIPTION

QTY.

1

5060008

SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.25 MG

2

2

5060010

WASHER, LOCK 3/8 MG

2

3

5060031

WASHER, FLAT 3/8 MG

2

4

624-0320

PUMP, EMERGENCY

1

5**

624-0329

MOTOR, EMERGENCY PUMP DRIVE

1

**Contact JBT for appropriate IUID label when replacing this part.

4-15 Page 48 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. D

Figure 5 MANIFOLD ASSEMBLY, CHASSIS 623-5410

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 49 December 2015

Halvorsen MANIFOLD ASSEMBLY, CHASSIS 623-5410 ITEM

PART NO.

DESCRIPTION

QTY.

1**

623-6681

MANIFOLD SUB-ASSEMBLY (REF. FIG. 35)

1

2

623-8717

VALVE, PROPORTIONAL (REF. FIG. 37)

2

3

623-2906-004

SWITCH, PRESSURE 200 PSI 0.25 NPT

1

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing this part.

4-15 Page 50 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. E

Figure 6 Sheet 1 MANIFOLD SUB-ASSEMBLY, CHASSIS 623-6681

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 51 December 2015

Halvorsen

Figure 6 Sheet 2 MANIFOLD SUB-ASSEMBLY, CHASSIS 623-6681 4-15 Page 52 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen MANIFOLD SUB-ASSEMBLY, CHASSIS 623-6681 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5410-002

VALVE, SOLENOID

2

2

623-5410-003

VALVE, 2 POSITION 2 WAY

1

3

623-5938

VALVE, N.O. MOD. ELEMENT

2

4

623-5940

VALVE, CHECK

1

5

623-6681-014

VALVE

3

6

623-6681-007

VALVE, 350 PSI

1

7

623-6681-008

VALVE, 1500 PSI

1

8

623-6681-009

VALVE, 2500 PSI

1

9

623-6681-010

VALVE

4

10

623-6681-011

VALVE

1

11**

623-5410-001

BODY

1

12

623-5410-005

PLUG, ORIFICE

1

13

623-5410-004

COIL

2

14

623-6681-001

VALVE, PRESSURE REDUCING

1

15

625-4427

PLUG, CAVITY

1

16

623-6681-003

VALVE, 2500 PSI

1

17

624-0297

VALVE, HIGH PRESSURE BALL

1

*

624-0297-090

SEAL KIT

1

18

623-6681-004

VALVE

1

19

623-6681-005

VALVE

1

20

623-6681-006

VALVE, 4000 PSI

1

21

623-6681-012

VALVE, 3500 PSI

1

22

623-6681-013

VALVE, 3500 PSI

1

23

623-6681-015

COIL

5

24

624-0297-001

BOLT KIT

1

* NOT SHOWN **Contact JBT for appropriate IUID label when replacing this part.

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 53 December 2015

Halvorsen

REV. B

Figure 7 MANIFOLD, FAN DRIVE 623-8653

MANIFOLD, FAN DRIVE 623-8653 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8653-001

VALVE, PROPORTIONAL CONTROL

1

2

623-8653-002

COIL

1

3

623-8653-004

PRESSURE COMPENSATOR

1

4

623-8653-005

CHECK VALVE

1

5

623-8653-006

BODY, MANIFOLD

1

4-15 Page 54 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

15 SECTION A-A

Figure 8 Sheet 1 HYDRAULIC RESERVOIR ASSEMBLY 623-5930

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 55 December 2015

Halvorsen

1

3 12 13 2 14

9

10 8 11 12

4

7

6

6

Figure 8 Sheet 2 HYDRAULIC RESERVOIR ASSEMBLY 623-5930 4-15 Page 56 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HYDRAULIC RESERVOIR ASSEMBLY 623-5930 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5931

RESERVOIR - WELDMENT

1

2

623-6703

BREATHER

1

3

621-5724

FILTER, RETURN

1

4

620-1736

ADAPTER, 90, -24M ORB X -20M JIC

1

5

102-1775-2416

ADAPTER, STRAIGHT., -24M ORB X -16M JIC

1

6

620-0889

ADAPTER, PLUG, -16 ORB

2

7

620-0884

ADAPTER, PLUG, -4 ORB

1

8

519-4244-002

GASKET, FILTER

1

9

624-3043

GAUGE, HYDRAULIC FLUID LEVEL

1

10

621-5093-001

CAP, HYDRAULIC TANK

1

11

110-0046

SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.00 ZP

4

12

110-0243

WASHER, LOCK 0.38 ZP

8

13

110-0043

SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.25 ZP

4

14

102-0922

ADAPTER, CAP -20F JIC

1

15

624-3042

DIFFUSER

1

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 57 December 2015

50 1 39

12

19

3 2

20 16

8

17

44

27

27

26

26

33

45

45

52

44

42

52

DETAIL G

DETAIL F

7

RETRACT

40

37

13

44

2

38

37

41

40

1

51

11

EXTEND

Halvorsen

Figure 9 Sheet 1 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 58 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL D

PITCHARM REAR VIEW SOME COMPONENTS REMOVED FOR CLARITY

Figure 9 Sheet 2 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 59 December 2015

Halvorsen

10

24

23 24 23 22

28

22

57

29

56 37

48 17

DETAIL G

Figure 9 Sheet 3 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 60 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

42

2

16

43

46 P

16

21

19

8

6

46

B2 6

38 720 34

16

16

24

2

24

16

9

38

2

43

2

2

43

43

43

DETAIL E

43

24

52

52

23

23

22

25

40

22

37

40

23

23

22

22

Halvorsen

Figure 9 Sheet 4 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 61 December 2015

39 39

12

54

37 40

12

12

49

40

49

30 10

SOME COMPONENTS REMOVED FOR CLARITY

53

50

51

38

41

37

41

11

Halvorsen

Figure 9 Sheet 5 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 62 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

23

22

23

28

22

6 18

24

12

24

40

37

40

12

47

8

31

16

12

16

6 18

4 15

SOME COMPOENETS REMOVED FOR CLARITY

4 46

55

11

Halvorsen

Figure 9 Sheet 6 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 63 December 2015

Halvorsen 32 32

32

32

15 6

11 18

11 6

11

11

SECTION A-A

Figure 9 Sheet 7 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 64 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 32

32

32

32

6 30

12

16

11

5

15

55

SOME COMPONENTS REMOVED FOR CLARITY

4

Figure 9 Sheet 8 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 65 December 2015

Halvorsen 53

SOME COMPONENTS REMOVED FOR CLARITY

6 4 30 5 8

15

16 6

12

18

45 44

43

31 31 SECTION B-B 11 11 15 31

15

8

30

8

11 31

11 6 SOME COMPONENTS REMOVED FOR CLARITY

6

Figure 9 Sheet 9 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 66 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 55

55

12

4 46

38 36 34

6

PITCHARM REAR VIEW MANIFOLD ASSEMBLY SOME COMPONENTS REMOVED FOR CLARITY 18 8

6

16 12

16

8

Figure 9 Sheet 10 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 67 December 2015

Halvorsen

12

55

6 4 6

8

8 16

12

16 18 DETAIL D SOME COMPONENTS REMOVED FOR CLARITY

Figure 9 Sheet 11 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 68 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 18

8 11

11 11

11 15

31

6

8

8

31

35 38 36 DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

Figure 9 Sheet 12 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 69 December 2015

Halvorsen

13

40 37 13

11

40

35 38 36

T 31

47 P 8 DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

Figure 9 Sheet 13 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 70 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 31

31

35 38 36

11

11

15

6

6

15

11

SOME COMPONENTS REMOVED FOR CLARITY

11 8

8

Figure 9 Sheet 14 SCISSOR HYDRAULIC INSTALLATION 625-9350

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 71 December 2015

Halvorsen

47 35 38 36

8

P

T

8 DETAIL F SOME COMPONENTS REMOVED FOR CLARITY

Figure 9 Sheet 15 SCISSOR HYDRAULIC INSTALLATION 625-9350 4-15 Page 72 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen SCISSOR HYDRAULIC INSTALLATION 625-9350 ITEM

PART NO.

DESCRIPTION

QTY.

1

102-1277

ADAPTER, REDUCER 12FJIC X 08MJIC

1

2

102-1774-0808

ADAPTER, STRAIGHT -08MJIC X -08MJIC

7

3

102-1774-0812

ADAPTER, STRAIGHT -12MJIC X -08MJIC

1

4

102-1775-0406

ADAPTER, STRAIGHT -04MORB X -06MJIC

1

5

102-1775-0606

ADAPTER, STRAIGHT -06MORB X -06MJIC

1

6

102-1775-0806

ADAPTER, STRAIGHT -08MORB X -06MJIC

6

7

102-1775-1006

ADAPTER, STRAIGHT -10MORB X -6MJIC

1

8

102-1775-1008

ADAPTER, STRAIGHT -10MORB X -08MJIC

8

9

102-1775-1208

ADAPTER, STRAIGHT -12MORB X -08MJIC

1

10

102-1776-1208

ADAPTER, REDUCER 06MJIC X 04FJIC

2

11

102-1777-0606

ADAPTER, 90 -06MORB X -06MJIC

11

12

102-1777-0806

ADAPTER, 90 -08MORB X -06MJIC

6

13

102-1777-1006

ADAPTER, 90 -10MORB X -06MJIC

3

15

102-1778-0606

ADAPTER, 90 SW -06FJIC X -06MJIC

4

16

102-1778-0808

ADAPTER, 90 SW -08FJIC X -08MJIC

9

17

102-1778-1212

ADAPTER, 90 SW -12FJIC X -12MJIC

2

18

102-1779-0606

ADAPTER, 45 -06FJIC X -06MJIC

2

19

102-1779-0808

ADAPTER, 45 -08FJIC X -08MJIC

2

20

102-1780-081212

ADAPTER, TEE UNION -08-12-12JIC

1

21

102-1782-0008

ADAPTER, 90 SW -06FJIC X -06MJIC

1

22

102-1783-0404

ADAPTER, BH -04MJIC X -04MJIC

8

23

102-1783-0606

ADAPTER, BH -06MJIC X -06MJIC

8

24

102-1783-0808

ADAPTER, BH -08MJIC X -08MJIC

7

25

102-1783-1212

ADAPTER, BH -12MJIC X -12MJIC

1

26

102-1784-0004

ADAPTER, BH 90 -02MJIC

2

27

102-1784-0006

ADAPTER, BH 90 -02MJIC

2

28

102-1786-0008

ADAPTER, BH RN -02MJIC

2

29

102-1786-0012

ADAPTER, BH RN -02MJIC

1

30

102-1788-0004

ADAPTER, PLUG -04ORB

3

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 73 December 2015

Halvorsen SCISSOR HYDRAULIC INSTALLATION 625-9350 ITEM

PART NO.

DESCRIPTION

QTY.

31

102-1788-0010

ADAPTER, PLUG -10MORB

4

32

102-1790-0606

ADAPTER, 45 -06MORB X -06MJIC

8

33

102-1791-1212

FITTING, STRAIGHT SWIVEL, 12 O-RING X 12 JIC

1

34

107-2259

SCREW, HHC GR 5 0.38-16-4.5MG

3

35

107-2260

SCREW, HHC GR 5 0.38-16-5 MG

4

36

107-2261

NUT, PYH GR 5 0.38-16 MG

7

37

107-9259

NUT, PTH 8 M8 X 1.25 MG

9

38

107-9276

WASHER, FLAT STD HARD M10 NG

39

107-9313

SCREW, HHC-F 10.9 M10 X 1.5 X 20 MG

40

239-8852-003

CLAMP, SUPPORT 0.88 NC

10

41

239-8852-004

CLAMP, SUPPORT 1.00 NC

3

42

620-4440

CLAMP, TWIN TUBE 3/8 IN.

2

43

620-4442

TUBE CLAMP DOUBLE 1/2 IN.

7

44

620-4443

TUBE CLAMP SINGLE 1/2 IN.

4

45

620-4447

CLAMP, SINGLE TUBE 3/4 IN.

3

46

623-5411

MANIFOLD, REAR PITCH

1

47

623-5413

MANIFOLD, INNER / OUTER SCISSORS

2

48

627-9548

BULKHEAD

1

49

623-8650

CYLINDER, PITCH

2

50

623-8658

ADAPTER, 90 SW-12ORB X -12 JIC

2

51

623-8659

ADAPTER, 90 SW-100RB X -08 JIC

2

52

624-3129

TUBE CLAMP DOUBLE 1/4 IN.

4

53

623-5945-003

HOSE ASSEMBLY KIT

1

54

625-9350-002

IH-SCISSOR TUBE ASSEMBLY KIT

1

55

102-1329

ADAPTER, 06MORB X 06MJIC

1

56

107-9275

WASHER, FLAT STD HARD M8 MG

2

57

628-4456

PLATE, SPACER SCISSOR BULKHEAD

2

16 2

* NOT SHOWN

4-15 Page 74 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A

Figure 10 Sheet 1 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 75 December 2015

Halvorsen A

Figure 10 Sheet 2 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 4-15 Page 76 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen A

Figure 10 Sheet 3 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 77 December 2015

Halvorsen

A

B

C

Figure 10 Sheet 4 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 4-15 Page 78 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

A

B

P

C

Figure 10 Sheet 5 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 79 December 2015

Halvorsen

B

B

Figure 10 Sheet 6 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 4-15 Page 80 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

B

B

Figure 10 Sheet 7 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 81 December 2015

Halvorsen

A

Figure 10 Sheet 8 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 4-15 Page 82 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

A

B

B

Figure 10 Sheet 9 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 83 December 2015

Halvorsen

Figure 10 Sheet 10 HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 4-15 Page 84 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 ITEM

PART NO.

DESCRIPTION

QTY.

1

620-2013-045-S

HOSE ASSEMBLY, -4 X 45 IN. LG SLVD

1

2

620-2013-048-S

HOSE ASSEMBLY, -4 X 48 IN. LG SLVD

1

3

519-0196-020

HOSE ASSEMBLY, -6 X 20 IN. LG

1

9

519-0196-036

HOSE ASSEMBLY, -6 X 36 IN. LG

1

10

519-0196-056

HOSE ASSEMBLY, -6 X 56 IN. LG

1

11

519-0196-051-S

HOSE ASSEMBLY, -6 X 51 IN. LG SLVD

1

13

519-0196-068

HOSE ASSEMBLY, -6 X 68 IN. LG

1

15

519-0197-016-S

HOSE ASSEMBLY, -8 X 16 IN. LG SLVD

1

16

519-0197-024-S

HOSE ASSEMBLY, -8 X 24 IN. LG SLVD

1

18

519-0197-054-S

HOSE ASSEMBLY, -8 X 54 IN. LG SLVD

1

19

519-0197-055-S

HOSE ASSEMBLY, -8 X 55 IN. LG SLVD

1

20

519-0197-056-S

HOSE ASSEMBLY, -8 X 56 IN. LG SLVD

1

21

519-0197-057-S

HOSE ASSEMBLY, -8 X 57 IN. LG SLVD

1

23

519-0196-039

HOSE ASSEMBLY, -6 X 39 IN. LG

1

24

519-0196-042

HOSE ASSEMBLY, -6 X 42 IN. LG PRIMARY

1

24

519-0196-041

HOSE ASSEMBLY, -6 X 41 IN. LG ALTERNATE

1

25

519-0196-046

HOSE ASSEMBLY, -6 X 46 IN. LG

1

26

519-0196-050-S

HOSE ASSEMBLY, -6 X 50 IN. LG SLVD

2

27

519-0197-022

HOSE ASSEMBLY, -8 X 22 IN. LG

2

29

519-0196-053

HOSE ASSEMBLY, -6 X 53 IN. LG

1

30

519-0196-018-S

HOSE ASSEMBLY, -6 X 18 IN. LG SLVD PRIMARY

1

30

519-0196-017-S

HOSE ASSEMBLY, -6 X 17 IN. LG SLVD ALTERNATE

1

32

519-0196-033

HOSE ASSEMBLY, -6 X 33 IN. LG

1

33

519-0196-067

HOSE ASSEMBLY, -6 X 67 IN. LG

1

34

519-0196-111-S

HOSE ASSEMBLY, -6 X 111 IN. LG SLVD PRIMARY

1

34

519-0196-108-S

HOSE ASSEMBLY, -6 X 108 IN. LG SLVD ALTERNATE

1

35

519-0196-112-S

HOSE ASSEMBLY, -6 X 112 IN. LG SLVD PRIMARY

1

35

519-0196-111-S

HOSE ASSEMBLY, -6 X 111 IN. LG SLVD ALTERNATE

1

36

519-0197-048-S

HOSE ASSEMBLY, -8 X 48 IN. LG SLVD

2

37

620-1847-054-S

HOSE ASSEMBLY, -12 X 54 IN. LG SLVD

1

38

519-0196-030-S

HOSE ASSEMBLY, -6 X 30 IN. LG SLVD

4

39

519-0196-055-S

HOSE ASSEMBLY, -6 X 55 IN. LG SLVD

1

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 85 December 2015

Halvorsen DETAIL D

DETAIL A

DETAIL B DETAIL C

DETAIL E

ML25K3P SCISSORS

Figure 11 Sheet 1 TUBE ASSEMBLY KIT, SCISSOR 625-9350-002 4-15 Page 86 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 16 4

17 5

7 18 6 19 DETAIL A

20

3 DETAIL B

20 1 DETAIL C

Figure 11 Sheet 2 TUBE ASSEMBLY KIT, SCISSOR 625-9350-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 87 December 2015

Halvorsen 23 24 22 19

18 21

17

16

DETAIL D

3

1

DETAIL E

Figure 11 Sheet 3 TUBE ASSEMBLY KIT, SCISSOR 625-9350-002 4-15 Page 88 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL K

DETAIL J

DETAIL H

DETAIL N

DETAIL F

DETAIL G

DETAIL L DETAIL M ML25K3P SCISSORS

Figure 11 Sheet 4 TUBE ASSEMBLY KIT, SCISSOR 625-9350-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 89 December 2015

Halvorsen 8

3

11 DETAIL F

13 12 14 8

2 15 DETAIL G

DETAIL H

Figure 11 Sheet 5 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022 4-15 Page 90 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 10

DETAIL J

10

12 DETAIL K 11

3 DETAIL L

Figure 11 Sheet 6 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 91 December 2015

Halvorsen 2

15 14

13

DETAIL M

24 23

DETAIL N

Figure 11 Sheet 7 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022 4-15 Page 92 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL V

DETAIL R DETAIL T

DETAIL U

ML25K3P SCISSORS

Figure 11 Sheet 8 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 93 December 2015

Halvorsen 9

DETAIL R

21

22

DETAIL T

Figure 11 Sheet 9 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022 4-15 Page 94 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

6

7

5

4 DETAIL U

9

DETAIL V

Figure 11 Sheet 10 TUBE ASSEMBLY KIT, SCISSOR 625-9350-022

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 95 December 2015

Halvorsen TUBE ASSEMBLY KIT, SCISSOR 625-9350-002 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-6707

A-TUBE 0.75 SST

1

2

623-6708

A-TUBE 0.38 SST

1

3

623-6709

A-TUBE 0.50 SST

2

4

623-6710

A-TUBE 0.25 SST

1

5

623-6711

A-TUBE 0.25 SST

1

6

623-6712

A-TUBE 0.38 SST

1

7

623-6713

A-TUBE 0.38 SST

1

8

623-6714

A-TUBE 0.50 SST

1

9

623-6746

A-TUBE 0.50 SST

1

10

623-6747

A-TUBE 0.50 SST

1

11

623-6750

A-TUBE 0.50 SST

1

12

623-6751

A-TUBE 0.50 SST

1

13

623-6753

A-TUBE 0.25 SST

1

14

623-6754

A-TUBE 0.25 SST

1

15

623-6755

A-TUBE 0.38 SST

1

16

623-6756

A-TUBE 0.25 SST

1

17

623-6757

A-TUBE 0.25 SST

1

18

623-6758

A-TUBE 0.38 SST

1

19

623-6759

A-TUBE 0.38 SST

1

20

623-6879

A-TUBE 0.50 SST

1

21

624-8566

A-TUBE 0.50 SST

1

22

624-8567

A-TUBE 0.50 SST

1

23

624-8568

A-TUBE 0.50 SST

1

24

624-8569

A-TUBE 0.75 SST

1

4-15 Page 96 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 12 MANIFOLD ASSEMBLY, REAR PITCH 623-5411

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 97 December 2015

Halvorsen MANIFOLD ASSEMBLY, REAR PITCH 623-5411 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5411-001

BODY

1

2

624-0296

VALVE, 3 POSITION DO3 DIRECTIONAL

1

*

620-6451-090

SEAL KIT

1

*

620-6451-092

BOOT REPLACEMENT

1

*

620-6451-093

COIL REPLACEMENT

1

3

111-2282

SCREW, SOCKET HEAD CAP, GR 8 10-24 X 1.25

4

4

623-5411-002

VALVE, COUNTER BALANCE

1

5

620-0110-001

VALVE, SHUTTLE

1

6

620-0123-001

VALVE, NEEDLE

2

7

620-1664-001

VALVE PRESSURE COMP. FLOW CONTROL

1

8

620-1326-001

VALVE, SHUTTLE

1

9

623-5411-003

VALVE, PRESSURE REDUCING

1

* NOT SHOWN

4-15 Page 98 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. B

Figure 13 MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS 623-5413

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 99 December 2015

Halvorsen MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS 623-5413 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5413-001

BODY

1

2

625-6345

VALVE, DIRECTIONAL

3

*

625-6345-001

COIL REPLACEMENT

1

3

623-5413-002

VALVE, CHECK

6

4

623-5413-003

VALVE, NEEDLE W/CHECK

2

5

623-5413-004

VALVE

4

* NOT SHOWN

4-15 Page 100 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

VIEW C

VIEW E

Figure 14 Sheet 1 DECK HYDRAULIC INSTALLATION 628-0452

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 101 December 2015

Halvorsen

DETAIL C

DETAIL B

Figure 14 Sheet 2 DECK HYDRAULIC INSTALLATION 628-0452 4-15 Page 102 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

K

Halvorsen

K

23

13 25 20 32 34 49

51 47 36 19 10

40 15 41 51 47 36 19

20 49 34 32

13 25

12

51 47 36 19 40 3 47 50 17

39 35 48 48 35 39 39

4

59 54 35 33 55

27 59 58

8

BOTTOM VIEW FRONT OF LOADER

Figure 14 Sheet 3 DECK HYDRAULIC INSTALLATION 628-0452

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 103 December 2015

Halvorsen

48 35

9

18 18 5

61

5 14

14

DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

Figure 14 Sheet 4 DECK HYDRAULIC INSTALLATION 628-0452 4-15 Page 104 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 59 58 40

8

27

4 59

19 36 51 47

10 13 7 46 36 47 51

19 36 51 47 10

13 25

20 32 34 49

19 36 51 47

45 36 47 53

40 24 40

21 17

6 36 47 50

50 47 36 6 21

17

19 36 51 47 53 47 36 45 47 51 36 19

25 13 49 34 32 20

47 51 36 19 3 61

BOTTOM VIEW REAR OF LOADER SOME COMPONENTS REMOVED FOR CLARITY

49 34 32 20

Figure 14 Sheet 5 DECK HYDRAULIC INSTALLATION 628-0452

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 105 December 2015

Halvorsen 19 36 51 47 40 9 T

13 7

42 TP 40

9 P

17

1 57 34 32

DETAIL C SOME COMPONENTS REMOVED FOR CLARITY

Figure 14 Sheet 6 DECK HYDRAULIC INSTALLATION 628-0452 4-15 Page 106 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

9 P

43

12 T 9

P 44

22 12

62 34 32 2

DETAIL D SOME COMPONENTS REMOVED FOR CLARITY

Figure 14 Sheet 7 DECK HYDRAULIC INSTALLATION 628-0452

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 107 December 2015

Halvorsen 9

16

T1 11

P1 9

7

17

DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

9 P

P 44 SECTION K-K

Figure 14 Sheet 8 DECK HYDRAULIC INSTALLATION 628-0452 4-15 Page 108 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DECK HYDRAULIC INSTALLATION 628-0452 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5415

MANIFOLD, ASSEMBLY STOPS AND LIFT

1

2

623-5416

MANIFOLD, 5 STATION

1

3

623-8170

CUSTOM MANIFOLD

1

4

621-5639-001

CYLINDER, PALLET STOP-NGSL

2

5

623-6556

CYLINDER ASSEMBLY

6

623-2474

MANIFOLD, HEADER

2

7

102-1778-0606

ADAPTER, 90 SW -06FJIC X -06MJIC

5

8

102-1777-0606

ADAPTER, 90 -06MORB X -06MJIC

2

9

102-1777-1008

ADAPTER, 90 -10MORB X -08MJIC

23

10

102-1796-0808

ADAPTER, 90 -08MJIC X -08MJIC

4

11

102-1778-0808

ADAPTER, 90 SW -08FJIC X -08MJIC

1

12

102-1774-0808

ADAPTER, STRAIGHT -08MJIC X -08MJIC

8

13

102-1780-0006

ADAPTER, TEE UNION -06JIC

11

14

102-1777-0406

ADAPTER, 90 -04MORB X -06MJIC

18

15

102-1786-0006

ADAPTER, BH RN -02MJIC

1

16

102-1775-1008

ADAPTER, STRAIGHT -10MORB X -08MJIC

1

17

102-1775-0606

ADAPTER, STRAIGHT -06MORB X -06MJIC

25

18

102-1775-0406

ADAPTER, STRAIGHT -04MORB X -06MJIC

18

19

620-4440

CLAMP, TWIN TUBE 3/8 IN.

14

20

620-4442

TUBE CLAMP DOUBLE 1/2 IN.

7

21

102-1775-0806

ADAPTER, STRAIGHT -08MORB X -06MJIC

4

22

102-1775-0808

ADAPTER, STRAIGHT -08MORB X -08MJIC

10

23

623-5952-003

IH-DECK HOSE ASSEMBLY KIT

1

24

627-6080-002

IH-DECK TUBE ASSEMBLY KIT

1

25

102-1782-0006

ADAPTER, 90 SW -06FJIC X -06MJIC

7

27

102-1329

ADAPTER, 06MORB X 06MJIC

2

32

107-9259

NUT, PTH 8 M8 X 1.25 MG

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

18

14

4-15 Page 109 December 2015

Halvorsen DECK HYDRAULIC INSTALLATION 628-0452 ITEM

PART NO.

DESCRIPTION

QTY.

33

107-9260

NUT, PTH 8 M10 X 1.50 MG

1

34

107-9275

WASHER, FLAT STD HARD M8 MG

14

35

107-9276

WASHER, FLAT STD HARD M10 MG

37

36

107-9258

NUT, PTH 8 M6 X 1.00 MG

24

39

239-8852-008

CLAMP, SUPPORT 2.00 NC

3

40

102-1774-0606

ADAPTER, STRAIGHT -06MJIC X -06MJIC

41

102-1795-0006

ADAPTER, 90 SW -06FJIC X -06MJIC

1

42

102-1788-0004

ADAPTER, PLUG -04ORB

1

43

102-1788-0006

ADAPTER, PLUG -06ORB

1

44

102-1788-0010

ADAPTER, PLUG -10MORB

2

45

620-4441

TUBE CLAMP SINGLE 3/8 IN.

2

46

620-4443

TUBE CLAMP SINGLE 1/2 IN.

1

47

107-9450

WASHER, FENDER STD HARD M6 MG

30

48

107-9317

SCREW, HHC 10.9 M10 X 1.5 X 40 MG

36

49

107-9309

SCREW, HHC-F 10.9 M8 X 1.25 X 60 MG

7

50

107-9036

SCREW, HHC 8.8 M6 X 1 X 70 MG

6

51

107-9034

SCREW, HHC 8.8 M6 X 1 X 55 MG

16

53

107-9033

SCREW, HHC 8.8 M6 X 1 X 50 MG

4

54

107-9316

SCREW, HHC-F 10.9 X 1.5 X 35 MG

1

55

239-8852-007

CLAMP, SUPPORT 1.50 NC

1

57

107-2225

SCREW, SHCSLO 10.9 M8 X 1.25 X 20 MG

3

58

103-0725

PIN, CLEVIS 0.75 X 2.00 11-285Z

2

59

103-0693

PIN, COTTER 0.094 X 1.75 S.S.

4

61

102-0031

ADAPTER, 90 SWIVEL -06FJIC X -06MJIC

1

62

107-9303

SCREW, HHC 10.9 M8 X 1.25 X 30 MG

4

13

* NOT SHOWN

4-15 Page 110 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

VIEW C

VIEW E

Figure 15 Sheet 1 HOSE ASSEMBLY KIT, DECK 623-5952-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 111 December 2015

Halvorsen FROM ‘B’ PORT 20 MODULE 7 TO A2 OF MANIFOLD FROM ‘B’ PORT MODULE 6 19 TO B5 OF MANIFOLD

FROM ‘A’ PORT 22 MODULE 7 TO B2 OF MANIFOLD

FROM ‘A’ PORT MODULES 19 TO A5 OF MANIFOLD

VIEW A

FROM ‘B’ PORT T0 ‘A’ PORT 19 MODULE 6

11

VIEW B

TO ‘A’ PORT MODULE 4

30 TO ‘B’ PORT MODULE 4 TO PORT OPP. 1 ROD END

13 FROM ‘A’ PORT T0 ‘B’ PORT 15 MODULE 1

27

FROM ‘A’ PORT T0 ‘B’ PORT 18 MODULE 2

TO ‘A’ PORT MODULE 1

TO ‘A’ PORT MODULE 2

4

28 4 6

8

Figure 15 Sheet 2 HOSE ASSEMBLY KIT, DECK 623-5952-003 4-15 Page 112 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

VIEW A SOME COMPONENTS REMOVED FOR CLARITY

T PORT TO T1 24 STOP/LIFT MANIFOLD

B5

A5

B4

A4

B3

A3

B2

A2

B1

A1

TO A1 10

P PORT 21 TO P1 OF STOP/LIFT MANIFOLD

12 TO B3

13 TO A3

TO B1 13

13 TO A4

12 TO B4

Halvorsen

Figure 15 Sheet 3 HOSE ASSEMBLY KIT, DECK 623-5952-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 113 December 2015

B3 B4 7 TO A3 POINT B

POINT A

TO B4

4

TO A4 4

TO B3

7

CONNECT TO 23 POINT B

CONNECT TO 3 POINT A

VIEW B SOME COMPNENTS REMOVED FOR CLARITY

B2

A3 A4

4 TO B2

5 TO A2

A2

Halvorsen

Figure 15 Sheet 4 HOSE ASSEMBLY KIT, DECK 623-5952-003 4-15 Page 114 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

TO ‘A’ PORT MODULE 9 TO ‘B’ PORT 13 MODULE 8

TO ‘A’ PORT FROM ‘B’ PORT 23 MODULE 9

VIEW E

10

2

1

Halvorsen

Figure 15 Sheet 5 HOSE ASSEMBLY KIT, DECK 623-5952-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 115 December 2015

Halvorsen HOSE ASSEMBLY KIT, DECK 623-5952-003 ITEM

PART NO.

DESCRIPTION

QTY.

1

519-0196-020-S

HOSE ASSEMBLY, -6 X 20 IN. LG SLVD

3

2*

519-0197-027-S

HOSE ASSEMBLY, -8 X 27 IN. LG SLVD

2

3

519-0196-028-S

HOSE ASSEMBLY, -6 X 28 IN. LG SLVD

1

4

519-0196-036-S

HOSE ASSEMBLY, -6 X 36 IN. LG SLVD

5

5

519-0196-037-S

HOSE ASSEMBLY, -6 X 37 IN. LG SLVD

1

6

519-0196-039-S

HOSE ASSEMBLY, -6 X 39 IN. LG SLVD

1

7

519-0196-040-S

HOSE ASSEMBLY, -6 X 40 IN. LG SLVD

2

8

519-0196-042-S

HOSE ASSEMBLY, -6 X 42 IN. LG SLVD

1

10

519-0197-043-S

HOSE ASSEMBLY, -8 X 43 IN. LG SLVD

2

11

519-0197-060-S

HOSE ASSEMBLY, -8 X 60 IN. LG SLVD

1

12

519-0197-047-S

HOSE ASSEMBLY, -8 X 47 IN. LG SLVD

2

13

519-0197-048-S

HOSE ASSEMBLY, -8 X 48 IN. LG SLVD

5

15

519-0197-068-S

HOSE ASSEMBLY, -8 X 68 IN. LG SLVD

1

18

519-0197-104-S

HOSE ASSEMBLY, -8 X 110 IN. LG SLVD

1

19

519-0197-086-S

HOSE ASSEMBLY, -8 X 86 IN. LG SLVD

1

20

519-0197-112-S

HOSE ASSEMBLY, -8 X 112 IN. LG SLVD

1

21

519-0197-114-S

HOSE ASSEMBLY, -8 X 114 IN. LG SLVD

1

22

519-0197-106-S

HOSE ASSEMBLY, -8 X 106 IN. LG SLVD

1

23

519-0197-125-S

HOSE ASSEMBLY, -8 X 125 IN. LG SLVD

1

24

519-0197-139-S

HOSE ASSEMBLY, -8 X 139 IN. LG SLVD

1

25

519-0197-132-S

HOSE ASSEMBLY, -8 X 132 IN. LG SLVD

1

26

519-0197-151-S

HOSE ASSEMBLY, -8 X 151 IN. LG SLVD

1

27

519-0197-082-S

HOSE ASSEMBLY, -8 X 82 IN. LG SLVD

1

28

519-0196-014-S

HOSE ASSEMBLY, -6 X 14 IN. LG SLVD

1

29

519-0196-025-S

HOSE ASSEMBLY, -6 X 25 IN. SLVD

1

30

519-0197-064-S

HOSE ASSEMBLY, -08 X 64 IN. SLVD

1

* NOT SHOWN

4-15 Page 116 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

VIEW A

VIEW B

VIEW C VIEW D

Figure 16 Sheet 1 TUBE ASSEMBLY KIT, DECK 627-6080-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 117 December 2015

Halvorsen 8

10

48

6

47

7

49

50 4 3

VIEW SHOWN LOOKING FROM BOTTOM TO TOP 5

9

VIEW A

Figure 16 Sheet 2 TUBE ASSEMBLY KIT, DECK 627-6080-002 4-15 Page 118 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 18

41

38

37

42

39

40

44

43

16

21 19

17 20 15 22

51 VIEW SHOWN LOOKING FROM BOTTOM TO TOP

51

1

1

46

2

VIEW B

Figure 16 Sheet 3 TUBE ASSEMBLY KIT, DECK 627-6080-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 119 December 2015

Halvorsen 33

34

27

31

36

11

35

12

29

32

28 VIEW C

30

VIEW SHOWN LOOKING FROM BOTTOM TO TOP

Figure 16 Sheet 4 TUBE ASSEMBLY KIT, DECK 627-6080-002 4-15 Page 120 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 14

13 45

25 26

45

24

26

25

24

23

VIEW SHOWN LOOKING FROM BOTTOM TO TOP

VIEW D

Figure 16 Sheet 5 TUBE ASSEMBLY KIT, DECK 627-6080-002

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 121 December 2015

Halvorsen TUBE ASSEMBLY KIT, DECK 627-6080-002 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8180

TUBE ASSEMBLY -08

2

2

623-8181

TUBE ASSEMBLY -08

1

3

623-8183

TUBE ASSEMBLY -06

1

4

623-8184

TUBE ASSEMBLY -06

1

5

623-8185

TUBE ASSEMBLY -06

1

6

623-8186

TUBE ASSEMBLY -06

1

7

623-8187

TUBE ASSEMBLY -06

1

8

623-8188

TUBE ASSEMBLY -06

1

9

623-8189

TUBE ASSEMBLY -06

1

10

623-8190

TUBE ASSEMBLY -06

1

11

623-8195

TUBE ASSEMBLY -06

1

12

627-1550

TUBE ASSEMBLY -06

1

13

628-4191

A-TUBE, 0.38 SST

1

14

628-4189

A-TUBE, 0.38 SST

1

15

623-8617

A-TUBE, 0.375 SST

1

16

623-8618

TUBE ASSEMBLY -06

1

17

623-8619

A-TUBE, 0.375 SST

1

18

623-8620

TUBE ASSEMBLY -06

1

19

627-1532

TUBE ASSEMBLY -06

1

20

627-1534

TUBE ASSEMBLY -06

1

21

623-8623

TUBE ASSEMBLY -06

1

22

623-8624

A-TUBE, 0.375 SST

1

23

623-8625

A-TUBE, 0.375 SST

2

24

623-8626

TUBE ASSEMBLY -06

2

25

623-8627

A-TUBE, 0.375 SST

2

26

623-8628

TUBE ASSEMBLY -06

2

27

623-8629

TUBE ASSEMBLY -06

1

4-15 Page 122 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen TUBE ASSEMBLY KIT, DECK 627-6080-002 ITEM

PART NO.

DESCRIPTION

QTY.

28

623-8630

A-TUBE, 0.375 SST

1

29

623-8631

A-TUBE, 0.375 SST

1

30

623-8632

TUBE, 0.38 SST

1

31

623-8633

TUBE ASSEMBLY -06

1

32

623-8634

A-TUBE, 0.375 SST

1

33

623-8635

TUBE ASSEMBLY -06

1

34

623-8636

TUBE ASSEMBLY -06

1

35

623-8637

TUBE ASSEMBLY -06

1

36

623-8638

TUBE ASSEMBLY -06

1

37

623-8640

A-TUBE, 0.375 SST

1

38

623-8641

TUBE ASSEMBLY -06

1

39

623-8642

TUBE ASSEMBLY -06

1

40

623-8643

TUBE ASSEMBLY -06

1

41

623-8644

TUBE ASSEMBLY -06

1

42

623-8645

TUBE ASSEMBLY -06

1

43

623-8646

TUBE ASSEMBLY -06

1

44

623-8647

TUBE ASSEMBLY -06

1

45

623-8648

TUBE ASSEMBLY -06

2

46

623-8651

TUBE ASSEMBLY -08

1

47

624-3050

TUBE ASSEMBLY -06

1

48

624-3051

TUBE ASSEMBLY -06

1

49

624-3052

TUBE ASSEMBLY -06

1

50

624-3053

TUBE ASSEMBLY -06

1

51

624-3054

TUBE ASSEMBLY -08

2

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 123 December 2015

Halvorsen

REV. B

Figure 17 MANIFOLD ASSEMBLY, STOPS AND LIFT 623-5415 4-15 Page 124 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen MANIFOLD ASSEMBLY, STOPS AND LIFT 623-5415 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-5415-004

VALVE, PARKER

1

*

622-6094-091

REPLACEMENT COIL

1

2

623-5954

VALVE, SOLENOID, 2 POS. 4 WAY

3

*

622-6094-091

REPLACEMENT COIL

1

3

623-5415-001

BODY

1

4

623-5415-003

VALVE, 2500 PSI

1

5

623-5415-005

VALVE, 1500 PSI

1

6

620-6157-001

VALVE

2

7

623-5415-002

VALVE, SHUTTLE

1

8

623-5415-006

VALVE, 800 PSI

1

* NOT SHOWN

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 125 December 2015

Halvorsen

REV. B

Figure 18 MANIFOLD ASSEMBLY, FIVE STATIONS 623-5416 4-15 Page 126 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen MANIFOLD ASSEMBLY, FIVE STATIONS 623-5416 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-8163

MANIFOLD, FIVE STATIONS

1

2

627-3126

VALVE, 3 POSITION DO3 DIRECTIONAL

5

*

620-6451-093

COIL REPLACEMENT

2

*

620-6452-090

SEAL KIT

1

*

620-6451-092

BOOT REPLACEMENT

2

3

623-8654

RELIEF MODULE, CROSS OVER

5

*

620-8654-001

CARTRIDGE, 1850 PSI

2

*

620-0132-002

BODY, WITH BUNA N SEALS

1

4

107-1162

SCREW, SOCKET HEAD CAP, GR 8 10-24 X 3

20

* NOT SHOWN

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 127 December 2015

Halvorsen

Figure 19 Sheet 1 CAB HYDRAULIC INSTALLATION 623-5949 4-15 Page 128 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 19 Sheet 2 CAB HYDRAULIC INSTALLATION 623-5949

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 129 December 2015

Halvorsen CAB HYDRAULIC INSTALLATION 623-5949 ITEM

PART NO.

DESCRIPTION

QTY.

1*

624-4309

PLATE, SPACER

1

2

624-0340

VALVE, BRAKE, TANDEM

1

3*

620-0128

VALVE, SHUTTLE

2

4*

624-5212

VALVE, STEERING

1

5

623-5949-003

HOSE ASSEMBLY KIT (REF. FIG. 87)

1

6*

102-1814-0608

ADAPTER, STRAIGHT SWIVEL, -6M ORB X -8F JIC

1

7

102-1781-0606

ADAPTER, TEE, -6M ORB X -6M JIC

4

8

102-1775-0606

ADAPTER, STRAIGHT, -6M ORB X -6M JIC

4

9*

102-1775-0608

ADAPTER, STRAIGHT, -6M ORB X -8M JIC

1

10

102-1786-0008

ADAPTER, B.H. RUN, -8M JIC

1

11

102-1776-0806

ADAPTER, REDUCER, -8F JIC X -6M JIC

1

12*

102-1775-0604

ADAPTER, STRAIGHT, -6M ORB X -4M JIC

1

13

102-1786-0006

ADAPTER, B.H. RUN, -6M JIC

2

14

102-1783-0808

ADAPTER, B.H., -8M JIC X -8M JIC

3

15

102-1783-0606

ADAPTER, B.H., -6M JIC X -6M JIC

2

16*

102-1789-0808

ADAPTER, CONNECTOR 90º

2

17*

102-1777-0808

ADAPTER, 90, -8M ORB X -8M JIC

2

18*

102-1777-0606

ADAPTER, 90, -6M ORB X -6M JIC

1

19*

102-1777-0404

ADAPTER, 90, -4M ORB X -4M JIC

1

21

102-1778-0606

ADAPTER, 90 SWIVEL, -6F JIC X -6M JIC

5

22

102-1775-0406

ADAPTER, STRAIGHT, -4M ORB X -6M JIC

2

23*

624-4218

SWITCH, BRAKE PRESSURE DIFFERENTIAL

1

24*

118-2677-002

TEE, 0.25 -18 NPT, STEEL

1

25*

102-1782-0006

ADAPTER, TEE RUN SWIVEL, -6M JIC

1

26*

102-1243

ADAPTER, STRAIGHT, -4M NPT X -6F JIC

1

27*

624-4215

TUBE ASSEMBLY, -6

1

28*

624-4216

TUBE ASSEMBLY, -6

1

4-15 Page 130 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CAB HYDRAULIC INSTALLATION 623-5949 ITEM

PART NO.

DESCRIPTION

QTY.

29

107-9267

NUT, HEX 8 M8 X 1.25 MG

2

30

102-9275

WASHER, FLAT STD HARD M8 MG

31*

107-9066

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 60 MG

4

32*

624-5126

SPACER, BRAKE

2

33

107-9259

NUT, PTH 8 M8 X 1.25 MG

6

34

107-9061

SCREW, HEX HEAD CAP, 8.8 M8 X 1.25 X 35 MG

4

35*

118-2659-001

ADAPTER, STRAIGHT, -4M NPT X -2 FNPT

2

10

* NOT SHOWN

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 131 December 2015

Halvorsen

Figure 20 Sheet 1 HOSE ASSEMBLY KIT, CAB 623-5949-003 4-15 Page 132 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen T

P

L

R

SOME HOSES REMOVED FOR CLARITY

SOME HOSES REMOVED FOR CLARITY

P R

T L

Figure 20 Sheet 2 HOSE ASSEMBLY KIT, CAB 623-5949-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 133 December 2015

Halvorsen LS

2

3

1

SOME HOSES REMOVED FOR CLARITY

B1

B2

Figure 20 Sheet 3 HOSE ASSEMBLY KIT, CAB 623-5949-003 4-15 Page 134 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 20 Sheet 4 HOSE ASSEMBLY KIT, CAB 623-5949-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 135 December 2015

Halvorsen HOSE ASSEMBLY KIT, CAB 623-5949-003 ITEM

PART NO.

DESCRIPTION

QTY.

1

519-0196-012

HOSE ASSEMBLY, -6 X 12 IN. LG

3

2

519-0196-017

HOSE ASSEMBLY, -6 X 17 IN. LG

2

3

519-0196-022

HOSE ASSEMBLY, -6 X 22 IN. LG

1

4

519-0196-037

HOSE ASSEMBLY, -6 X 37 IN. LG

2

5

519-0196-045

HOSE ASSEMBLY, -6 X 45 IN. LG

1

6

519-0197-057

HOSE ASSEMBLY, -8 X 57 IN. LG

3

7

620-2013-019

HOSE ASSEMBLY, -4 X 19 IN. LG

1

8

519-0197-054

HOSE ASSEMBLY, -8 X 54 IN. LG

1

4-15 Page 136 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A

Figure 21 Sheet 1 HYDRAULIC INSTALLATION, FINAL ASSEMBLY 623-7170

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 137 December 2015

Halvorsen

Figure 21 Sheet 2 HYDRAULIC INSTALLATION, FINAL ASSEMBLY 623-7170 4-15 Page 138 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 21 Sheet 3 HYDRAULIC INSTALLATION, FINAL ASSEMBLY 623-7170

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 139 December 2015

Halvorsen HYDRAULIC INSTALLATION, FINAL ASSEMBLY 623-7170 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-4314

TUBE ASSEMBLY, -12

2

2

623-9590

WELDMENT, CLAMP, LIFT CYLINDER

2

3

623-7170-003

HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT (REF. Figure 21 Sheet 1)

1

4

623-5396-500

CYLINDER, MAIN LIFT

2

*

623-5397-001

REPLACEMENT BLEEDER SCREW

1

*

623-5396-090

SEAL KIT, MAIN LIFT CYLINDER

1

*

623-4468

BEARING, SPHERICAL

1

*

104-1585

RETAINING RINGS, BEARING

1

*

623-5925

VALVE WITH COIL

1

*

623-5410-004

COIL

1

5

102-1786-0012

ADAPTER, B.H. RUN, -12M JIC

1

6

102-1792-1216

ADAPTER, REDUCER, -12F JIC X -16M JIC

1

7

102-1776-0604

ADAPTER, REDUCER, -6F JIC X -4M JIC

2

8

102-1778-1212

ADAPTER, 90 SW., -12F JIC X -12M JIC

1

9

102-1780-0008

ADAPTER, TEE UNION, -8 JIC

2

10

102-1777-1212

ADAPTER, 90, -12M ORB X -12M JIC

2

11

102-1777-0606

ADAPTER, 90, -6M ORB X -6M JIC

1

12

102-1783-1212

ADAPTER, B.H., -12M JIC X -12M JIC

1

14

624-8900

SLEEVE, WEAR TRIP MAIN CYLINDER

2

15*

107-2271

TIE, CABLE 32 IN. HD BLACK PLT 8H-CO

6

* NOT SHOWN

4-15 Page 140 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 22 Sheet 1 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT 623-7170-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 141 December 2015

Halvorsen

Figure 22 Sheet 2 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT 623-7170-003 4-15 Page 142 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 22 Sheet 3 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT 623-7170-003

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 143 December 2015

Halvorsen

Figure 22 Sheet 4 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT 623-7170-003 4-15 Page 144 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT 623-7170-003 ITEM

PART NO.

DESCRIPTION

QTY.

1

519-0196-065-S

HOSE, ASSEMBLY FJIC SW-06 X 65 SLVD

1

2

519-0196-124-S

HOSE, ASSEMBLY FJIC SW-06 X 124 SLVD

1

3

519-0196-145-S

HOSE ASSEMBLY FJIC SW-06 X 145 SLVD

1

4

519-0197-014-S

HOSE, ASSEMBLY FJIC SW-08 X 14 SLVD

1

5

519-0197-016-S

HOSE, ASSEMBLY FJIC SW-08 X 16 SLVD

1

6

519-0197-055-S

HOSE, ASSEMBLY FJIC SW-08 X 55 SLVD

1

7

519-0197-064-S

HOSE, ASSEMBLY FJIC SW-08 X 64 SLVD

1

8

519-0197-086-S

HOSE, ASSEMBLY FJIC SW-08 X 86 SLVD

2

9

519-0197-144-S

HOSE, ASSEMBLY FJIC SW-08 X 144 SLVD

10

519-0197-149-S

HOSE, ASSEMBLY FJIC SW-08 X 149 SLVD

1

11

620-1847-029

HOSE, ASSEMBLY FJIC SW-12 X 29 LG

1

12

620-1848-065-S

HOSE, ASSEMBLY, 16 X 65 SLVD

1

13

620-2013-136-S

HOSE, ASSEMBLY FJIC SW-04 X 136 SLVD

2

HYDRAULIC SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-15 Page 145 December 2015

Halvorsen

Figure 23 VALVE BLOCK ASSEMBLY A/C MANIFOLD 625-4073

VALVE BLOCK ASSEMBLY A/C MANIFOLD 625-4073 ITEM

PART NO.

DESCRIPTION

QTY.

3

623-6681-010

VALVE, SUN

1

5

623-6681-015

COIL, 24 VDC, SUN

1

4-15 Page 146 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 16. Electrical System

Assembly

Assy. No.

Figure

Page

1.

CHASSIS ELECTRICAL INSTALLATION

627-9621-001

Figure 1 Sheet 1

2

2.

WINTERIZATION ELECTRICAL INSTALLATION

624-3490

Figure 2 Sheet 1

23

3.

WINTERIZATION BOX ELECTRICAL INSTALLATION

623-5459

Figure 3 Sheet 1

29

4.

ELECTRICAL INSTALLATION, POWER MODULE

628-5469

Figure 4 Sheet 1

34

5.

ELECTRICAL ASSEMBLY, MAIN PANEL

628-0554-001

Figure 5 Sheet 1

44

6.

SCISSOR ELECTRICAL INSTALLATION

628-0414

Figure 6 Sheet 1

58

7.

DECK ELECTRICAL INSTALLATION

624-3249

Figure 7 Sheet 1

67

8.

DECK PANEL ELECTRICAL ASSEMBLY

624-2911

Figure 8 Sheet 1

78

9.

TAIL LIGHT ASSEMBLY, 24V LEFT TURN

624-5754

Figure 9

88

10. TAIL LIGHT ASSEMBLY, 24V RIGHT TURN

624-5756

Figure 10

90

11. CAB ELECTRICAL INSTALLATION

628-0563-001

Figure 11 Sheet 1

92

12. DASH PANEL ELECTRICAL ASSEMBLY

628-0600-001

Figure 12 Sheet 1

103

13. WIPER PANEL ELECTRICAL ASSEMBLY

624-3258

Figure 13 Sheet 1

109

14. CONVEY PANEL ELECTRICAL ASSEMBLY

624-2915

Figure 14 Sheet 1

112

15. A/C CONNECTOR ELECTRICAL ASSEMBLY

627-7214

Figure 15

116

16. PROXIMITY SWITCH ELECTRICAL ASSEMBLY

622-6730

Figure 16

117

17. ACCELERATOR PEDAL ELECTRICAL ASSEMBLY

627-7150

Figure 17

118

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 1 December 2015

Halvorsen

DETAIL A HARNESS CONTINUED ONTO SCISSORS TO PROXIMITY SWITCH

13

DETAIL BG

RIGHT SIDE ISOMETRIC VIEW

Figure 1 Sheet 1 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 21

17 38 25 19

DETAIL A SOME COMPONENTS REMOVED FOR CLARITY

7 71

REF 56

9 DETAIL BG SOME COMPONENTS REMOVED FOR CLARITY

Figure 1 Sheet 2 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 3 December 2015

Halvorsen

DETAIL B

LEFT SIDE ISOMETRIC VIEW

21

38 25 19 17 DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

Figure 1 Sheet 3 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

P

Halvorsen 25 17 19

P

V

V

DETAIL K

4" - 8 THD

VELVAC

N

U

U

DETAIL AD

N

DETAIL J

DETAIL H

Figure 1 Sheet 4 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 5 December 2015

Halvorsen DETAIL AE 49 48 51

47

41

39

50

52

DETAIL AD

49

DETAIL AE SOME COMPONENTS REMOVED FOR CLARITY

Figure 1 Sheet 5 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL C

G

ALTERNATOR 67 POS (+) POST DETAIL H

F

DETAIL W

DETAIL AL

4" - 8 THD

VELVAC

G

DETAIL E

F

DETAIL D

Figure 1 Sheet 6 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 7 December 2015

Halvorsen 28 17 25 38

3LS-A

12 26 29 43

DETAIL C 27 25 38

10SOL 22 11SOL DETAIL D

Figure 1 Sheet 7 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 7

13

DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

24 16 37

SECTION F-F SOME COMPONENTS REMOVED FOR CLARITY

19 25 38

SECTION G-G

21

2LS

Figure 1 Sheet 8 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 9 December 2015

Halvorsen 25 380

60.0

23 14

1

DETAIL J

SECTION M-M

18 25 38

23

22 SECTION N-N

Figure 1 Sheet 9 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen R

R

SECTION P-P

6

STARTER

6

SECTION R-R

Figure 1 Sheet 10 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 11 December 2015

Halvorsen 63

50 22

21

SECTION U-U ROTATED 90 & SOME COMPONENTS REMOVED FOR CLARITY

86

3

4

SECTION V-V ROTATED 90 FOR CLARITY

Figure 1 Sheet 11 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

AB

AB

Halvorsen

DETAIL AA

DETAIL X

WIRES 17, 18 AND 176 DETAIL Y DETAIL W

Figure 1 Sheet 12 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 13 December 2015

Halvorsen 47SOL

9SOL

8SOL

4SOL 21

3SOL

1SOL

13SOL

MANIFOLD ASSEMBLY 7SOL-A 7SOL

3PS

DETAIL AA

Figure 1 Sheet 13 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

31

7TAS

1TAS-A 53 32 11 26 29 43

2LS

33

21

4POT SECTION AB-AB

21 5CON

DETAIL X

5

40 39 41

21

E-PUMP

4

20 8 WIRE #6 DETAIL Y

Figure 1 Sheet 14 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 15 December 2015

Halvorsen 14

42

14

57

45

44 43 46 1

58 14

54 41 61 62

59 62 61 470

69

40 39 41

55 68 58

56 41 61 62

64

58 70

71 66

65

Figure 1 Sheet 15 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen INSTALL GLOW PLUG WIRE FROM ENGINE

50

WIRE 404

WIRE 2 FROM STARTER

WIRE 477

DETAIL AL

60 GROUND +12VDC +24VDC

SECTION BJ-BJ

Figure 1 Sheet 16 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 17 December 2015

Halvorsen

15

58 68

59

M 1SOL-B

M 8 60

L 30

BJ

BJ

21

L

2 57

2 DETAIL K SOME COMPONENTS REMOVED FOR CLARITY

Figure 1 Sheet 17 CHASSIS ELECTRICAL INSTALLATION 627-9621-001 4-16 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

6

(BEHIND ITEM 7) 58

14 SW (+)

7

BATT (+)

71

14

38 25 17

9

2

BATT (-)

69

71 67 1 SW (-)

5 3

SECTION L-L ROTATED 90 FOR CLARITY

Figure 1 Sheet 18 CHASSIS ELECTRICAL INSTALLATION 627-9621-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 19 December 2015

Halvorsen CHASSIS ELECTRICAL INSTALLATION 627-9621-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

621-4966-018

AE-CABLE 2/0 BLK 0.375 - 0.375 W/L

1

2

621-4966-012

AE-CABLE 2/0 BLK 0.375 - 0.375 W/L

2

3

621-4966-066

AE-CABLE 2/0 BLK 0.375 - 0.375 W/L

1

4

624-3481-096

AE-CABLE 2/0 NEG (BLK)

1

5

624-8875-140

AE-CABLE 2/0 RED 0.38 - 0.38, W/L

1

6

621-5428-078

AE-CABLE 2/0 RED 0.312 - 0.375 W/L

1

7

625-4823-096

AE-CABLE 2/0 RED 0.312 - 0.375 W/L

1

8

621-5428-012

AE-CABLE 2/0 RED 0.312 - 0.375 W/L

1

9

519-9424-102

AE-CABLE 4-AWG BLACK 0.25 - 0.375 W/L

1

11

623-8524

AE-LIMIT SWITCH, DPDT

1

12

623-8523

AE-LIMIT SWITCH, SPDT

1

13

628-0554-001

AE-MAIN PANEL, NGSL, ENG

1

14

624-8875-018

AE-CABLE 2/0 RED 0.38 - 0.38, 18 IN.

2

15

623-7304

BATTERY, OPTIMA (12 VOLTS DC)

2

16

107-9418

SCREW, HFLNG 8.8 M10 X 1.5 X 30 MG

4

17

107-9410

SCREW, HFLNG 8.8 M8 X 1.25 X 25 MG

10

18

239-8852-001

CLAMP, SUPPORT 0.50 N.C.

3

19

239-8852-002

CLAMP, SUPPORT 0.75 N.C.

8

20

623-2326

RELAY, POWER 300A, 28 VDC

1

21

628-0553

HE-CHASSIS, NGSL, T3

1

22

624-3262

HE-CHASSIS FRONT

1

23

6223-8831

HORN, 108 DB 335 HZ 24V, SEALED

1

24

107-2180

NUT, PTCH 10 M10 X 1.50 MG

4

25

107-9259

NUT, PTH 8 M8 X 1.25 MG

26

117-7576

NUT, PTH A2 TH #10-24 S.S.

4

27

623-6744

PLATE, COVER

1

28

624-1436

PLATE, PROXIMITY SWITCH REAR

1

4-16 Page 20 December 2015

18

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHASSIS ELECTRICAL INSTALLATION 627-9621-001 ITEM

PART NO.

DESCRIPTION

QTY.

29

107-0780

SCREW, SPAN GR 2 #10-24 X 2 ZP

4

30

620-9056

SW DISCONNECT 2 CIRCUITS

1

31

623-5009

SWITCH, LOW TEMPERATURE 32 F

1

32

514-4745

SWITCH, TEMP. NO ABOVE 180F

1

33

514-3086-004

SENDER, TEMP. WATER 100230 F

1

34

105-0210

NYLON CABLE WRAP, 7.3 IN. - 50 LB

20

35

623-4995

NYLON CABLE WRAP, LARGE 14.5 IN. 50 LB

20

36

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

20

37

107-9276

WASHER, FLAT STD HARD M10 MG

4

38

107-9275

WASHER, FLAT STD HARD M8 MG

18

39

107-9258

NUT, PTH 8 M6 X 1.00 MG

11

40

107-9017

SCREW, HHC-F 8.8 M6 X 1 X 20 MG

6

41

107-9274

WASHER, FLAT STD HARD M6 MG

27

42

624-5019

LANYARD - 9.00 WITH TAB AND SPLIT RING

1

43

107-1975

WASHER, FLAT STD A2 M5 S.S.

8

44

107-1976

NUT, PTH GR A2 M5 X 0.8 S.S.

4

45

624-6252

CONNECTOR, NATO

1

46

107-2512

SCREW, PPAN A2 M5 X 0.8 X 25 S.S.

4

47

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

3

48

1079019

SCREW, HHC-F 8.8 M6 X 1 X 30 MG

2

49

627-8774-001

TCM, AL2100SP TRANSMISSION

1

50

627-6036

HE-AL2100SP TCM, ML44K

1

51

625-9209

BRACKET, TCM

1

52

625-9582

W-SHIELD, TCM WEATHER

1

53

106-1197

BUSHING, HEX 08 MPT X 06 FNPT BR

1

54

624-7821-030

BREAKER, MANUAL HIGH AMP

1

55

624-7821-040

BREAKER, MANUAL HIGH AMP

1

56

627-8723-130

AE-CABLE 8-AWG RED #10-0.31, W/L

1

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 21 December 2015

Halvorsen CHASSIS ELECTRICAL INSTALLATION 627-9621-001 ITEM

PART NO.

DESCRIPTION

QTY.

57

627-1136-036

AE-CABLE 8-AWG BLK 0.38-0.38, W/L

1

58

627-1281-024

AE-CABLE 8-AWG RED 0.25-0.38, W/L

3

59

627-8716-012

AE-CABLE 8-AWG RED 0.38-0.38, W/L

1

60

627-6326

CONVERTER, EQUALIZER

1

61

107-1107

NUT, PTH A2 0.25-20 S.S

6

62

107-1522

SCREW, PPAN GR 2 0.25-20 X 1 S.S.

6

63

627-5817

AE-CAN, ML44K

1

64

620-0757

CONTACTOR, 24V SPNO 50 AMP

1

65

620-2983-001

DIODE, 3 AMP (400V)

1

66

627-7180-012

AE-CABLE 8-AWG RED 0.25-.32, W/L

1

67

625-4823-078

AE-CABLE 1/0 RED 0.312 - 0.375 W/L

1

68

627-8729

AE-CABLE, 12V INTERLOCK

1

69

627-7189-032

AE-CABLE 18-AWG YEL #10 - 0.375, W/L

1

70

627-8702

AE-DIODE, 6A, WITH TERMINAL

1

71

627-8742

HE-12V CONTROL, ML44K

1

* NOT SHOWN

4-16 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 28

30

SECTION B-B

18 14 12

Figure 2 Sheet 1 WINTERIZATION ELECTRICAL INSTALLATION 624-3490

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 23 December 2015

Halvorsen 7 3

4

6

27 SECTION F-F

FROM HYDRAULIC 7 TANK 137”

17 15 23

7 FROM ENGINE 112” GANG BOX

28

SECTION A-A

Figure 2 Sheet 2 WINTERIZATION ELECTRICAL INSTALLATION 624-3490 4-16 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DETAIL D

TRANSMISSION HEATER PAD

DETAIL E

OIL PAN HEATER TO WINTERIZATION 7 BOX

8

4

TANK HEATER 31 20 19 25 16 4

5

4

9

5

DETAIL D SOME ITEMS REMOVED FOR CLARITY

4

8 FROM BATTERY GANGBOX 31”

Figure 2 Sheet 3 WINTERIZATION ELECTRICAL INSTALLATION 624-3490

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 25 December 2015

Halvorsen 6

4

7

TO ENGINE GANGBOX

31 19 25 16

13 10 11

8

4

29

DETAIL E SOME ITEMS REMOVED FOR CLARITY

28

22 21

4AC

3AC

26

SECTION C-C SOME ITEMS REMOVED FOR CLARITY

Figure 2 Sheet 4 WINTERIZATION ELECTRICAL INSTALLATION 624-3490 4-16 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen WINTERIZATION ELECTRICAL INSTALLATION 624-3490 ITEM

PART NO.

DESCRIPTION

QTY.

1

105-0211

NYLON CABLE WRAP, 13.4 IN. - 120 LB

20

2

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

10

3

106-0024

ADAPTER, BUSHING 16 MNPT X 08 FNPT

1

4

106-0125

SEALING RING, 0.50

8

5

106-0135

CONNECTOR, CORD 0.38 LIQUID TIGHT

2

6

106-0142

CONNECTOR, CORD 0.38 90 DEG. LIQUID TIGHT

2

7

106-0517

CONDUIT 0.38 LIQUID TIGHT

8

106-0941

CONNECTOR, CORD 0.50 WATERTIGHT OVAL

3

9

106-0945

CORD, CONNECTOR, 0.5 IN. ST (0.125 - 0.25)

1

10

107-1975

WASHER, FLAT STD A2 M5 S.S.

1

11

107-1976

NUT, PTH A2 M5 X 0.8 S.S.

1

12

107-2071

WASHER, SEALING 0.375 BONDED S.S.

4

13

107-2268

SCREW, PPAN A2 #10-24 X 0.75 S.S.

1

14

107-9081

SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG

4

15

107-9259

NUT, PTH 10 M8 X 1.25 MG

1

16

107-9274

WASHER, FLAT STD HARD M6 MG

8

17

107-9275

WASHER, FLAT STD HARD M8 MG

1

18

107-9285

NUT, HEX 10 M10 X 1.5 MG

4

19

239-3648-002

TERMINAL MEDIUM PIGTAIL SPLICE

5

20

239-3648-003

TERMINAL LARGE PIGTAIL SPLICE

3

21

239-3650-001

TERMINAL SLIP-ON FEMALE 14-AWG INS

1

22

239-3650-002

TERMINAL SLIP-ON FEMALE 10-AWG INS

1

23

239-8852-007

CLAMP, SUPPORT 1.50 NC

1

24

515-3000-014

WIRE 14-AWG (THHN)

25

600682

SCREW, HHC GR 5 0.25-20 X 0.75 MG

8

26

620-1317-003

FLEX-GARD, NYLON SLIT 1/2 IN.

3

27

620-9390

HEATER, 1500W 120V IMMERSION

1

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

24 ft.

135 ft.

4-16 Page 27 December 2015

Halvorsen WINTERIZATION ELECTRICAL INSTALLATION 624-3490 ITEM

PART NO.

DESCRIPTION

QTY.

28

623-5459-001

AE-WINTERIZATION BOX

1

29

623-7310

HEATER, BATTERY 50W

2

30

623-7313

GASKET, M-ENCLOSURE

1

31

623-7321

M-GANG BOX 5 OUTLETS WITH COVER

2

32

624-8942-004

TUBING, SHRINK 3/8 IN.

4-16 Page 28 December 2015

0.6 ft.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

3

3

1

1

4

4 26 42

2 36 35 34 33

1

3

SOME ITEMS REMOVED FOR CLARITY

Figure 3 Sheet 1 WINTERIZATION BOX ELECTRICAL ASSEMBLY 623-5459

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 29 December 2015

Halvorsen 44 38 44 37

40 7

44 28 42

DETAIL E 27

5

DETAIL G

15

44

43

7 40

6 14 SECTION A-A

18 45

20

28

32

32

42 30

42 16

31

45 19

27 43

23 22 39 18 45 SECTION C-C

10 9

8

21

SECTION B-B

Figure 3 Sheet 2 WINTERIZATION BOX ELECTRICAL ASSEMBLY 623-5459 4-16 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 41

20

12 11 13 21

42

43 SECTION D-D 38

39

SECTION F-F

31 31

DETAIL E

DETAIL G

Figure 3 Sheet 3 WINTERIZATION BOX ELECTRICAL ASSEMBLY 623-5459

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 31 December 2015

Halvorsen WINTERIZATION BOX ELECTRICAL ASSEMBLY 623-5459 ITEM

PART NO.

DESCRIPTION

QTY.

1

106-0006

LOCKNUT, #141 1/2 IN. CONDUIT

3

2

106-0078

CORD CONNECTOR, 0.5 IN. ST (0.25-0.375)

1

3

106-0125

SEALING - 1/2 IN. O-RING

3

4

106-0142

CONNECTOR, CORD 0.38 90º LIQUID TIGHT

2

5

107-0806

RIVET - CHERRY SST

2

6

107-1073

SCREW, HHC A2 0.31-18 X 1 S.S.

4

7

107-1111

NUT, PTH A2 0.31-18 S.S.

4

8

107-1382

SCREW, SPAN A2 #8-32 X 0.75 S.S.

2

9

107-1482

NUT, PTH A2 #8-32 S.S.

2

10

107-1919

WASHER, FLAT NARROW A2 #10 S.S.

4

11

107-2006

NUT, PTH A2 M4 X 0.7 S.S.

4

12

107-2063

SCREW, SPAN A2 M4 X 0.7 X 20 S.S.

4

13

107-2074

WASHER, SEAL A2 M4 S.S.

4

14

107-2203

WASHER, SEALING 0.312 BONDED S.S.

4

15

107-2871

WASHER, FLAT STD 0.31 S.S.

4

16

107-2872

SCREW, PPAN A2 #6-32 X 0.25 S.S.

4

17

239-3646-013

TERMINAL, RING 0.375 10-AWG

1

18

239-3650-001

TERMINAL SLIP-ON FEMALE 14-AWG INS

4

19

239-3650-002

TERMINAL SLIP-ON FEMALE 10-AWG INS

3

20

239-8418

RELAY, 120V 50/60 HZ DPDT

1

21

514-2056-006

RELAY, SOCKET 8 PIN OCTAL (DIN)

1

22

515-1210-003

CIRCUIT BREAKER (MINI-MAG) 15A

1

23

515-1420

CIRCUIT BREAKER, BOOT

1

24

515-3000-010

WIRE 10-AWG (THHN)

1 ft.

25

515-3000-014

WIRE 14-AWG (THHN)

30 ft.

26

620-1049-003

CONTROL CABLE 18-AWG, 3 COND.

27

622-0244-001

MOUNTING TRACK, 2M DIN

4-16 Page 32 December 2015

2 ft. 1

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen WINTERIZATION BOX ELECTRICAL ASSEMBLY 623-5459 ITEM

PART NO.

DESCRIPTION

QTY.

28

622-0244-003

END PLATE COVER (USK)

1

29

622-0244-005

MARKER STRIP (USK) 10 BLANKS

1

30

622-0244-007

TERMINAL BLOCK, 26-8 AWG USK10

5

31

622-0244-009

TERMINAL BLOCK, GROUND 20-8 AWG

2

32

622-0244-023

INSERTION BRIDGE 10 POS USK10

1

33

622-2967-003

CONNECTOR, RECEPTACLE 3 POS (MALE)

1

34

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

3

35

622-2967-019

CONNECTOR, WEDGE 3 POS RECEPTACLE

1

36

622-2967-047

CONNECTOR, BOOT 3 POS RECEPTACLE

1

37

622-7277-001

VAPOR CORROSION INHIBITOR 5CU

1

38

623-7306

PLUG, MALE 3 PRONG 30A WITH COVER

1

39

623-7307

RELAY, 240V 50/60 HZ SPDT

1

40

623-7308

TRANSFORMER, AUTO 3 KVA 50/60 HZ

1

41

623-7309-001

PLACARD, HIGH VOLTAGE CAUTION

1

42

623-7314

M-ENCLOSURE WINTERIZATION BOX

1

43

623-7315

M-INNER PANEL WINTERIZATION

1

44

623-7316

DECAL, WINTERIZATION BOX

1

45

624-8942-003

TUBING, SHRINK 3:3, BLACK 1/4 IN.

5 ft.

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 33 December 2015

Halvorsen

DETAIL C

DETAIL A DETAIL B

NON-CAB SIDE ISOMETRIC VIEW

REF 628-0554-001 ENG-R 32

Figure 4 Sheet 1 ELECTRICAL INSTALLATION, POWER MODULE 628-5469 4-16 Page 34 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 32 7POT-B 22

DETAIL A 32 SB-1

REF 623-3700-006

DETAIL B SOME ITEMS REMOVED FOR CLARITY

Figure 4 Sheet 2 ELECTRICAL INSTALLATION, POWER MODULE 628-5469

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 35 December 2015

32 12BUS1

6CON 32 WIRE #477

34 ECAN-P REF 627-3290-221

12 10 4

DETAIL C

34 ECUK-P

REF 627-3290-087

24 20

RED WIRE TO POSITIVE 27 TERMINAL

STATOR HOUSING

26

17 16 18

28

BLUE & 27 ORANGE WIRE

ALTERNATOR 32

BLACK WIRE 27 30 TO GROUND TERMINAL

5

7

6 19

29

REF 627-6211

23

6CON 32 WIRE #404

Halvorsen

Figure 4 Sheet 3 ELECTRICAL INSTALLATION, POWER MODULE 628-5469 4-16 Page 36 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

22

7POT-A 32

7POT 32

31

22

ITAS 32 WIRE #474 TO “NO” WIRE #1 TO “G”

10MTR-P 32

DETAIL E

REF 627-3958

32 9MTR-P

REF 627-3958

Halvorsen

Figure 4 Sheet 4 ELECTRICAL INSTALLATION, POWER MODULE 628-5469

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 37 December 2015

DETAIL H

TOP VIEW

DETAIL F

DETAIL E

Halvorsen

Figure 4 Sheet 5 ELECTRICAL INSTALLATION, POWER MODULE 628-5469 4-16 Page 38 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen IPS 32 WIRE #57 TO “NO” WIRE #1 TO “G”

29

21

1 CON WIRE #8 32 REF 625-5699

SECTION D-D SOME ITEMS REMOVED FOR CLARITY 3POT WIRE #53 32 REF 232-8790-011

3POT WIRE #1 32

DETAIL F

Figure 4 Sheet 6 ELECTRICAL INSTALLATION, POWER MODULE 628-5469

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 39 December 2015

Halvorsen

EXTERNAL 32 REG-P

27 25

32 PFTEMP-P 8

9 11 32 2HTR-P

32 WNF-P

15 14 13

REF 627-3290-222 30

27 SECTION J-J SOME ITEMS REMOVED FOR CLARITY

Figure 4 Sheet 7 ELECTRICAL INSTALLATION, POWER MODULE 628-5469 4-16 Page 40 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

DETAIL H SOME ITEMS REMOVED FOR CLARITY

REF 627-2969

BUS477 32

REF 627-6149

PCAN-P 32

DCAN-R 32

TCMENG-P 32

REF 627-6036

Halvorsen

Figure 4 Sheet 8 ELECTRICAL INSTALLATION, POWER MODULE 628-5469

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 41 December 2015

Halvorsen ELECTRICAL INSTALLATION, POWER MODULE 628-5469 ITEM

PART NO.

DESCRIPTION

QTY.

1

105-0210

NYLON CABLE WRAP, 7.3 IN. - 50 LB

2

105-0211

NYLON CABLE WRAP, 13.4 IN. - 120 LB

3

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

4

107-0015

SCREW, HHC GR 5 0.5-13 X 6.5 ZP

1

5

107-1107

NUT, PTH A2 0.25-20 S.S.

2

6

107-1522

SCREW, PPAN GR 2 0.25-20 X 1 S.S.

2

7

107-1927

WASHER, FLAT STD A2 0.25 S.S

4

8

107-1975

WASHER, FLAT STD A2 M5 S.S.

8

9

107-1976

NUT, PTH GR A2 M5 X 0.8 S.S.

4

10

107-2125

WASHER, FLAT NARROW 0.56 MG

2

11

107-2170

SCREW, HHC A2 M5-0.8 X 20

4

12

107-2257

NUT, PTH GR 5 TH 0.5-13 MG

1

13

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

2

14

107-9258

NUT, PTH 8 M6 X 1.00 MG

2

15

107-9274

WASHER, FLAT STD HARD M6 MG

4

16

107-9278

WASHER, FLAT STD HARD M12 MG

2

17

110-0065

SCREW, HHC GR 5 0.5-13 X 1.75 ZP

1

18

110-0237

NUT, PTH GR 5 0.5-13 ZP

1

19

238-8421

RELAY, SOLENOID

1

20

239-3646-013

TERMINAL, RING 0.375 10-AWG

1

21

621-1874

SWITCH, OIL PRESSURE

1

22

623-8537

SENSOR, TEMPERATURE FAN DRIVE CONT.

3

23

623-9915

AE-DIODE WITH RING TERMINALS

1

24

624-8942-004

TUBING, SHRINK 3:1, BLACK 3/8 IN.

1

25

625-4112-001

REGULATOR, EXTERNAL

1

26

625-4112-004

ALTERNATOR, 24 VDC, 120A, T3

1

27

625-4112-005

HE-EXT REGULATOR, T3

1

4-16 Page 42 December 2015

31 5 10

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ELECTRICAL INSTALLATION, POWER MODULE 628-5469 ITEM

PART NO.

DESCRIPTION

QTY.

28

625-4828

CABLE, GROUND 1/0, 16 IN.

1

29

627-1436-024

AE-CABLE 8-AWG RED 0.32-0.38, W/L

1

30

627-5536

PLATE, EXTERNAL REGULATOR

1

31

627-7213

SWITCH, TEMPERATURE, 125 ºF

1

32

628-5454

HE-POWER MOD

1

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 43 December 2015

Halvorsen 13 12 41

13 12 149

CUT 19.75 65 66 65 66 CUT 17.25

CUT 22.50 61

13 12 41

13 12 41

CUT 15.38 65 66

66 65 CUT 9.25

5 61 65 66 CUT 17.10 5 61 65 66 5

61 17 11 67 13

CUT 18.00 65 66 CUT 19.83 65 66 CUT 15.00 61

102 123

Figure 5 Sheet 1 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 4-16 Page 44 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

137

113

13 12 41

CUT 19.50 61

5

CUT 19.50 66 65

13 17 11

67

CUT 19.50 61

5

CUT 66 65 19.50

67

13 17 11

CUT 19.50 61

125

SECTION A-A

108

C

B

FDC-RA

FDC-PC FDC-PB FDC-PA FDC-RB

118

117

3

4

3

C

3

13 17 11 35

105 MAIN STUD

13 17 2 45

B

98

13 17 18

100

94

73 80 83 FDC-PA

75 80 69 85 FDC-PB

72 78 82 FDC-RA

74 78 84 69 FDC-RB

72 78 82 FDC-RC

Halvorsen

Figure 5 Sheet 2 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 45 December 2015

Halvorsen 11

13 17 126 127 REV NEU RPM (NEG)

13

98 RPM (POS)

12

LAMP POWER 41

SHIFT POWER PTO IN

SECTION B-B

PTO OUT

98

S/S ORG INGR-RED BATT-BLUE

GRN-BLK BLU-RED/BLK BLU-RED/BLK

IGNS-GRN

HI-GRN/BLK HI-GRN/BLK

SSOL-WHT SECTION C-C

Figure 5 Sheet 3 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 4-16 Page 46 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 32-SOL WIRE #127 29-SOL WIRE #125

30-SOL WIRE #127

12 46-SOL WIRE #153

PALLET STOP AND CONVEY MODULE LIFT MANIFOLD 37 38 39 DETAIL F SOME COMPONENTS REMOVED FOR CLARITY

31

REFER TO 624-3263 HE-MAIN PANEL TO DECK BOX

12FT 16 12 27 22

DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

1

34-SOL WIRE #135

35-SOL WIRE #136

33-SOL WIRE #133 36-SOL WIRE #140

40-SOL WIRE #138

41-SOL WIRE #143

37-SOL WIRE #139

38-SOL WIRE #134

CONVEY MODULE CONVEYING MANIFOLD

39-SOL WIRE #144 42-SOL WIRE #142 DETAIL G SOME COMPONENTS REMOVED FOR CLARITY

12

Figure 5 Sheet 4 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 47 December 2015

108

42 21 114

23 21 114

8

122

129

122

131

52

55

56

39

57

108

90

60

58

129

89

59

91

60

92

39 38 7

DETAIL G

122

108

108

129

108

93

88

114 43 22

114 29 20

130 8

7 15

Halvorsen

Figure 5 Sheet 5 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 4-16 Page 48 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 143 138 13RES 12RES 135

136 11RES

138 14RES 138 17RES

143 138 19RES

15RES 138 8RES 136

138 16RES

10RES 138

138 18RES

9RES 135 143

60 91 59

DETAIL G

Figure 5 Sheet 6 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 49 December 2015

Halvorsen 30 45 45

108

28 45

2PB-1

WL-TGS

15TGS

45 30 45 7TGS

1TGS-A

2TGS-A

7

8 15

71 78 69 70

MP-RA

MP-RB

128

68 69 78 71

ENG-R

MP-RC

71 78 69 68

CHS-FRT

CHAS-R

120 121 69 78 79

128

113 3

140 121 69 78

3 115

SECTION D-D

Figure 5 Sheet 7 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 4-16 Page 50 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 11

13 17 128 10 9

15 8

7

99

108 31

46

SECTION E-E

Figure 5 Sheet 8 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 51 December 2015

145

9 10

145

47

17 2 13

97

32

96

35

37 40

49

145

44 47 48

17 2 13

119 47

17 2 13

112 6

36 40

8

92

7 38 39

129

108

31 95 46 11 17 34 24 26 25 27

7 124 8 15

89

Halvorsen

Figure 5 Sheet 9 ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 4-16 Page 52 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

DWG-623-9526

DWG-ELECT FABRICATION PRACTICES

1

2

HFS0148

SCREW, SRND A2 #10-32 X 0.75 S.S.

8

3

106-0006

LOCKNUT, #141 1/2 IN. CONDUIT

5

4

106-0079

CORD CONNECTOR, 0.5 IN. ST (0.375-0.50)

1

5

107-0811

RIVET, PRO 0.188 X 0.25 ALUMINUM

6

107-1107

NUT, PTH A2 0.25-20 S.S.

7

107-1382

SCREW, SPAN A2 #8-32 X 0.75 S.S.

56

8

107-1482

NUT, PTH A2 #8-32 S.S.

56

9

107-1522

SCREW, PPAN GR 2 0.25-20 X 1 S.S.

4

10

107-1927

WASHER, FLAT STD A2 0.25 S.S.

4

11

107-2061

SCREW, SPAN A2 #10-32 X 1 S.S.

77

12

107-2090

NUT, HEX A2 #10-24 S.S.

24

13

107-2091

WASHER, FLAT A2 #10 S.S.

69

15

107-2322

WASHER, FLAT A2 #8 S.S.

30

17

107-2324

NUT, PTH A2 #10-32 S.S.

89

18

107-2325

SCREW, SRND A2 #10-32 X 1.75 S.S.

4

20

237-5752-001

SWITCH GUARD, RED

1

21

237-5752-005

SWITCH GUARD, RED (ALT KEYWAY)

3

22

237-7505

SWITCH, DPDT TOGGLE (ON) OFF (ON)

1

23

239-0854

SWITCH, DPDT TOGGLE ON ON (ON)

1

24

239-2601-005

CIRCUIT BREAKER, 5A, #8 TERMINAL

3

25

239-2601-010

CIRCUIT BREAKER, 10A, #8 TERMINAL

15

26

239-2601-015

CIRCUIT BREAKER, 15A, #8 TERMINAL

7

27

239-2601-020

CIRCUIT BREAKER, 20A, #8 TERMINAL

2

28

239-3121

JUMPER, TOGGLE SWITCH

1

29

239-3327

SWITCH, SPST TOGGLE OFF - ON

1

30

239-3646-022

TERMINAL, RING

3

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

27 2

4-16 Page 53 December 2015

Halvorsen ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 ITEM

PART NO.

DESCRIPTION

QTY.

31

239-3646-003

TERMINAL, RING

32

239-3646-004

TERMINAL, RING #10 14-AWG

6

33

239-3646-006

TERMINAL, RING 0.312 14-AWG

1

34

239-3646-009

TERMINAL, RING

27

35

239-3646-012

TERMINAL, RING

5

36

239-3646-016

TERMINAL, RING 0.250 8-AWG

1

37

239-3646-017

TERMINAL, RING 0.312 8-AWG

1

38

239-3650-001

TERMINAL SLIP-ON FEMALE 14-AWG INS

44

39

239-3650-003

TERMINAL SLIP-ON FEMALE 18-AWG INS

58

40

239-8101-008

WIRE, INSULATED, AUTO, 8-AWG RED THHN

41

3616387

SCREW, PPAN A2 #10-24 X 0.5 S.S.

42

515-3065

SWITCH, SPDT TOGGLE (ON) ON

2

43

519-8841

SWITCH GUARD, 3 POSITIONS

1

44

620-0757

CONTACTOR, 24V SPNO 50 AMP

2

45

620-1240-002

TERMINAL, RING

18

46

620-1240-003

TERMINAL, RING #8 18-AWG

18

47

620-1240-004

TERMINAL, RING #10 18-AWG

37

48

620-1240-006

TERMINAL, RING

2

49

620-2983-001

DIODE, 3 AMP, 400V

3

50

620-3900-014

WIRE, 14-AWG, GXL, YELLOW

51

620-3900-018

WIRE STRANDED YELLOW 18 GA GXL

52

620-4478-004

RESISTOR, 300K 0.5W 5%

1

55

620-9546

MOUNT, TIME DELAY

3

56

621-1033-002

TIME DELAY MOD. (1-100 SEC.)

1

57

621-1034

FLASHER-24V S.S.

2

58

621-2736

RELAY, SOCKET LY2

14

59

621-2737

TRACK MOUNTED SOCKET PTF14

12

60

621-2738

RELAY HOLD-DOWN CLIP

52

4-16 Page 54 December 2015

20

3 24

60 520

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 ITEM

PART NO.

DESCRIPTION

QTY.

61

622-0244-001

MOUNTING TRACK, 2 M DIN

62

622-0244-002

TERMNAL BLOCK, 22-12 AWG

83

63

622-0244-004

TERMINAL BLOCK, END CAP

4

64

622-1345-001

RELAY, LY2 12 VDC WITH LED

1

65

622-1358-011

DUCT, WIRING (2 IN. X 2 IN.)

16

66

622-1358-012

DUCT, WIRING, COVER (2 IN.)

16

67

622-1560

STANDOFF, 0.5 IN. DELRIN

12

68

622-2962-005

CONNECTOR, RECP, DRC FLANGE 40 “A”

69

622-2962-009

CONNECTOR, SEALING PLUG

70

622-2962-010

CONNECTOR, RECP, DRC FLANGE 40 “B”

1

71

622-2962-020

CONNECTOR, GASKET, DRC, RECP 40 POS

3

72

622-2967-001

CONNECTOR, RECP 2 POS (MALE)

2

73

622-2967-002

CONNECTOR, PLUG 2 POS (FEMALE)

1

74

622-2967-003

CONNECTOR, RECP 3 POS (MALE)

1

75

622-2967-004

CONNECTOR, PLUG 3 POS (FEMALE)

1

78

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

200

79

622-2967-014

CONNECTOR, PIN 14-16 AWG SOLID

11

80

622-2967-015

CONNECTOR, SOCKET 16-18 AWG SOLID

4

82

622-2967-017

CONNECTOR, WEDGE 2 POS RECP

2

83

622-2967-018

CONNECTOR, WEDGE 2 POS PLUG

1

84

622-2967-019

CONNECTOR, WEDGE 3 POS RECP

1

85

622-2967-020

CONNECTOR, WEDGE 3 POS PLUG

1

88

622-5906

SWITCH, PUSH-BUTTON, N.C., RED

1

89

622-6214-004

RELAY 24V SPDT WITH DIODE, BRACKET

19

90

622-6328

RELAY, LY2 24VDC WITH DIODE

13

91

622-6328-001

RELAY, LY4 24VDC WITH DIODE

12

92

622-7161

M-MOUNT, MODULE DIN

14

93

622-7165

E-STOP GUARD WITH FINGER HOLES

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

2

2 57

1

4-16 Page 55 December 2015

Halvorsen ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 ITEM

PART NO.

DESCRIPTION

QTY.

94

622-7277-001

VAPOR CORROSION INHIBITOR 5CU

95

623-1506

GASKET, CDM CIRCUIT BREAKER

27

96

623-1513-012

AE-CABLE 12.0 IN. (4-AWG / RED)

1

97

623-1513-048

AE-CABLE 48.0 IN. (4-AWG / RED)

1

98

623-7300-002

STONE BENNETT ACCESSORY BOX

1

99

623-7848

BUSS BAR, GROUND 20 POSITION

1

100

627-0334

AE-CONTROLLER, FAN DRIVE ML44K

1

102

624-2907

ME-PNL FOR (624-2903)

1

105

624-2919

TERMINAL BLOCK, SINGLE STUD 0.31 IN.

1

108

624-3244

DE-MAIN PANEL

1

112

624-7821-040

BREAKER, MANUAL HIGH AMP

1

113

625-4733

M-CORD CONNECTOR, 0.5 IN. ST (0.125-0.25)

2

114

625-8370

SEAL, PANEL BUSHING

5

115

625-8413

CORD CONNECTOR, 5 HOLE, 4X 0.12, 1X 0.20

1

117

106-0007

LOCKNUT CONDUIT 3/4 IN.

1

118

106-0086

CONNECTOR CORD 0.75 (0.50-0.625)

1

119

238-8421

RELAY, SOLENOID

1

120

622-2962-001

CONNECTOR, RECP, DRC FLANGE 70 “A”

1

121

622-2962-035

CONNECTOR, GASKET, DRC, RECP 70 POS

2

122

622-6214-003

RELAY, CUBE 12V WITH DIODE

7

123

627-6055

ME-ENCL (30 X 24 X 10), ML44K

1

124

627-6467-001

PE-MAIN PANEL CB’S, ML44K, ENG

1

125

627-6471

PLATE, SUB-PANEL, MEP

1

126

627-6474

PLATE, SUB-PANEL, MEP

1

127

627-6475

HINGE, CONT., 2.0 W, 0.187 PIN

1

128

627-6478

A-BRKT, SUB-PANE, STOP

2

129

627-1539

DE-MAIN PANEL, ML44K

1

130

624-7170

PE-MAIN PANEL E-STOP

1

4-16 Page 56 December 2015

1

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 ITEM

PART NO.

DESCRIPTION

QTY.

131

239-3650-002

TERMINAL SLIP-ON FEMALE 10-AWG INS

132

620-3900-010

WIRE, STRANDED YELLOW 10 GA GXL

15

133

620-3900-012

WIRE, STRANDED YELLOW 12 GA GXL

15

134

621-5215-001

TUBING, HEAT SHRINK 0.12/0.25 1 FT.

4

135

625-6920-475

RESISTOR, MF 475 0.4W 1%

2

136

625-6920-590

RESISTOR, MF 590 0.4W 1%

2

137

627-6540

CORD CONNECTOR, 2 HOLE, 2X 0.20

1

138

625-6920-003

RESISTOR, MF 1.00K 0.4W 1%

8

139

622-0244-007

TERMINAL BLOCK, 18-8 AWG USK10

1

140

622-2962-022

CONNECTOR, RECP, DRC FLANGE 70 “B”

1

141

622-0244-005

MARKER STRIP (USK) 10 BLANKS

142

622-0244-003

END PLATE COVER (USK)

2

143

624-8942-205

TUBING, SHRINK 3:1, CLEAR 1/2 IN.

1

144

624-8942-206

TUBING, SHRINK 3:1, CLEAR 3/4 IN.

0.5

145

239-3647-003

TERMINAL, RING 0.312 4-AWG

6

146

622-0244-022

INSERTION BRIDGE 10 POS USK4

1

147

515-5917-004

TUBING 1/2 SPIRAL WRAP

10

148

624-8942-055

TUBING, SHRINK 3:1, BLACK 1/2 IN.

0.3

149

107-2874

SCREW, PPAN A2 #10-24 X 0.375 S.S.

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

1

8.1

6

4-16 Page 57 December 2015

Halvorsen

TOP VIEW

DETAIL B

Figure 6 Sheet 1 SCISSOR ELECTRICAL INSTALLATION 628-0414 4-16 Page 58 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 17

16

31

14 30 297 CONNECTS TO 16CB

32 SECTION A-A ROTATED 90 FOR CLARITY

29 28

8

6

7

1 11

3 18 9

3

5

6

28 29 DETAIL B

Figure 6 Sheet 2 SCISSOR ELECTRICAL INSTALLATION 628-0414

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 59 December 2015

Halvorsen DETAIL C 31 TO 627-6423 30

297 CONNECTS 17CB LOCATED IN DECK BOX

DETAIL D

DETAIL E

LEFT SIDE ISO VIEW

Figure 6 Sheet 3 SCISSOR ELECTRICAL INSTALLATION 628-0414 4-16 Page 60 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 23SOL

14SOL

25SOL

16SOL

27SOL 21SOL 15 DETAIL C

15 20SOL 18SOL

DETAIL E

10

4

2 13

12 2 10

4

DETAIL D

Figure 6 Sheet 4 SCISSOR ELECTRICAL INSTALLATION 628-0414

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 61 December 2015

Halvorsen DETAIL F

DETAIL G DETAIL M DETAIL H

28 29

DETAIL M

3 27

Figure 6 Sheet 5 SCISSOR ELECTRICAL INSTALLATION 628-0414 4-16 Page 62 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 17SOL

24SOL

15SOL

26SOL

28SOL 22SOL 15

DETAIL F

15

10 10

DETAIL G

DETAIL H

Figure 6 Sheet 6 SCISSOR ELECTRICAL INSTALLATION 628-0414

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 63 December 2015

Halvorsen

DETAIL K

DETAIL J

22 23 24 4

15

DETAIL J

BOOT SUPPLIED WITH LIGHT ITEM 22 25 26

DETAIL K NTS

REAR VIEW

Figure 6 Sheet 7 SCISSOR ELECTRICAL INSTALLATION 628-0414 4-16 Page 64 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen SCISSOR ELECTRICAL INSTALLATION 628-0414 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-0780

SCREW, SPAN GR 2 #10-24 X 2 ZP

8

2

107-9017

SCREW, HHC-F 8.8 M6 X 1 X 20 MG

4

3

107-9259

NUT, PTH 8 M8 X 1.25 MG

11

4

107-9274

WASHER, FLAT STD HARD M6 MG

12

5

107-9275

WASHER, FLAT STD HARD M8 MG

1

6

107-9410

SCREW, HFLNG 8.8 M8 X 1.25 X 25 MG

9

7

110-0253

WASHER, FLAT STD #10 ZP

8

8

117-7576

NUT, PTH A2 TH #10-24 S.S.

8

9

239-8852-019

CLAMP, SUPPORT 1.31 NC

1

10

622-6730

A-PROXIMITY SWITCH, 18 MM

2

11

623-8523

AE-LIMIT SWITCH, SPDT

4

12

623-9529

W-PROXY SWITCH

1

13

624-1419

W-PROXY SWITCH

1

14

624-3263

HE-MAIN BOX TO CABIN (C)

1

15

624-3264

HE-SCISSORS

1

16

624-3267

HE-MAIN BOX TO CABIN (A)

1

17

624-3268

HE-MAIN BOX TO CABIN (B)

1

18

624-4057

BRACKET, LIMIT SWITCH, SCISSOR

4

19

105-0210

NYLON CABLE WRAP, 7.3 IN. - 50 LB

25

20

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

25

21

623-4995

NYLON CABLE WRAP, LARGE 14.5 IN. 50 LB

25

22

624-7167

ULTRA BEAM, LT WORK

2

23

624-7175

INSERT, M6 X 1.0 CLOSED END, BLIND

8

24

107-9016

SCREW, HHC-F 8.8 M6 X 16 MG

8

25

239-3650-003

TERMINAL SLIP-ON FEMALE 18-AWG INS

4

26

621-5215-001

TUBING, HEAT SHRINK 0.12/0.25

1

27

239-8852-001

CLAMP, SUPPORT 0.5 N.C.

2

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 65 December 2015

Halvorsen SCISSOR ELECTRICAL INSTALLATION 628-0414 ITEM

PART NO.

DESCRIPTION

QTY.

28

HX0006

ROPE, WIRE 1/16 IN. S.S.

4

29

624-7434

CONNECTOR

4

30

625-4961-480

AE-CABLE 8-AWG RED #10-0.25, W/L

1

31

627-6418

HE-ECAB

1

32

627-2969

HE-SPEEDOMETER LONG

1

* NOT SHOWN

4-16 Page 66 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

DETAIL E

DETAIL F

DETAIL G

Halvorsen

Figure 7 Sheet 1 DECK ELECTRICAL INSTALLATION 624-3249

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 67 December 2015

Halvorsen 32-SOL WIRE #127 29-SOL WIRE #125

30-SOL WIRE #127

12 46-SOL WIRE #153

PALLET STOP AND CONVEY MODULE LIFT MANIFOLD 37 38 39 DETAIL F SOME COMPONENTS REMOVED FOR CLARITY

31

REFER TO 624-3263 HE-MAIN PANEL TO DECK BOX

12FT 16 12 27 22

DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

1

34-SOL WIRE #135

35-SOL WIRE #136

33-SOL WIRE #133 36-SOL WIRE #140

40-SOL WIRE #138

41-SOL WIRE #143

37-SOL WIRE #139

38-SOL WIRE #134

CONVEY MODULE CONVEYING MANIFOLD

39-SOL WIRE #144 42-SOL WIRE #142 DETAIL G SOME COMPONENTS REMOVED FOR CLARITY

12

Figure 7 Sheet 2 DECK ELECTRICAL INSTALLATION 624-3249 4-16 Page 68 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 57 48 36

8 8

8

36 48 56 52

DETAIL N

56 48 36

53

8

DETAIL P

54 48 47 36

8

18

54

8

36 47 48

18

52 36 47 48 46 53

0.5 FT SECTION U-U

46 0.5 FT

48 47 36 SECTION V-V

Figure 7 Sheet 3 DECK ELECTRICAL INSTALLATION 624-3249

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 69 December 2015

18 52

36

12

0.5 FT

46

9 20 28 40

12

20 28 40 3

SECTION B-B SOME COMPONENTS REMOVED FOR CLARITY

53

0.5 FT

46

18

12

53

8

36

DETAIL N

5

8

6

12

20 28 33

29 32

2

9

6

29 32

6

29 32

8

DETAIL P

4

20 28 33

52

Halvorsen

Figure 7 Sheet 4 DECK ELECTRICAL INSTALLATION 624-3249 4-16 Page 70 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 17

50 60 44 43

DETAIL C

59 DETAIL M

DETAIL H DETAIL K

DETAIL J REFER TO 624-3267 HE-MAIN PANEL TO CABIN (A) REFER TO 624-3268 HE-MAIN PANEL TO CABIN (B)

13

DETAIL M

49 48 36 23 DETAIL C

27 6.5 FT

Figure 7 Sheet 5 DECK ELECTRICAL INSTALLATION 624-3249

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 71 December 2015

11

12

50

11

40 28 20

2

7

DETAIL K

12

50

17

46 0.5 FT

Halvorsen

Figure 7 Sheet 6 DECK ELECTRICAL INSTALLATION 624-3249 4-16 Page 72 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

11

11

12

DETAIL J

61

Halvorsen

Figure 7 Sheet 7 DECK ELECTRICAL INSTALLATION 624-3249

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 73 December 2015

Halvorsen DETAIL W

56 48 36

8

55

8

SECTION AA-AA

55 17

17 46

46

0.5 FT

9

36 47 48

12

34 28 20 14

48 47 36 34 28 15 20

0.5 FT

8 9

46

46

0.5 FT

0.5 FT

SECTION A-A

14 20 28 34

34 28 20 15

Figure 7 Sheet 8 DECK ELECTRICAL INSTALLATION 624-3249 4-16 Page 74 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 46 0.5 FT

17

8

48 47 36

36 47 48

8 8

51 8

57 48 36

36 48 57

55 DETAIL W

27 4.5 FT 23

42 44 43 1 DETAIL H

Figure 7 Sheet 9 DECK ELECTRICAL INSTALLATION 624-3249

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 75 December 2015

Halvorsen DECK ELECTRICAL INSTALLATION 624-3249 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-2911

AE-DECK PANEL NGSL

1

2

623-8524

LIMIT SWITCH ASSEMBLY, DPDT

2

3

623-8523

LIMIT SWITCH ASSEMBLY, SPDT

2

4

624-5754

24V LEFT TURN ASSEMBLY

1

5

624-5756

24V RIGHT TURN ASSEMBLY

1

6

107-9063

SCREW, HHC, 8.8 M8 X 1.25 X 45 MG

5

7

624-3485

BRACKET, FRONT LIMIT SWITCH

1

8

239-8852-001

CLAMP, SUPPORT 0.50 NC

22

9

239-8852-002

CLAMP, SUPPORT 0.75 NC

6

11

239-8852-004

CLAMP, SUPPORT 1.00 NC

7

12

624-3265

HE-DECK

1

13

624-3478

HE-DECK BOX TO CABIN

1

14

627-5110

AE-HEADLIGHT, 24V ADJUSTABLE

2

15

623-7323

LIGHT, AMBER 24V

2

16

620-1317-001

FLEX -GARD, NYLON SPLIT 5/16 IN.

17

623-7324

AE-MARKER LIGHT, AMBER

4

18

623-7325

AE-MARKER LIGHT, RED

4

20

117-7576

NUT, PTH A2 TH #10-24 S.S.

22

239-3646-011

TERMINAL, RING 0.25 10-AWG

2

23

239-3646-013

TERMINAL RING 0.375 10-AWG

2

24

105-0210

NYLON CABLE WRAP, 7.3 IN. - 50 LB

35

25

623-4995

NYLON CABLE WRAP, LARGE 14.5 IN. 50 LB

35

26

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

20

27

519-8558-010

WIRE, STRANDED BLACK 10 GA GXL

11

28

107-1975

WASHER, FLAT STD A2 M5 S.S.

28

29

107-9275

WASHER, FLAT STD HARD M8 MG

8

31

627-8859

W-BRACKET, COMPRESSOR A/C

1

32

107-9259

NUT, PTH 8 M8 X 1.25 MG

5

4-16 Page 76 December 2015

12

32

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DECK ELECTRICAL INSTALLATION 624-3249 ITEM

PART NO.

DESCRIPTION

QTY.

33

107-2220

SCREW, PAN HEAD PHILLIPS, A2 #10-24 X 1.5 S.S.

12

34

107-2268

SCREW, PAN HEAD PHILLIPS, A2 #10-24 X 0.75 S.S.

12

36

107-9450

WASHER, FENDER STD HARD M6 MG

38

37

107-9261

NUT, PTH 8 M12 X 1.75 MG

4

38

107-9278

WASHER, FLAT STD HARD M12 MG

8

39

107-9094

SCREW, HEX FLANGE, 8.8 M12 X 1.75 X 50 MG

4

40

107-2265

SCREW, SOCKET PAN HEAD, GR 2 #10-24 X 2.25 S.S.

8

42

107-9418

SCREW, HHC 8.8 M10 X 1.5 X 30 MG

4

43

107-9276

WASHER, FLAT STD HARD, M10 MG

8

44

107-9260

NUT, PTH 8 M10 X 1.50 MG

6

46

620-1317-009

FLEX-GARD, NYLON SLIT 1/4 IN.

5

47

107-9018

SCREW, HEX HEAD CAP - FULL THREAD 8.8 M6 X 1 X 25 MG

10

48

107-9258

NUT, PTH 8 M6 X 1.00 MG

17

49

107-9017

SCREW, HEX HEAD CAP - FULL THREAD 8.8 M6 X 1 X 20 MG

1

50

625-5670

HE-LEFT FRONT EXT MARKER LIGHT

1

51

625-5671

HE-RIGHT FRONT EXT MARKER LIGHT

1

52

625-5672

HE-LEFT REAR EXT MARKER LIGHT

1

53

625-5673

HE-RIGHT REAR EXT MARKER LIGHT

1

54

625-5741

BRACKET, REAR MARKER LIGHT

2

55

625-6115

HE-RIGHT FRONT DECK EXTENSION

1

56

107-9019

SCREW, HEX HEAD CAP - FULL THREAD 8.8 M6 X 1 X 30

3

57

107-9031

SCREW, HEX HEAD CAP 8.8 M6 X 1 X 40

3

59

625-8097

GUARD, LIMIT SW BOLT-ON

1

60

107-9084

SCREW, HEX HEAD CAP 8.8 M10 X 1.5 X 50 MG

2

61

239-8852-003

CLAMP, SUPPORT 0.88 NC

2

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 77 December 2015

Halvorsen COVER REMOVED 9 FOR CLARITY 29 18 20

28

12

8 LY-4 24V

4 3 2 1

10

9 12

8 LY-4 24V

4 1

3 3

2

LY-2 24V LY-2 24V

2 1

27 67

4

8

6

3

2

4

31CR

LY-2 24V LY-2 24V

5

30CR

8

6

3

5

4

6

1

37CR 36CR

4

1

3

2

LY-2 24V

38CR

4

6

7 5 6 5

7

2

LY-2 24V

5

7

39CR

13

8 7

1

1

9 6

33CR

10

8 7

5

2

14

11

8 7

3 2

A

26CR

1

13

8

5

4

7 6

3

14

11

34CR

7 6 5

4 19 18 21 25 41

8

57 68

39 17 58

AC-P4 60 56 55 54

AC-P3

52 64 53 59

Figure 8 Sheet 1 DECK PANEL ELECTRICAL ASSEMBLY 624-2911 4-16 Page 78 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

22 6

9 22

22

6

6

5

5

A

A

C

A

5

5

6

6

22

22

COVER REMOVED FOR CLARITY

C

B

5

B

11 39 25 26 41

11 39 25 26 41

Halvorsen

Figure 8 Sheet 2 DECK PANEL ELECTRICAL ASSEMBLY 624-2911

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 79 December 2015

35 46 23 14 45 AC-P4

AC-P3

DBOX-RB

15

2

45 14 23 46 34

34 46 23 14 45

2

2

15

15

DBOX-RC

DBOX-RA

Halvorsen

Figure 8 Sheet 3 DECK PANEL ELECTRICAL ASSEMBLY 624-2911 4-16 Page 80 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

SECTION B-B

DBOX-RC

61 47

3

49

61 47

61 47

48

30

DBOX-RB

SECTION A-A

65

47 61

10

9

DBOX-RA

4

Halvorsen

Figure 8 Sheet 4 DECK PANEL ELECTRICAL ASSEMBLY 624-2911

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 81 December 2015

51 36 46 23 45

1

SECTION C-C

BUS

Halvorsen

Figure 8 Sheet 5 DECK PANEL ELECTRICAL ASSEMBLY 624-2911 4-16 Page 82 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

51 62

SECTION D-D D

D

44 46 45

42

39

19CB

51

51

18CB

17CB

42

42

39

38 39

38 41

4

41 37

41

Halvorsen

Figure 8 Sheet 6 DECK PANEL ELECTRICAL ASSEMBLY 624-2911

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 83 December 2015

40

43

40

40

Halvorsen

Figure 8 Sheet 7 DECK PANEL ELECTRICAL ASSEMBLY 624-2911 4-16 Page 84 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DECK PANEL ELECTRICAL ASSEMBLY 624-2911 ITEM

PART NO.

DESCRIPTION

QTY.

1

623-7848

BUSS BAR, GROUND 20 POS

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

3

624-8297

CONNECTOR, CORD, 0.5 IN. ST, 2 WIRE

1

4

623-9135

DECAL, DECK BOX

1

5

622-1358-011

DUCT, WIRING, 2 IN. X 2 IN.

7 ft.

6

622-1358-012

DUCT, WIRING COVER 2 IN.

7 ft.

7

DWG-623-9526

DWG-ELECTRICAL FABRICATION PRACTICES

1

8

622-7161

M-MOUNT, MODULE DIN

1

9

624-2905

ME-ENCL (24 X 20 X 8)

1

10

624-2929

ME-PNL FOR (624-2905)

1

11

622-0244-001

MOUNTING TRACK, 2M DIN

1

14

622-2962-009

PLUG, SEALING CONNECTOR

15

622-2962-005

CONNECTOR, RECEPTACLE, DRC 40 “A”

2

16

622-2962-001

CONNECTOR, RECEPTACLE, DRC FLANGE 70 “A”

1

17

622-6214-004

RELAY, 24V SPDT WITH DIODE, BRACKET

1

18

621-2738

RELAY, HOLD-DOWNS CLIP

19

622-6328

RELAY, LY2 24 VDC WITH DIODE

6

20

622-6328-001

RELAY, LY4 24 VDC WITH DIODE

2

21

621-2736

RELAY, SOCKET LY2

6

22

107-0811

RIVET, PRO, 0.188 X 0.25 ALUMINUM

12

23

107-2875

SCREW, PPAN ROUND GR 2 #8-32 X 0.75 ZP

12

25

107-2858

SCREW, PPAN A2 #10-32 X 0.75 S.S.

7

26

622-1560

STANDOFF, 0.5 IN. DELRIN

6

27

622-0244-002

TERMINAL BLOCK, 22-12 AWG

28

622-0244-004

END CAP

2

29

621-2737

TRACK MOUNTED SOCKET PTF 14

2

30

622-7277-001

VAPOR CORROSION INHIBITOR 5CU

1

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

1 125

25

16

67

4-16 Page 85 December 2015

Halvorsen DECK PANEL ELECTRICAL ASSEMBLY 624-2911 ITEM

PART NO.

DESCRIPTION

QTY.

34

622-2962-020

CONNECTOR, GASKET, DRC, RECEP. 40 POS

2

35

622-2962-035

CONNECTOR, GASKET, DRC, RECEP. 70 POS

1

36

239-3646-003

TERMINAL, RING #8 14-AWG

8

37

239-2601-010

CIRCUIT BREAKER, 10A, #8 TERMINAL

1

38

239-2601-015

CIRCUIT BREAKER, 15A, #8 TERMINAL

2

39

107-2324

NUT, PTH A2 #10-32 S.S.

40

107-2873

SCREW, PPAN A2 #10-32 X 1 S.S.

41

107-2091

WASHER, FLAT A2 #10 S.S.

42

623-1506

GASKET, CDM CIRCUIT BREAKER

3

43

625-4950

PE-DECK PANEL CB’S

1

44

107-2867

SCREW, PPAN A2 #8-32 X.5 S.S.

4

45

107-1482

NUT, PTH A2 #8-32 S.S.

18

46

107-2322

WASHER, FLAT A2 #8 S.S.

18

47

106-0006

LOCKNUT, #141 1/2 IN. CONDUIT

4

48

106-0079

CORD CONNECTOR, 0.5 IN. ST (0.375-0.50)

1

49

625-4733

M-CORD CONNECTOR, 0.5 IN. ST (0.125-0.25)

1

51

239-3646-009

TERMINAL, RING #8 10-AWG

52

622-2967-006

CONNECTOR, PLUG 4 POS (FEMALE)

1

53

622-2967-022

CONNECTOR, WEDGE 4 POS PLUG

1

54

625-4919-006

CONNECTOR, PLUG 4 POS (FEMALE)

1

55

625-4919-016

CONNECTOR, SOCKET (12-14 AWG) SOLID

4

56

625-4919-022

CONNECTOR, WEDGE 4 POS PLUG

1

57

239-1754

CORD, 16-AWG 4 COND TYPE SJTO

5 ft.

58

HEW0056

CORD, ELECTRICAL 12/4 SO

5 ft.

59

624-8942-006

TUBING, SHRINK

3 in.

60

624-8942-007

TUBING, SHRINK 1.0

3 in.

61

106-0125

SEALING - 1/2 IN. O-RING

62

620-3900-010

WIRE, STRANDED YELLOW 10 GA GXL

4-16 Page 86 December 2015

13 6 13

11

4 2 ft.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DECK PANEL ELECTRICAL ASSEMBLY 624-2911 ITEM

PART NO.

DESCRIPTION

QTY.

63

620-3900-018

WIRE, STRANDED YELOW 18 GA GXL

64

622-2967-015

CONNECTOR, SOCKET (16-18 AWG) SOLID

4

65

106-0081

CORD CONNECTOR, 0.5 IN. ST (0.5-0.625)

1

67

622-0244-005

MARKER STRIP (USK) 10 BLANKS

7

68

623-4929-003

CONDUIT, FLEXIBLE NYLON 0.5 IN.

69

621-5215-001

TUBING, HEATSHRINK 0.12/0.25

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

200 ft.

0.83 ft. 2

4-16 Page 87 December 2015

Halvorsen

REV. A

Figure 9 TAIL LIGHT ASSEMBLY, 24V LEFT TURN 624-5754 4-16 Page 88 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen TAIL LIGHT ASSEMBLY, 24V LEFT TURN 624-5754 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-7682

TAIL LIGHT ASSEMBLY

1

2

620-0231-001

LENS, YELLOW TAIL LIGHT

1

3

622-2962-009

PLUG, SEALING CONNECTOR

1

4

622-2967-014

CONNECTOR, PIN 12-14 AWG SOLID

5

5*

620-4710

LAMP, 24V, STOP / TAIL

1

6*

620-0796

LAMP, 28V, #1683

1

7

622-2967-007

CONNECTOR, RECEP. 6 POS MALE

1

8

622-2967-023

CONNECTOR, WEDGE 6 POS RECEPTACLE

1

9*

622-2967-049

BOOT, 6 POS RECEPTACLE

1

10*

620-0231-002

LENS, RED / WHITE

1

11*

620-0231-003

LENS, RED

2

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 89 December 2015

Halvorsen

REV. A

Figure 10 TAIL LIGHT ASSEMBLY, 24V RIGHT TURN 624-5756 4-16 Page 90 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen TAIL LIGHT ASSEMBLY, 24V RIGHT TURN 624-5756 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-7682

TAIL LIGHT ASSEMBLY

1

2

620-0231-001

LENS, YELLOW TAIL LIGHT

1

3

622-2962-009

PLUG, SEALING CONNECTOR

1

4

622-2967-014

CONNECTOR, PIN 12-14 AWG SOLID

5

5*

620-4710

LAMP, 24V, STOP / TAIL

1

6*

620-0796

LAMP, 28V, #1638

1

7

622-2967-007

CONNECTOR, RECEPTACLE 6 POS MALE

1

8

622-2967-023

CONNECTOR, WEDGE 6 POS RECEPTACLE

1

9*

622-2967-049

BOOT, 6 POS RECEPTACLE

1

10*

620-0231-002

LENS, RED / WHITE

1

11*

620-0231-003

LENS, RED

2

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 91 December 2015

Halvorsen 9 13 14 9 24

DETAIL D 4

18 4 DETAIL F

5

6

30

DETAIL F

DETAIL D LEFT SIDE ISO VIEW

Figure 11 Sheet 1 CAB ELECTRICAL INSTALLATION 628-0563-001 4-16 Page 92 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL E

16 9

DETAIL E

RIGHT SIDE ISO VIEW

Figure 11 Sheet 2 CAB ELECTRICAL INSTALLATION 628-0563-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 93 December 2015

Halvorsen 3MTR-A

CABIN RA

23 CABIN RB

BACK VIEW REAR WIPER MOTOR

CABIN RC 23 DETAIL G

DETAIL K

DETAIL J

DETAIL L

DETAIL H SECTION A-A DETAIL K LEFT VIEW

Figure 11 Sheet 3 CAB ELECTRICAL INSTALLATION 628-0563-001 4-16 Page 94 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 8

23

3

21

23

3

7

DETAIL B

DETAIL G

REAR WIPER MOTOR REFERENCE ONLY

DOME LIGHT REFERENCE ONLY 3

7

7

23 DETAIL H

DETAIL J

Figure 11 Sheet 4 CAB ELECTRICAL INSTALLATION 628-0563-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 95 December 2015

Halvorsen DETAIL L

8

3

23

DETAIL M

SECTION D-D

BACK VIEW

Figure 11 Sheet 5 CAB ELECTRICAL INSTALLATION 628-0563-001 4-16 Page 96 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 23

DETAIL L 1

15 9

40

TSIG-R 23 TSIG-P

17

DETAIL M

Figure 11 Sheet 6 CAB ELECTRICAL INSTALLATION 628-0563-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 97 December 2015

Halvorsen

17 FLASHER SWITCH 3 10

DETAIL S 28 DETAIL R

29

19 BRAKE SWITCH

ISO VIEW CAB REMOVED FOR CLARITY

22 PRESSURE SWITCH

Figure 11 Sheet 7 CAB ELECTRICAL INSTALLATION 628-0563-001 4-16 Page 98 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 1 13 M

20

41A 70

11 ALARM

2PS-A DETAIL R 4MTR-A

SHOWN ON DRAWING 624-3486

4MTR DETAIL N

DETAIL S

Figure 11 Sheet 8 CAB ELECTRICAL INSTALLATION 628-0563-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 99 December 2015

Halvorsen

23

DETAIL N

ISO VIEW COMPLETE INSTALLATION CAB REMOVED FOR CLARITY

Figure 11 Sheet 9 CAB ELECTRICAL INSTALLATION 628-0563-001 4-16 Page 100 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 84D CONNECT TO L 84C CONNECT TO H

3MTR

84E CONNECT TO P FRONT WIPER MOTOR VIEW FROM INSIDE CAB UNDER DASH PANEL

UPPER RUBBER SEAL

LOWER RUBBER SEAL

INSTALL SPOT LIGHTS AS SHOWN ALL PARTS SHOWN ARE INCLUDED WITH LIGHT

Figure 11 Sheet 10 CAB ELECTRICAL INSTALLATION 628-0563-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 101 December 2015

Halvorsen CAB ELECTRICAL INSTALLATION 628-0563-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

105-0210

NYLON CABLE WRAP, 7.3 IN. - 50 LB

20

2

105-0214

NYLON CABLE WRAP, 3.6 IN. - 18 LB

20

3

107-0047

SCREW, SHWTAP F #10-24 X 0.5 ZP

15

4

107-9046

SCREW, HHC 8.8 M8 X 1.25 X 25 MG

7

5

107-9259

NUT, PTH 8 M8 X 1.25 MG

7

6

107-9275

WASHER, FLAT STD HARD M8 MG

6

7

239-9076-004

CLAMP, 0 0.50 STEEL CUSHIONED

6

8

239-9076-008

CLAMP, P 1.00 STEEL CUSHIONED

6

9

620-0805-003

SCREW, SPAN 4.8 M4 X 0.7 X 20 ZP

26

10

622-6214-004

RELAY, 24V SPDT WITH DIODE, BRACKET

3

11

622-7926-001

ALARM, SONEALERT 65DB

1

12

623-4995

NYLON CABLE WRAP, LARGE 14.5 IN. - 50 LB

*

624-6624-001

BULB, H3 24V 70W

1

13

623-7300-003

SHIFTER, JOYSTICK STONE BENNETT

1

14

624-2915

AE-CONVEY PANEL

1

15

624-3258

AE-WIPER PANEL

1

16

628-0600-001

AE-PANEL DASH, ML25K3P, ENG

1

17

624-3486

AE-TURN SIGNAL

1

18

627-7150

AE-PEDAL, TIER 3

1

19

624-3943

SWITCH, LOW PRESSURE

1

20

624-5018

BRACKET, HARNESS

1

21

624-6625

AE-LIGHT, SPOT 24 VDC

2

22

624-7180

AE-SWITCH, PRESSURE

1

23

625-4055

HE-CAB

1

24

520-1001-004

SEAL, PLUG BUTTON 0.875 IN. WHITE

1

27

627-6423

HE-ECAB2

1

28

627-5730

HE-CAN, CAB, SHORT

1

29

627-2971

HE-SPEEDOMETER, SHORT

1

30

627-7122

W-ACCELERATOR PEDAL STAND

1

31

621-5215-001

TUBING, HEAT SHRINK 0.12/0.25

2

10

* NOT SHOWN

4-16 Page 102 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 75

39 40

80

73 37

76

35 38 41 25 9 36 71 25 54 87 74 22 18 20

77

23 18 20

71 14 25 71

55 33 15 39

19 18

35 24 18 20

6 21 18 20

12

16 26 33 55

Figure 12 Sheet 1 DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 103 December 2015

Halvorsen

Figure 12 Sheet 2 DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001 4-16 Page 104 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

2TACH-P1

Halvorsen

83 84 29 69

2GA-P

67

68

70

1GA-P

67

70

68

FROM CCAN-P (REF)

67

CAN GAUGE DETAIL NOT TO SCALE

Figure 12 Sheet 3 DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 105 December 2015

Halvorsen DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-2962-018

CONNECTOR, BOOT 70 POS PLUG OR RECEPTACLE

1

2

DWG-623-9526

DWG-ELECTRICAL FABRICATION PRACTICES

1

3

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

9

4

622-2967-012

CONNECTOR, PLUG 12 POS (FEMALE)

1

5

622-2967-008

CONNECTOR, PLUG 6 POS (FEMALE)

3

6

622-2967-028

CONNECTOR, WEDGE 12 POS PLUG

1

7

622-2967-024

CONNECTOR, WEDGE 6 POS PLUG

3

8

623-9137

DE-DASH PANEL

1

9

623-5913-006

GAUGE, FUEL LEVEL 24V

1

12

623-5913-008

GAUGE, HOURMETER

1

14

623-5913-007

GAUGE, HYDRAULIC TEMPERATURE

1

15

624-3252

AE-JOYSTICK AND CARD, RAISE / LOWER

1

16

519-6725

JOYSTICK, 4 WAY

1

17

239-3121

JUMPER, TOGGLE SWITCH

1

18

620-0764

LAMP, 24V #1864 (T3 1/4)

19

519-2207

AE-LIGHT, PANEL ILLUMINATION 1/2 X 1/2

20

620-0763-001

LIGHT, PILOT, BASE

21

620-0763-004

LIGHT, PILOT, LENS, AMBER

8

22

620-0763-007

LIGHT, PILOT, LENS, BLUE

1

23

620-0763-003

LIGHT, PILOT, LENS, GREEN

2

24

620-0763-002

LIGHT, PILOT, LENS, RED

25

623-5913-009

LIGHT KIT, 24 VDC

3

26

107-1482

NUT, PTH A2 #8-32 S.S.

4

29

622-2962-009

CONNECTOR, SEALING PLUG

30

622-2967-052

RECEPTACLE, 12 POS WITH BUSSED PINS

1

31

622-2967-054

RECEPTACLE, 6 POS WITH BUSSED PINS

3

32

622-2962-003

CONNECTOR, PLUG, DRC, 70 “A” KEY

1

4-16 Page 106 December 2015

24 3 22

11

18

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001 ITEM

PART NO.

DESCRIPTION

QTY.

33

107-2844

SCREW, PRND GR 2 #8-32 X 0.75 S.S.

6

35

238-1579

SWITCH, SPDT TOGGLE (ON) OFF (ON)

2

36

238-6221

SWITCH, SPDT TOGGLE ON ON

1

37

239-0854

SWITCH, DPDT TOGGLE ON ON (ON)

1

38

232-8790-101

SWITCH, DPST TOGGLE ON ON

1

39

515-3065

SWITCH, SPDT TOGGLE (ON) ON

2

40

622-5906

SWITCH, PUSH-BUTTON, N.C., RED

1

41

622-6481

GUARD, TOGGLE SWITCH

1

43

519-5559-009

TERMINAL FEMALE SLIP-ON 18-AWG X 0.187

8

44

239-3650-001

TERMINAL SLIP-ON FEMALE 14-AWG INS

1

45

239-3650-003

TERMINAL SLIP-ON FEMALE 18-AWG INS

1

46

239-3646-004

TERMINAL, RING #10 14-AWG

4

47

620-1240-004

TERMINAL, RING #10 18-AWG

1

48

239-3646-001

TERMINAL, RING #4 14-AWG

23

49

620-1240-001

TERMINAL, RING #4 18-AWG

28

50

239-3646-008

TERMINAL, RING

1

51

239-3646-002

TERMINAL, RING #6 14-AWG

5

52

620-1240-002

TERMINAL, RING #6 18-AWG

12

53

621-5215-001

TUBING, HEAT SHRINK 0.12/0.25

4

54

623-5913-003

GAUGE, VOLTS, 24 VDC

1

55

107-2322

WASHER, FLAT A2 #8 S.S.

6

57

620-3900-018

WIRE, STRANDED YELLOW 18 GA GXL

59

624-2920

CONNECTOR, 9 POS (FEMALE)

1

60

624-2921

CONNECTOR, PIN (FEMALE)

8

61

622-2967-015

CONNECTOR, SOCKET (16-18 AWG) SOLID

62

624-6609

VARISTOR, METAL OXID 31 VDC

1

63

622-2967-001

CONNECTOR, RECP 2 POS (MALE)

1

64

622-2967-017

CONNECTOR, WEDGE 2 POS RECP

1

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

225

94

4-16 Page 107 December 2015

Halvorsen DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001 ITEM

PART NO.

DESCRIPTION

QTY.

67

622-2967-062

CONNECTOR, RECP 3 WAY Y

3

68

627-1824

HE-CAN, CAB GAUGE

2

69

627-1854

HE-CAN, CAB GAUGE W/RES.

1

70

627-1862

HE-CAN, INTERCONNECT

2

71

520-1001-006

SEAL, PLUG BUTTON 0.5 IN. BLACK

3

72

625-6920-002

RESISTOR, MF 2.61K 0.4 1%

1

73

627-6033-001

PE-PANEL DASH, ML44K, ENG

1

74

627-6469

GAUGE, COOLANT TEMPERATURE 280 F

1

75

627-6468

GAUGE, TACHOMETER 3500 RPM

1

76

627-7141-001

AE-GAUGE, SPEEDOMETER, ENG

1

77

627-6470

GAUGE, OIL PRESSURE 100 PSI

1

78

622-2967-027

CONNECTOR, WEDGE 12 POS RECP

1

79

622-2967-011

CONNECTOR, RECP 12 POS (MALE)

1

80

627-2005

LAMP, 12 VDC BA9S RED LED

1

81

623-4929-007

CONDUIT, FLEXIBLE NYLON 1-3/16 IN.

2

82

620-3900-014

WIRE STRANDED YELLOW 14 GA GXL

1

83

622-2967-004

CONNECTOR, PLUG 3 POS (FEMALE)

1

84

622-2967-020

CONNECTOR, WEDGE 3 POS PLUG

1

85

622-2967-022

CONNECTOR, WEDGE 4 POS PLUG

1

86

622-2967-006

CONNECTOR, PLUG 4 POS (FEMALE)

1

87

520-1001-007

SEAL, PLUG BUTTON 0.687 IN.

1

88

624-2913-001

CONTROL CARD, DECK RAISE / LOWER

1

* NOT SHOWN

4-16 Page 108 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A

Figure 13 Sheet 1 WIPER PANEL ELECTRICAL ASSEMBLY 624-3258

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 109 December 2015

Halvorsen

Figure 13 Sheet 2 WIPER PANEL ELECTRICAL ASSEMBLY 624-3258 4-16 Page 110 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen WIPER PANEL ELECTRICAL ASSEMBLY 624-3258 ITEM

PART NO.

DESCRIPTION

QTY.

1

239-5109-005

CIRCUIT BREAKER, 3 AMP

2

2

622-2967-014

CONNECTOR, PIN 12-14 AWG SOLID

1

3

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

11

4

622-2967-010

CONNECTOR, PLUG 8 POS FEMALE

1

5

622-2967-011

CONNECTOR, RECEP. 12 POS MALE

1

6

622-2967-016

CONNECTOR, SOCKET 14-16 AWG SOLID

4

7

622-2967-015

CONNECTOR, SOCKET 16-18 AWG SOLID

10

8

622-2967-027

CONNECTOR, WEDGE 12 POS RECEP

1

9

622-2967-026

CONNECTOR, WEDGE 8 POS PLUG

1

10

623-9136*

DECAL, PANEL WIPER

1

11

624-0786

DIMMER SWITCH

2

12

625-3469

A-DIMMER SWITCH BEZEL

1

624-0786-003

SWITCH, DIMMER BEZEL

1

14

239-3121

JUMPER, TOGGLE SWITCH

1

15

620-0764

LAMP, 24V

1

16

519-2207

AE-LIGHT, PANEL ILLUMINATOR 1/2 X 1/2

1

17

624-3259*

PE-PANEL WIPER

1

18

622-7278-002

SPLICE PARALLEL, 10-09 AWG

1

19

237-5490

SWITCH, TOGGLE DPDT

3

20

238-0520

SWITCH, TOGGLE SPDT

2

21

239-3650-003

TERMINAL, SLIP-ON FEMALE 18-AWG INS

4

22

622-7278-001

TERMINAL, SPLICE PARALLEL 14-AWG

2

23

620-1240-001

TERMINAL, RING #4 18-AWG

1

24

239-3646-002

TERMINAL, RING #6 14-AWG

3

25

620-1240-002

TERMINAL, RING #6 18-AWG

17

26

621-5215-001

TUBING, HEAT SHRINK 1 FT.

1

27

621-5215-002

TUBING, HEAT SHRINK 1 FT.

2

28*

620-3900-014

WIRE, STRANDED YELLOW 14 GA GXL

18 ft.

29*

620-3900-018

WIRE, STRANDED YELLOW 18 GA GXL

17 ft.

*

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 111 December 2015

Halvorsen

Figure 14 Sheet 1 CONVEY PANEL ELECTRICAL ASSEMBLY 624-2915 4-16 Page 112 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 14 Sheet 2 CONVEY PANEL ELECTRICAL ASSEMBLY 624-2915

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 113 December 2015

Halvorsen CONVEY PANEL ELECTRICAL ASSEMBLY 624-2915 ITEM

PART NO.

DESCRIPTION

QTY.

1

624-2917

JOYSTICK AND CARD, CONVEY

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

12

3

622-2967-011

CONNECTOR, RECEP. 12 POS MALE

1

4

622-2967-027

CONNECTOR, WEDGE 12 POS RECEP.

1

5

624-3245*

DECAL, CONVEY PANEL

1

6*

DWG-623-9526

ELECTRICAL FABRICATION PRACTICES

1

7

620-0764

LAMP, 24V

6

8

237-5418

LIGHT, PANEL ILLUMINATOR

1

9

620-0763-001

LIGHT, PILOT, BASE

5

10

620-0763-003

LIGHT, PILOT, LENS, GREEN

3

11

620-0763-002

LIGHT, PILOT, LENS, RED

2

12

118-5262

NUT, PTH GR 5 #10-32 ZP

2

13

111-7119

SCREW, PAN ROUND GR 2 #10-32 X 1.50 ZP

2

14

238-6221

SWITCH, TOGGLE SPDT

4

15

237-5490

SWITCH, TOGGLE DPDT

1

16

515-3065

SWITCH, TOGGLE SPST

1

17

622-2967-017

CONNECTOR, WEDGE 2 POS RECEP.

1

18

622-2962-009

PLUG, SEALING CONNECTOR

1

19

239-3646-001

TERMINAL, RING #4 14-AWG

5

20

620-1240-001

TERMINAL, RING #4 18-AWG

7

21

239-3646-008

TERMINAL, RING #6 10-AWG

6

22

239-3646-002

TERMINAL, RING #6 14-AWG

5

23

620-1240-002

TERMINAL, RING #6 18-AWG

4

24

621-5215-001

TUBING, HEATSHRINK 0.12/0.25 1 FT.

25

620-3900-018

WIRE, STRANDED YELLOW 18 GA GXL

26*

107-1919

WASHER, FLAT NARROW A2 #10 S.S.

2

27

624-2914*

PLACARD, CONVEY PANEL

1

4-16 Page 114 December 2015

1

3 ft. 18 ft.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CONVEY PANEL ELECTRICAL ASSEMBLY 624-2915 ITEM

PART NO.

DESCRIPTION

QTY.

28

622-7278-001

TERMINAL, SPLICE PARALLEL 14-AWG

1

29

622-2967-014

CONNECTOR, PIN 12-14 AWG SOLID

1

30

622-2967-001

CONNECTOR, RECEP. 2 POS MALE

1

33

624-2920

CONNECTOR, 9 POS FEMALE

1

34

624-2921

CONNECTOR, PIN FEMALE

9

35

624-6609

VARISTOR, METAL OXIDE 31 VDC

1

36

622-6481

SWITCH, TOGGLE GUARD

5

37

624-2913-002

CONTROL CARD, CONVEY

5

* NOT SHOWN

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 115 December 2015

Halvorsen 5

4

3

2

2 9MTR-R

3

4

5

10MTR-R

1

Figure 15 A/C CONNECTOR ELECTRICAL ASSEMBLY 627-7214

A/C CONNECTOR ELECTRICAL ASSEMBLY 627-7214 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-4404

A-CAC

1

2

622-2967-001

CONNECTOR, RECP 2 POS (MALE)

2

3

622-2967-014

CONNECTOR, PIN 14-16 AWG SOLID

4

4

622-2967-017

CONNECTOR, WEDGE 2 POS RECP

2

5

622-2967-046

CONNECTOR, BOOT 2 POS RECP

2

6

DWG-623-9526

DWG-ELECTRICAL FABRICATION PRACTICES

1

4-16 Page 116 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 12.00 304.8

A (BLUE)

C (BLACK)

1

6

2

5

WIRE

3

4

B (BROWN)

PIN BODY

STRIP WIRE BACK FAR ENOUGH TO BE ABLE TO BE DOUBLED OVER. THIS IS NECESSARY TO INSURE PROPER CRIMPING OF PIN BODIES.

Figure 16 PROXIMITY SWITCH ELECTRICAL ASSEMBLY 622-6730

PROXIMITY SWITCH ELECTRICAL ASSEMBLY 622-6730 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-6729

PROXIMITY SWITCH 18 MM

1

2

622-2967-003

CONNECTOR, RECP 3 POS (MALE)

1

3

622-2967-019

CONNECTOR, WEDGE 3 POS RECP

1

4

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

3

5

621-5215-004

TUBING, HEATSHRINK 0.38/0.75 1 FT.

0.2 ft.

6

621-5215-002

TUBING, HEATSHRINK 0.18/0.38 1 FT.

0.2 ft.

7

DWG-623-9526

ELECTRICAL FABRICATION PRACTICES

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

1

4-16 Page 117 December 2015

Halvorsen

3-D REF VIEW 32.0 17.0

AT IDLE

AT WIDE OPEN THROTTLE

8.22 208.8

B BLACK

1

GREEN

ORANGE 1 2 3

6 5 4

RED 6.17

VIOLET

WHITE

REAR VIEW OF CONNECTOR

156.7

3 2 4

6

5

13.1

1.90

0.78

48.3

19.8

0.97 2.87

1.94

72.9

49.3

24.7

0.46 11.8

Figure 17 ACCELERATOR PEDAL ELECTRICAL ASSEMBLY 627-7150 4-16 Page 118 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen ACCELERATOR PEDAL ELECTRICAL ASSEMBLY 627-7150 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-4095

PEDAL, ACCELERATOR, TIER3, NSS

1

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

6

3

622-2967-007

CONNECTOR, RECP 6 POS (MALE)

1

4

622-2967-023

CONNECTOR, WEDGE 6 POS RECP

1

5

622-2967-049

CONNECTOR, BOOT 6 POS RECP

1

6

623-4929-002

CONDUIT, FLEXIBLE NYLON 0.38 IN.

2

ELECTRICAL SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-16 Page 119 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 17. Identification

Assembly

Assy. No.

Figure

Page

1.

IDENTIFICATION INSTALLATION, CHASSIS

623-5500-001

Figure 1 Sheet 1

2

2.

IDENTIFICATION INSTALLATION, CAB

623-5500-002

Figure 2 Sheet 1

7

3.

IDENTIFICATION INSTALLATION, DECK

623-5500-003

Figure 3 Sheet 1

12

4.

MAINTENANCE STANDARD DECAL KIT

627-4879

Figure 4 Sheet 1

18

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 1 December 2015

Halvorsen

REV. E Figure 1 Sheet 1 IDENTIFICATION INSTALLATION, CHASSIS 623-5500-001 4-17 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 1 Sheet 2 IDENTIFICATION INSTALLATION, CHASSIS 623-5500-001

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 3 December 2015

Halvorsen

Figure 1 Sheet 3 IDENTIFICATION INSTALLATION, CHASSIS 623-5500-001 4-17 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 17

Figure 1 Sheet 4 IDENTIFICATION INSTALLATION, CHASSIS 623-5500-001

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 5 December 2015

Halvorsen IDENTIFICATION INSTALLATION 623-5500-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

515-8930

DECAL, NO STEP WARNING

2

515-8933

DECAL, HOT EXHAUST

2

3

515-9904

DECAL, DIESEL

1

4

519-2556

DECAL, DANGER, HIGH VOLTAGE

1

5

622-7213

DECAL, BRIDGE WARNING

1

6

622-7902

DECAL, HOT EXHAUST WARNING

3

7

623-0350

REFLECTIVE STRIP, 2 X 10 SILVER

12

8

624-1204

DECAL, NATO PLUG

1

9

624-5139

STENSIL, TIE DOWN

2

10

624-5141

STENSIL, T.P. 100 PSI

2

11

624-5143

STENSIL, HYDRAULIC OIL

1

12

624-5145

DECAL, BATTERY DISCONNECT

1

13

624-6063

DECAL, HYDRAULIC LEVEL MX STAND

1

14

624-6064

DECAL, DECK FULLY DOWN

1

15

624-5144

STENSIL, TOW POINT

1

16

624-6607

DECAL, DANGER 120 VOLTS

3

17

624-0313

PLACARD, DOT FLIP HAZARD

1

18

624-7169

STENSIL, 25 000 LB

2

4-17 Page 6 December 2015

10

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

REV. A Figure 2 Sheet 1 IDENTIFICATION INSTALLATION, CAB 623-5500-002

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 7 December 2015

Halvorsen

Figure 2 Sheet 2 IDENTIFICATION INSTALLATION, CAB 623-5500-002 4-17 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 2 Sheet 3 IDENTIFICATION INSTALLATION, CAB 623-5500-002

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 9 December 2015

Halvorsen

Figure 2 Sheet 4 IDENTIFICATION INSTALLATION, CAB 623-5500-002 4-17 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen IDENTIFICATION INSTALLATION, CAB 623-5500-002 ITEM

PART NO.

DESCRIPTION

QTY.

1

515-9904

DECAL, DIESEL

1

2

622-7883

DECAL, HAND PINCHPOINT WARNING

3

3

623-0350

REFLECTIVE STRIP, 2 X 10 SILVER

4

624-5149

DECAL, MAINTENANCE SUPPORT WARNING

2

5

624-5148

DECAL, WASHER RESERVOIR

1

-6

625-4852

DECAL, WASHER FLUID

1

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

18

4-17 Page 11 December 2015

Halvorsen

REV. C Figure 3 Sheet 1 IDENTIFICATION INSTALLATION, DECK 623-5500-003 4-17 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 3 Sheet 2 IDENTIFICATION INSTALLATION, DECK 623-5500-003

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 13 December 2015

Halvorsen

Figure 3 Sheet 3 IDENTIFICATION INSTALLATION, DECK 623-5500-003 4-17 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 3 Sheet 4 IDENTIFICATION INSTALLATION, DECK 623-5500-003

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 15 December 2015

Halvorsen

Figure 3 Sheet 5 IDENTIFICATION INSTALLATION, DECK 623-5500-003 4-17 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen IDENTIFICATION INSTALLATION, DECK 623-5500-003 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-7883

DECAL, HAND PINCH POINT WARNING

1

2

623-0350

REFLECTIVE STRIP, 2 X 10 SILVER

3*

624-0313

PLACARD, DOT FLIP HAZARD

3

4

624-5137

STENSIL, HARNESS REQUIRED

1

5

624-5140

DECAL, SLING POINT

1

6

624-5139

STENCIL, TIE DOWN

1

7

624-7169

STENCIL, 25 000 LB.

1

24

* NOT SHOWN

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 17 December 2015

Halvorsen

Figure 4 Sheet 1 MAINTENANCE STANDARD DECAL KIT 627-4879 4-17 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 Sheet 2 MAINTENANCE STANDARD DECAL KIT 627-4879

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 19 December 2015

Halvorsen

Figure 4 Sheet 3 MAINTENANCE STANDARD DECAL KIT 627-4879 4-17 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 Sheet 4 MAINTENANCE STANDARD DECAL KIT 627-4879

IDENTIFICATION The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-17 Page 21 December 2015

Halvorsen MAINTENANCE STANDARD DECAL KIT 627-4879 ITEM

PART NO.

DESCRIPTION

QTY.

1

627-8696

DE-RIGHT SIDE, MAINTENANCE STAND

1

2

627-8698

DE-LEFT SIDE, MAINTENANCE STAND

1

3

627-8288

DE-MAINTENANCE STAND

2

4-17 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen Section 18. Air Conditioning System

Assembly

Assy. No.

Figure

Page

1.

AIR CONDITIONER CONDENSER FAN

625-3088

Figure 1

2

2.

AIR CONDITIONER COMPRESSOR MOTOR

625-3089-500

Figure 2

4

3.

A/C EVAPORATOR, LOUVER BOX

625-3091

Figure 3 Sheet 1

6

4.

REFRIGERANT HOSES KIT, A/C

625-4728

Figure 4 Sheet 1

9

5.

AIR CONDITIONING SYSTEM INSTALLATION

627-8134

Figure 5 Sheet 1

13

6.

AIR CONDITIONING ELECTRICAL INSTALLATION

627-8136

Figure 6 Sheet 1

18

7.

AIR CONDITIONING HYDRAULIC INSTALLATION

627-8135

Figure 7 Sheet 1

18

8.

MANIFOLD, A/C MOTOR

625-4073

Figure 8 Sheet 1

32

9.

DRIER ASSEMBLY, A/C RECEIVER

625-3864

Figure 9

35

10. AIR CONDITIONING SYSTEM ASSEMBLY

625-4534

Figure 10 Sheet 1

36

11. A/C HYDRAULIC HOSE KIT

627-8135-001

Figure 11 Sheet 1

39

12. A/C HYDRAULIC TUBE KIT

627-8135-002

Figure 12 Sheet 1

48

13. A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY

625-4887

Figure 13

54

14. A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY

625-4132

Figure 14

55

15. A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY

625-4130

Figure 15

56

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 1 December 2015

Halvorsen

Figure 1 AIR CONDITIONER CONDENSER FAN 625-3088 4-18 Page 2 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen AIR CONDITIONER CONDENSER FAN 625-3088 ITEM

PART NO.

DESCRIPTION

QTY.

1*

625-3088-001

A-BOX, A/C BOND CHASSIS

1

2

625-3088-002

A-COIL, A/C BOND

1

3*

625-3088-003

FAN, A/C CONDENSER

1

4*

625-3088-004

BULKHEAD, #6 A/C BOND

1

5*

625-3088-005

BULKHEAD, #8 A/C BOND

1

*

625-3088-006

COVER, A/C BOND

1

*

625-3088-007

HARDWARE, A/C BOND

1

*

625-3088-008

O-RING, A/C #8 HBNR

1

*

625-3088-009

O-RING, A/C #6 HBNR

1

* NOT SHOWN

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 3 December 2015

Halvorsen

Figure 2 AIR CONDITIONER COMPRESSOR MOTOR 625-3089-500 4-18 Page 4 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen AIR CONDITIONER COMPRESSOR MOTOR 625-3089-500 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3089-001

BASE, A/C COMPRESSOR

1

2

625-3089-002

COMPRESSOR, A/C

1

3

625-3089-003

HOUSING, A/C COMPRESSOR BELL

1

4

625-3089-004

COUPLING, A/C COMPRESSOR

1

5

625-3089-005

MOTOR, A/C COMPRESSOR HYDRAULIC

1

6*

625-3089-006

HARDWARE, A/C COMPRESSOR

1

* NOT SHOWN **NOTE: CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING P/N 625-3089-500.

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 5 December 2015

Halvorsen 1

10

Figure 3 Sheet 1 A/C EVAPORATOR, LOUVER BOX 625-3091 4-18 Page 6 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 3 Sheet 2 A/C EVAPORATOR, LOUVER BOX 625-3091

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 7 December 2015

Halvorsen A/C EVAPORATOR, LOUVER BOX 625-3091 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3091-001

A-BOX, A/C EVAPORATOR CHASSIS

1

2

625-3091-002

A-BOX, A/C EVAPORATOR LOUVER BOX

1

3

625-3091-003

RESISTOR, A/C EVAPORATOR BLOWER MOTOR

1

4

625-3091-004

THERMOSTAT, A/C EVAPORATOR PRESET

1

5

625-3091-005

RELAY, A/C EVAPORATOR FAN OVERRIDE

1

6

625-3091-006

BRACKET, A/C EVAPORATOR EXP VALVE

1

7

625-3091-007

VALVE, A/C EVAPORATOR EXPANSION VALVE

1

8

625-3091-008

A-COIL, A/C EVAPORATOR

1

9*

625-3091-009

FILTER, A/C EVAPORATOR RETURN AIR

1

10

625-3091-010

KNOB, A/C EVAPORATOR RETURN AIR FILTER

2

11

625-3091-011

VALVE, A/C EVAPORATOR RUBBER CHECK

2

12

625-3091-012

BLOWER, A/C EVAPORATOR

1

13

625-3091-013

SWITCH, A/C EVAPORATOR MODE TOGGLE

1

14

625-3091-014

SWITCH, A/C EVAPORATOR FAN SPD TOGGLE

1

-16

625-3091-016

HE-EVAPORATOR, A/C

1

* NOT SHOWN

4-18 Page 8 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 Sheet 1 REFRIGERANT HOSES KIT, A/C 625-4728

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 9 December 2015

Halvorsen

Figure 4 Sheet 2 REFRIGERANT HOSES KIT, A/C 625-4728

Figure 4 Sheet 3 REFRIGERANT HOSES KIT, A/C 625-4728 4-18 Page 10 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 4 Sheet 4 REFRIGERANT HOSES, KIT A/C 625-4728

Figure 4 Sheet 5 K-REFRIGERANT HOSES, A/C 625-4728

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 11 December 2015

Halvorsen REFRIGERANT HOSES KIT, A/C 625-4728 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-4610

A-HOSE, REFRIGERANT SUCTION

1

2

625-4611

A-HOSE, REFRIGERANT COMPRESSOR DISCHARGE

1

3

625-4612

A-HOSE REFRIGERANT CONDITIONER LIQUID

1

4

625-4766

A-HOSE, REFRIGERANT DRIER LIQUID

1

5

625-4771

A-HOSE, REFRIGERANT OIL SEPARATOR DISCHARGE

1

6

625-4777

A-HOSE, REFRIGERANT OIL SEPARATOR

1

7

625-4832

A-VALVE, A/C #10 SUCTION SERVICE

1

8

625-4833

A-VALVE, A/C #8 DISCHARGE SERVICE

1

*

625-4833-001

O-RING, A/C COMPRESSOR

1

9

625-4918

ADAPTER, A/C 45 FLARE FITTING

1

* NOT SHOWN

4-18 Page 12 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

ML25K3P CHASSIS ML25K3P SCISSORS

ML25K3P CHASSIS HYD

DETAIL B

23

20

ML25K3P CHASSIS CAB

23

23

DETAIL E

G

DETAIL D

G

DETAIL C

ML25K3P CHASSIS DECK

DETAIL A

Halvorsen

Figure 5 Sheet 1 AIR CONDITIONING SYSTEM INSTALLATION 627-8134

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 13 December 2015

22

2.2 FT

29 30 6

2.3 FT

30 29

SECTION G-G SOME COMPONENTS REMOVED FOR CLARITY

1.5 FT

20

15

22

30 29

23

27

DETAIL B

33

34

1

17

6

23

9

DETAIL C

25 9

33

28

33

Halvorsen

Figure 5 Sheet 2 AIR CONDITIONING SYSTEM INSTALLATION 627-8134 4-18 Page 14 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 11 8

5

F

7 10 32

18

16

22

24 9

18

F

31

6 23 20

20

J

DETAIL A

24 9 19

J 10 7

H

H

6

4

10 13 23

DETAIL D SOME COMPONENTS REMOVED FOR CLARITY

22 COVER REMOVED

20

7

4 10 DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

Figure 5 Sheet 3 AIR CONDITIONING SYSTEM INSTALLATION 627-8134

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 15 December 2015

Halvorsen 7 10 32

2 11

31

20 86 11 2

SECTION F-F

26

SECTION H-H

20

20

SECTION F-F SOME COMPONENTS REMOVED FOR CLARITY

Figure 5 Sheet 4 AIR CONDITIONING SYSTEM INSTALLATION 627-8134 4-18 Page 16 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen AIR CONDITIONING SYSTEM INSTALLATION 627-8134 ITEM

PART NO.

DESCRIPTION

QTY.

1

107-9031

SCREW, HHC 8.8 M6 X 1 X 40 MG

1

2

107-2704

SCREW, HHC GR5 0.38-16 X 0.5 MG

4

4

107-9410

SCREW, HFLNG 8.8 M8 X 1.25 X 25 MG

5

107-9084

SCREW, HHC 8.8 M10 X 1.5 X 50 MG

2

6

107-9258

NUT, PTH 8 M6 X 1.00 MG

6

7

107-9259

NUT, PTH 8 M8 X 1.25 MG

13

8

107-9260

NUT, PTH 8 M10 X 1.50 MG

2

9

107-9274

WASHER, FLAT STD HARD M6 MG

12

10

107-9275

WASHER, FLAT STD HARD M8 MG

17

11

107-9276

WASHER, FLAT STD HARD M10 MG

8

13

600681

SCREW, HHC GR 5 0.31-18 X 0.75 MG

4

15

239-8852-007

CLAMP, SUPPORT 1.50 NC

3

16

625-4154

W-BRACKET, CONDENSOR A//C

1

17

625-4235

BRACKET, REF-HOSE, A/C

1

18

625-4501

MOUNT, 3/8-16 X 3/8-16F

4

19

625-4502

MOUNT, CAPTURED

4

20

625-4534

A-A/C SYSTEM

1

22

627-8136

IE-A/C SYSTEM OPTION

1

23

627-8135

IH-A/C SYSTEM OPTION

1

24

107-9018

SCREW, HHC-F 8.8 M6 X 1 X 25 MG

4

25

107-9030

SCREW, HHC 8.8 M6 X 1 X 30 MG

1

26

625-4001

DECAL, A/C MODE

1

27

625-5918

GUARD, FRONT, A/C REFRIGERANT HOSE

1

28

625-5920

GUARD, REAR, A/C REFRIGERANT HOSE

1

29

620-1317-004

FLEX-GARD, NYLON SLIT 5/8 IN.

9

30

620-1317-007

FLEX-GARD, NYLON SLIT 1-1/4 IN.

9

31

623-9632

A-MUD FLAP

1

32

107-9412

SCREW, HFLNG 8.8 M8 X 1.25 X 35 MG

2

33

107-9456

WASHER, FLAT NARROW HARD M10 MG

5

34

107-9278

WASHER, FLAT STD HARD M12 MG

2

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

11

4-18 Page 17 December 2015

3-D REF VIEW

DETAIL H

DETAIL A

DETAIL E

ML25K3P CAB

ML25K3P DECK

5

DETAIL B

Halvorsen

Figure 6 Sheet 1 AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136 4-18 Page 18 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 8 AC1A-P AC2A-P

REF 624-2911 AE-DECK PANEL NGSL

4 AC1A-R AC2A-R DETAIL

A REF 625-3088 A-CONDENSER, AC ACCOND

5

DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

Figure 6 Sheet 2 AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 19 December 2015

Halvorsen

4 REF 625-3091 A-EVAPORATOR, AC

AC1-P AC2-P

DETAIL E SOME COMPONENTS REMOVED FOR CLARITY

REF 625-4073 MANIFOLD, AC-MOTOR ACSOL 5

DETAIL H

Figure 6 Sheet 3 AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136 4-18 Page 20 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

3-D REF VIEW

DETAIL F

DETAIL G

Halvorsen

Figure 6 Sheet 4 AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 21 December 2015

Halvorsen

REF 625-4132 AE-SWITCH, AC FAN OVERRIDE ACF-R

5

REF 625-4130 AE-SWITCH, HIGH PRES AC ACH-P REF 625-3864 A-DRIER, AC RECEIVER

DETAIL F SOME COMPNENTS REMOVED FOR CLARITY

5

REF 625-4887 AE-SWITCH, LOW PRES AC ACL-P

REF 625-3089 A-COMPRESSOR, AC

DETAIL G SOME COMPNENTS REMOVED FOR CLARITY

Figure 6 Sheet 5 AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136 4-18 Page 22 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136 ITEM

PART NO.

DESCRIPTION

QTY.

2

623-4995

NYLON CABLE WRAP LARGE 14.5 IN. 50 LB

3

105-0210

NYLON CABLE WRAP, 7.3 IN. 50 LB

4

628-4448

HE-AC-SYSTEM OPTION, CAB

1

5

628-4449

HE-AC SYSTEM OPTION, DECK

1

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

5 10

4-18 Page 23 December 2015

Halvorsen DETAIL D DETAIL B

DETAIL D

ML25K3P DECK ML25K3P DECK

F

DETAIL B

F F F DETAIL A DETAIL A 6 16

14

6

14 REF 625-308916 A-COMPRESSOR, AC REF 625-3089 A-COMPRESSOR, AC 3 3 16 16

12

6

AO 1 AO 1

12 6 P 4 P 4

14 14 AR 4 AR 4

LS 5 LS 5

DETAIL A SOME COMPONENTS REMOVED DETAIL A FOR CLARITY SOME COMPONENTS REMOVED FOR CLARITY

LS 11 LS 11

DETAIL B SOME COMPONENTS REMOVED DETAIL B FOR CLARITY SOME COMPONENTS REMOVED FOR CLARITY

Figure 7 Sheet 1 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 4-18 Page 24 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen REF 623-5415 MANIFOLD, ASSY STOPS/LIFT

14

19

DETAIL D

4 9 10

13

17 10

8 3

12

19 P 16

REF 623-5415 MANIFOLD, ASSY STOPS/LIFT SECTION F-F SOME COMPONENTS REMOVED FOR CLARITY

Figure 7 Sheet 2 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 25 December 2015

Halvorsen

DETAIL H ML25K3P SCISSORS DETAIL K DETAIL J

ML25K3P CHASSIS ML25K3P CHASSIS HYD DETAIL R DETAIL E

3-D REF VIEW

DETAIL G

Figure 7 Sheet 3 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 4-18 Page 26 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 21

14 25 22 DETAIL E REF 623-5930 AH-RESERVIOR REF 514-8244 FILTER, HIGH PRESSURE 100 GPM

18

7 27

14

2

14

25

23 20

DETAIL G SOME COMPONENTS REMOVED FOR CLARITY

25 DETAIL H

Figure 7 Sheet 4 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 27 December 2015

Halvorsen 25 22

25

21 14

24 DETAIL K

DETAIL J

REF 620-4440 CLAMP, TWIN TUBE 3/8"

26 25

24

DETAIL R

Figure 7 Sheet 5 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 4-18 Page 28 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL C

ML25K3P SCISSORS

DETAIL L

DETAIL M

DETAIL P

DETAIL N

3-D REF VIEW ML25K3P CHASSIS

Figure 7 Sheet 6 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 29 December 2015

Halvorsen 14

14

21

23

22 21 25

DETAIL C SOME COMPNENTS REMOVED FOR CLARITY

25

25 DETAIL L 24 14

20 DETAIL M

25

23 DETAIL N SOME COMPNENTS REMOVED FOR CLARITY 21

22 14 DETAIL P

Figure 7 Sheet 7 AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 4-18 Page 30 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 ITEM

PART NO.

DESCRIPTION

QTY.

1

102-1775-0808

ADAPTER, STRAIGHT - 08MORB X -08MJIC

1

2

102-1776-1608

ADAPTER, REDUCER 06MJIC X 04FJIC

1

3

102-1777-0606

ADAPTER, 90 -06MORB X -06MJIC

2

4

102-1777-0808

ADAPTER, 90 -08MORB X -08MJIC

3

5

102-1778-0606

ADAPTER, 90 -06FJIC X -06MJIC

1

6

102-1778-0808

ADAPTER, 90 SW -08FJIC X -08MJIC

2

7

102-1782-0016

ADAPTER, TEE RN SWIVEL -16JIC

1

8

107-9412

SCREW, HFLNG 8.8 M8 X 1.25 X 35 MG

2

9

107-9259

NUT, PTH 8 M8 X 1.25 MG

2

10

107-9275

WASHER, FLAT STD HARD M8 MG

4

11

102-1775-0606

ADAPTER, STRAIGHT -06MORB X -06MJIC

1

12

625-4073

MANIFOLD, A/C MOTOR

1

13

625-4264

PLATE, MANIFOLD A/C

1

14

627-8135-001

IH-HOSE ASSEMBLY KIT, A/C SYSTEM OPTION

1

16

102-1775-1008

ADAPTER, STRAIGHT -10MORB X -08MJIC

3

17

5060064

SCREW, HHC GR 5 0.38-16 X 0.75 MG

2

18

102-1777-0806

ADAPTER, 90 -08MORB X -06MJIC

1

19

102-1795-0008

ADAPTER, TEE SWIVEL BR -08JIC

1

20

102-0200

ADAPTER, BH 90 -08MJIC

2

21

102-1783-0606

ADAPTER, BH -06MJIC X -06MJIC

5

22

102-1783-0808

ADAPTER, BH -08MJIC X -08MJIC

5

23

102-1784-0006

ADAPTER, BH 90 -02MJIC

2

24

628-4499

A-CLAMP, TWIN TUBE 3/8 IN. AND 1/2 IN.

3

25

627-8135-002

IH-TUBE ASSEMBLY KIT, A/C SYSTEM OPTION

1

26

3613557

SCREW, HHC GR 5 0.25-20 X 2.5 MG

1

27

102-1778-1616

ADAPTER, 90 SWIVEL -16FJIC X -16MJIC

1

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 31 December 2015

Halvorsen

Figure 8 Sheet 1 MANIFOLD, A/C MOTOR 625-4073 4-18 Page 32 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 8 Sheet 2 MANIFOLD, A/C MOTOR 625-4073

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 33 December 2015

Halvorsen MANIFOLD, A/C MOTOR 625-4073 ITEM

PART NO.

DESCRIPTION

QTY.

1

620-1326-001

VALVE SHUTTLE CSAB XXN

1

2

622-6079-001

COIL, 24 VDC, SUN

1

3

623-6681-010

MANIFOLD BODY, A/C REFRIGERANT

1

4

625-4073-001

VALVE, SUN DMDA-MNN

1

5

624-7796-001

COIL, 24 VDC, SUN

1

6

102-1788-0006

ADAPTER, PLUG -060RB

1

4-18 Page 34 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

Figure 9 DRIER ASSEMBLY, A/C RECEIVER 625-3864

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 35 December 2015

Halvorsen DETAIL D 5

6

DETAIL A SOME COMPONENTS REMOVED FOR CLARITY

7

DETAIL C

8

1

DETAIL A DETAIL B

DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

Figure 10 Sheet 1 AIR CONDITIONING SYSTEM ASSEMBLY 625-4534 4-18 Page 36 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

4

6

2 9

DETAIL C SOME COMPONENTS REMOVED FOR CLARITY

6

3

DETAIL D

Figure 10 Sheet 2 AIR CONDITIONING SYSTEM ASSEMBLY 625-4534

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 37 December 2015

Halvorsen AIR CONDITIONING SYSTEM ASSEMBLY 625-4534 ITEM

PART NO.

DESCRIPTION

QTY.

1

625-3864

A-DRIER, A/C RECEIVER

1

2

625-3797

SEPERATOR, AC/ OIL

1

3

625-3088

A-CONDENSOR, A/C

1

4

625-3089

A-COMPRESSOR, A/C

1

5

625-3091

A-EVAPORATOR, A/C

1

6

625-4728

K-REFRIGERANT HOSES, A/C

1

7

625-4130

AE-SWITCH, HIGH PRESSURE A/C

1

8

625-4132

AE-SWITCH, A/C FAN OVERRIDE

1

9

625-4887

AE-SWITCH, LOW PRESSURE A/C

1

4-18 Page 38 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

ML25K3P DECK

DETAIL F

DETAIL D

DETAIL H

ML25K3P SCISSORS

ML25K3P CHASSIS

DETAIL L

ML25K3P CHASSIS HYD

Figure 11 Sheet 1 A/C HYDRAULIC HOSE KIT 627-8135-001

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 39 December 2015

Halvorsen 11

8

DETAIL D

REF 625-4073 MANIFOLD, AC MOTOR 8 P

1 LSO

AR 4

LS1 REF 519-0196-124 HOSE, ASSY FJIC SW-06 X 124LG

DETAIL F

Figure 11 Sheet 2 A/C HYDRAULIC HOSE KIT 627-8135-001 4-18 Page 40 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 10

13

DETAIL H SOME COMPONENTS REMOVED FOR CLARITY

2

6 DETAIL L

Figure 11 Sheet 3 A/C HYDRAULIC HOSE KIT 627-8135-001

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 41 December 2015

Halvorsen DETAIL A

ML25K3P DECK

T

T DETAIL B

3 T

7 AO

REF 625-4073 MANIFOLD, AC-MOTOR

DETAIL A

Figure 11 Sheet 4 A/C HYDRAULIC HOSE KIT 627-8135-001 4-18 Page 42 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen REF 625-3089 A-COMPRESSOR, AC

7

11

4 DETAIL B SOME COMPONENTS REMOVED FOR CLARITY

1

REF 623-5415 MANIFOLD, ASSY STOPS/LIFT

LS1

3 P

SECTION T-T

Figure 11 Sheet 5 A/C HYDRAULIC HOSE KIT 627-8135-001

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 43 December 2015

Halvorsen ML25K3P SCISSORS

DETAIL M

ML25K3P CHASSIS HYD

DETAIL N

DETAIL P

DETAIL R

ML25K3P CHASSIS

3-D REF VIEW

Figure 11 Sheet 6 A/C HYDRAULIC HOSE KIT 627-8135-001 4-18 Page 44 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen 10

13

DETAIL M

12

9 DETAIL N SOME COMPONENTS REMOVED FOR CLARITY

Figure 11 Sheet 7 A/C HYDRAULIC HOSE KIT 627-8135-001

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 45 December 2015

Halvorsen

12

9

DETAIL P SOME COMPONENTS REMOVED FOR CLARITY

2

REF 514-8244 FILTER, HIGH PRESSURE 100 GPM

6 DETAIL R SOME COMPONENTS REMOVED FOR CLARITY

Figure 11 Sheet 8 A/C HYDRAULIC HOSE KIT 627-8135-001 4-18 Page 46 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen A/C HYDRAULIC HOSE KIT 627-8135-001 ITEM

PART NO.

DESCRIPTION

QTY.

1

519-0196-025-S

HOSE, ASSEMBLY FJIC SW-06 X 25 SLVD

1

2

519-0196-111-S

HOSE, ASSEMBLY FJIC SW-06 X 111 SLVD

1

3

519-0197-025-S

HOSE, ASSEMBLY FJIX SW-08 X 25 SLVD

1

4

519-0197-064-S

HOSE, ASSEMBLY FJIC SW-08 X 64 SLVD

1

6

519-0197-087-S

HOSE, ASSEMBLY FJIC SW-08 X 87 SLVD

1

7

519-0197-057-S

HOSE, ASSEMBLY FJIC SW-08 X 57 SLVD

1

8

519-0197-096-S

HOSE, ASSEMBLY FJIC SW-08 X 96 SLVD

1

9

519-0197-056-S

HOSE, ASSEMBLY FJIC SW-08 X 56 SLVD

1

10

519-0197-042-S

HOSE, ASSEMBLY FJIC SW-08 X 42 SLVD

1

11

519-0196-079-S

HOSE, ASSEMBLY FJIC SW-06 X 79 SLVD

1

12

519-0196-056-S

HOSE, ASSEMBLY FJIC SW-06 X 56 SLVD

1

13

519-0196-039-S

HOSE, ASSEMBLY FJIC SW-06 X 39 SLVD

1

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 47 December 2015

Halvorsen DETAIL E

DETAIL F

ML25K39 SCISSORS

DETAIL G

DETAIL J

DETAIL H

ML25K39 CHASSIS HYD

ML25K39 CHASSIS

3-D REF VIEW

Figure 12 Sheet 1 A/C HYDRAULIC TUBE KIT 627-8135-002 4-18 Page 48 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

6

5

DETAIL F

5 6

DETAIL E

Figure 12 Sheet 2 A/C HYDRAULIC TUBE KIT 627-8135-002

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 49 December 2015

Halvorsen 4

3

2

DETAIL G

1 DETAIL H

2

1

DETAIL J SOME COMPONENTS REMOVED FOR CLARITY

Figure 12 Sheet 3 A/C HYDRAULIC TUBE KIT 627-8135-002 4-18 Page 50 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

DETAIL B

DETAIL C ML25K3P SCISSORS

ML25K3P CHASSIS HYD

ML25K3P CHASSIS

3-D REF VIEW

Figure 12 Sheet 4 A/C HYDRAULIC TUBE KIT 627-8135-002

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 51 December 2015

Halvorsen 7

8

DETAIL B

3

4

DETAIL C

Figure 12 Sheet 5 A/C HYDRAULIC TUBE KIT 627-8135-002 4-18 Page 52 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen A/C HYDRAULIC TUBE KIT 627-8135-002 ITEM

PART NO.

DESCRIPTION

QTY.

1

628-0918

A-TUBE, 0.38 SST

1

2

628-0919

A-TUBE, 0.38 SST

1

3

628-0943

A-TUBE, 0.38 SST

1

4

628-0944

A-TUBE, 0.50 SST

1

5

628-0945

A-TUBE, 0.38 SST

1

6

628-0946

A-TUBE, 0.50 SST

1

7

628-0948

A-TUBE, 0.38 SST

1

8

628-0949

A-TUBE, 0.50 SST

1

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 53 December 2015

Halvorsen

HS200-121-0002

501-1-0-4 NO 8 35 PSIG YY-WW-E

BLACK HOUSING

1 .55

1/4" FEMALE FLARE (7/16-20 UNF-2B)

14.0

2

4

3

5

EPOXY SEAL

DEFLATOR .92

WIRE LEADS (2) 18 AWG, 600V PVC INSULATION, 1/32", BLUE, 105 C, UL 1015

.50

23.4

12.7 1.75 44.4

12.00 304.8

Figure 13 A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY 625-4887

A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY 625-4887 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-2967-017

CONNECTOR, WEDGE 2 POS RECEPTACLE

1

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

2

3

622-2967-001

CONNECTOR, RECP 2 POS (MALE)

1

4

622-2967-046

CONNECTOR, BOOT 2 POS RECEPTACLE

1

5

620-1317-009

FLEX-GARD, NYLON SLIT 1/4 IN.

1

4-18 Page 54 December 2015

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen

501-1-0-6 NO 180 240 PSIG HS400-121-0001 YY-WW-E

BLACK HOUSING 1/4" FEMALE FLARE (7/16-20 UNF-2B) .55

EPOXY SEAL DEFLATOR

14.0

4

23.4

1.80

12.8

45.7

2

1

WIRE LEADS (2) 18 AWG, 600V PVC INSULATION, 1/32", BLUE, 105 C, UL 1015

.50

.92

3

5

12.00 304.8

Figure 14 A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY 625-4132

A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY 625-4132 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-2967-002

CONNECTOR, PLUG 2 POS (FEMALE)

1

2

622-2967-015

CONNECTOR, SOCKET (16-18 AWG) SOLID

2

3

622-2967-018

CONNECTOR, WEDGE 2 POS PLUG

1

4

622-2967-040

CONNECTOR, BOOT 2 POS PLUG

1

5

620-1317-009

FLEX-GARD, NYLON SLIT 1/4 IN.

1

AIR CONDITIONING SYSTEM The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

4-18 Page 55 December 2015

Halvorsen

HS200-121-0003

501-1-0-5 NC 350 250 PSIG YY-WW-E WIRE LEADS (2) 18 AWG, 600V PVC INSULATION, 1/32", BLACK, 105 C, UL 1015

GREEN HOUSING

1/4" FEMALE FLARE (7/16-20 UNF-2B)

EPOXY SEAL

.55

5

14.0

1

DEFLATOR

.92

2

4

3

.50

23.4

1.80

12.7

45.7

12.00 304.8

Figure 15 A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY 625-4130

A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY 625-4130 ITEM

PART NO.

DESCRIPTION

QTY.

1

622-2967-017

CONNECTOR, WEDGE 2 POS RECEPTACLE

1

2

622-2967-013

CONNECTOR, PIN 16-18 AWG SOLID

2

3

622-2967-001

CONNECTOR, RECEPTACLE P 2 POS (MALE)

1

4

622-2967-046

CONNECTOR, BOOT 2 POS RECP

1

5

620-1317-009

FLEX-GARD, NYLON SLIT 1/4 IN.

4-18 Page 56 December 2015

1 ft.

ILLUSTRATED PARTS LIST The Illustrated Parts List includes alternate parts which may not be used with your configuration. For applicable parts refer to the product specification at the front of the manual.

Halvorsen CHAPTER 5. MANUFACTURERS’ APPENDICES

Section 1. Introduction GENERAL

Section 2. Engine VM MOTORS WORKSHOP MANUAL, ENGINE FAMILY R750

Section 3. Transmission ALLISON TRANSMISSION OPERATOR’S MANUAL (OM3063EN) SERVICE MANUAL (SM319EN) TRANSMISSION TROUBLESHOOTING MANUAL (TS319EN) MECHANIC’S TIPS (MT3190EN) STONE BENNETT CORP. DESCRIPTION AND INSTALLATION BULLETINS PARTS LIST MANUAL

Section 4. Axles and Steering KESSLER & CO., OFF-HIGHWAY AXLE DIVISION SERVICE MANUAL - JBT ML 42K4P (41.3485.3) DANFOSS HYDRAULICS SERVICE MANUAL (HN.21.AD.02) SPARE PARTS (HN.21.UA.52)

Section 5. Hydraulic Pumps and Motors LINDE HYDRAULICS CORP. HPR-75-02 PUMP INSTALLATION AND ADJUSTMENT INSTRUCTIONS SPARE PARTS LIST (REF. 253 804 91 11) SERVICE TRAINING, MAINTENANCE AND PARTS LIST

5-Contents Page 1 December 2015

Halvorsen PARKER HANNIFIN CORP. INTRODUCTION AND CONTROL OPTIONS CATALOG (2600-102-1/USA) PARKER PUMPS PARTS AND SERVICE (Bulletin PM 1620-12-M1/USA) ROSS OPERATION SERVICE MANUAL (2704)

Section 6. Hydraulic Cylinders PARKER HANNIFIN CORP. CYLINDER INFORMATION DRAWINGS CLOVER HYDRAULICS & ENGINEERING, INC. SPECIFICATIONS AND PARTS LIST DRAWINGS CYLINDER SEAL REPLACEMENT PROCEDURES TEXAS HYDRAULICS, INC. MAINTENANCE MANUAL

Section 7. Brakes AUSCO PRODUCTS SERVICE NOTES MICO, INC. PRODUCT CATALOG INSTALLATION AND SERVICE INSTRUCTIONS SERVICE INSTRUCTIONS

Section 8. Air Conditioner and Heater ESPAR HEATER SYSTEMS OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST VISIONAIRE, INC. MAINTENANCE GUIDE

5-Contents Page 2 December 2015

Halvorsen CHAPTER 5. MANUFACTURERS’ APPENDICES

Section 1. Introduction

WARNING BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER, WARNING AND CAUTION STATEMENTS. MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO MAINTENANCE SCHEDULES AND MANUFACTURERS’ RECOMMENDATIONS. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE CONTACT YOUR LOCAL JBT SERVICE CENTER BEFORE PROCEEDING. GENERAL This chapter contains instruction bulletins, parts lists, service manuals, etc., issued by major manufacturers’ appendices of the Halvorsen aircraft loader. Information is included only for components that are considered repairable. A list of manufacturers and their CAGE codes is included for those major components in Chapter 4, Section 2.

INTRODUCTION

5-1 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Halvorsen Section 2. Engine

VM MOTORS Florida Detroit Diesel-Allison WORKSHOP MANUAL, ENGINE FAMILY R750 R756IE3 Diesel Engine, Tier 3

ENGINE

5-2 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

R 750

Workshop Manual Engine Family R750 R754EU4

R756EU4

R756IE3

R754EU5

R

Common Rail Injection System

750

Unitary Displacement

R756EU5

4 (no. of cylinders)

4

x

x

4

x

6 (no. of cylinders)

x

6

6

x

6

Turbocharged

yes

yes

yes

yes

yes

I (Intercooler)

yes

yes

yes

yes

yes

EU4 - Emissions Certification

EURO 4 EC/EPA Stage3A

EURO 4 EC/EPA Stage3A

x

x

x

E3 - Emissions Certification

x

x

EC/EPA Stage3A

x

x

EU5 - Emissions Certification

x

x

x

EURO 5 EURO 5 EC/EPA Stage3B EC/EPA Stage3B

VM Order Number 42431133F Edition 9 - 10/2010



R 750

sections



R 750 SUMMARY INTRODUCTION....................................................................................................................... 6

Models Covered........................................................................................................................................ 6 R 754 and 756 EU4/EU5 common rail industrial engines are applied to vehicles of the road, such as road sweepers and trucks. R 756 IE3 are applied to vehicles not of the road, agricultural and lifting application................................................................................... 6 Notice To Users Of This Manual.......................................................................................................... 6 Replacement Parts................................................................................................................................... 7 Cleanliness And Care Of Product..................................................................................................... 7

Handling Precautions for Electric Circuits....................................................... 8

ENGINE electronic control unit ....................................................................................................... 8 Precautions for Arc Welding.............................................................................................................. 12

service manual - Updating........................................................................................... 13 General Information...................................................................................................... 17 Introduction............................................................................................................................................... 17 How To Order This Manual..................................................................................................................... 17 Engine Serial Number and engine plate identification.............................................................. 17

Maintenance....................................................................................................................... 19 Engine Specifications.............................................................................................................................. 19 Maintenance Intervals........................................................................................................................... 25 Maintenance Schedule - R750 EURO 4 - IE3........................................................................................ 25 Maintenance Schedule - R750 EURO 5................................................................................................. 26 Engine External Views............................................................................................................................ 27 Engine Oil ..................................................................................................................................................... 31 Coolant......................................................................................................................................................... 36 Air Filter Element..................................................................................................................................... 39 Fuel System................................................................................................................................................. 42 Fuel Filter.................................................................................................................................................... 43 alternator Belt / Poly - V (Serpentine) ............................................................................................ 45 Diesel Particulate Filter (DPF) - r 750 euro 4.................................................................................. 47 Diesel Particulate Filter (DPF) - r 750 euro 5.................................................................................. 50 Extended Storage.................................................................................................................................... 51

REMOVAL AND INSTALLATION............................................................................................ 52 FASTENER TIGHTENING SPECIFICATIONS........................................................................ 53 special tools..................................................................................................................... 54 Timing Side............................................................................................................................ 58 Timing Gears................................................................................................................................................ 59 Oil pump......................................................................................................................................................... 62 Crankshaft gear....................................................................................................................................... 67 Hydraulic pump Idler gear (between the crankshaft and camshaft gears).................. 68 injection pump Idler gear (between the camshaft and injection pump gears).............. 71 hydraulic pump gear assembly........................................................................................................... 72 belt tensioner - (automatic type)....................................................................................................... 76 belt tensioner bracket.......................................................................................................................... 77 idler pulleys............................................................................................................................................... 78 crankshaft hub and pulley.................................................................................................................. 79 water pump and pulley........................................................................................................................... 82 timing gear cover..................................................................................................................................... 83 front oil seal............................................................................................................................................. 84

ExHaust Side....................................................................................................................... 85 turbocharger............................................................................................................................................ 85 egr cooler.................................................................................................................................................. 86 intake Throttle / EGR valve & PROPER actuators....................................................................... 88 exhaust manifold...................................................................................................................................... 91 intake manifold.......................................................................................................................................... 92



R 750 Flywheel Side..................................................................................................................... 93

Crankshaft End Play (Axial Clearance)........................................................................................... 93 Flywheel....................................................................................................................................................... 94 FLYWHEEL RING GEAR.................................................................................................................................. 97 Flywhell housing...................................................................................................................................... 98 rear main bearing carrier.................................................................................................................... 100 THRUST WASHERS......................................................................................................................................... 100 REAR MAIN BEARING .................................................................................................................................... 101 Rear oil seal................................................................................................................................................ 101 cps target wheel bolt............................................................................................................................ 101

BASIc ENGINE....................................................................................................................... 102

cylinder head GASKET.............................................................................................................................. 102 cylinder head............................................................................................................................................. 103 Torque Procedure After the First 20‑30 Minutes of Operation............................................ 106 EXPANSION PLUGS........................................................................................................................................ 107 Cylinder Head End spacer..................................................................................................................... 107 VALVE GUIDES................................................................................................................................................ 108 VALVE SEATS................................................................................................................................................... 110 Valve Seat Reconditioning.................................................................................................................... 111 Valves............................................................................................................................................................. 112 Valve Springs.............................................................................................................................................. 114 Rocker ARM.................................................................................................................................................. 115 Valve Lifters............................................................................................................................................... 117 Valve Push Rods......................................................................................................................................... 119 fractured Connecting Rod.................................................................................................................. 120 removal......................................................................................................................................................... 120 BROACHED Connecting Rod.................................................................................................................... 124 removal......................................................................................................................................................... 124 piston............................................................................................................................................................. 128 Oil Pan & Oil Pickup.................................................................................................................................... 133 Oil Pickup...................................................................................................................................................... 133 Oil Pressure Relief Valve...................................................................................................................... 134

engine block..................................................................................................................... 136

crankcase.................................................................................................................................................... 136

engine block..................................................................................................................... 137

Liner................................................................................................................................................................ 137 camshaft....................................................................................................................................................... 140 Camshaft bearings .................................................................................................................................. 143 front journal Camshaft bushing...................................................................................................... 144 Piston Cooling Jets (Oil Spray Nozzles).......................................................................................... 145 crankshaft.................................................................................................................................................. 146 Crankshaft front main bearing......................................................................................................... 152

INJECTION SIDE.................................................................................................................... 153

INJECTION FUEL SYSTEM............................................................................................................................. 153 electrical sensors . ............................................................................................................................... 154 low pressure system requirements................................................................................................ 158 high pressure pump................................................................................................................................. 159 injector........................................................................................................................................................ 162 rail.................................................................................................................................................................. 164 HIGH PRESSURE fuel COMPONENTS TIGHTENING PROCEDURE........................................................ 165 oil filter HOUSING...................................................................................................................................... 166 oil delivery pipe to rocker arm.......................................................................................................... 167 rocker arm cover.................................................................................................................................... 168 coolant manifold..................................................................................................................................... 168 thermostatic valve ................................................................................................................................. 169 vacuum pump................................................................................................................................................ 170

ENGINE ELECTRICAL........................................................................................................... 171

Alternator................................................................................................................................................... 171 Alternator pulley.................................................................................................................................... 171 voltage regulator................................................................................................................................... 174 Alternator Bracket................................................................................................................................. 174 Starter.......................................................................................................................................................... 174



R 750 ENGINE CONTROL................................................................................................................ 175

DIAGNOSTIC TROUBLE CODES “euro 4”................................................................................................... 175 DIAGNOSTIC TROUBLE CODES “euro 5”................................................................................................... 181

labour time guide........................................................................................................... 192

KEY TO DEFINITIONS...................................................................................................................................... 192

electrical system.......................................................................................................... 201

Electrical Schematic Diagrams - “A” SIDE - Engine . ..................................................................... 201 engine Wiring harness............................................................................................................................ 203 installation electric diagram - “k” side - vehicle......................................................................... 207

Introduction



R 750 Models Covered

INTRODUCTION

R 754 and 756 EU4/EU5 common rail industrial engines are applied to vehicles of the road, such as road sweepers and trucks. R 756 IE3 are applied to vehicles not of the road, agricultural and lifting application.

Notice To Users Of This Manual

Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

DANGER

DANGER—indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

WARNING—indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. This manual has been written and published by the Service Department of VM Motori to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual at any time and without prior notice in accordance with the Company’s policy of constant product improvement. COPYRIGHT

© 2007 July, VM Motori S.p.A.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, whether electronic or mechanical, or by photocopying, recording or other means without prior permission in writing of VM Motori. Published by VM Motori, from whom further copies may be obtained through your normal literature ordering procedure (refer to front page to identify the order number). A copy of this manual is available from VM Motori web site Customer Reserved Area “Extranet” VM Motori S.p.A. - Service Department, Via Ferrarese 29 - 44042 Cento (FE) ITALY Every reasonable effort is made to ensure that the VM Motori’s publications are accurate, but nothing shown, described or referred to herein should be regarded as an infallible guide to the procedures, materials, specifications, dimensions, design or availability of any particular engine, nor does this publication constitute an offer for the sale of any particular engine. No liability can be accepted by the VM Motori or any Distributor or Dealer for any malfunction, damage, loss, injury or death caused by the use of incorrect or misinterpreted information, omissions or errors that may have arisen during the preparation of this workbook. It is assumed that these personnel are familiar with industrial product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of VM Motori Products, including the use of mechanics’ common hand tools and the special VM Motori or recommended tools from other suppliers. We could not possibly know of and advise the industrial trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to service these products. Refer to dealer service bulletins, warranty, owner manuals and installation manuals for other pertinent information concerning the products described in this manual. Extranet area contained in VM Motori web site is another source of information.



Introduction

R 750 Replacement Parts

Use of parts other than the recommended service replacement parts, will avoid the warranty on those parts that are damaged as a result.

WARNING

When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.

Cleanliness And Care Of Product A VM Motori Product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of a mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

Introduction



R 750 Handling Precautions for Electric Circuits ENGINE electronic control unit

WARNING IN ORDER TO AVOID ECU DAMAGE PAY ATTENTION TO THE FOLLOWING INSTRUCTIONS: • DO NOT CUT ENGINE VOLTAGE OFF DURING ENGINE OPERATION • before cut engine voltage off through elettrical devices (breakers, switch, etc.) wait for 30 sec. at least so that the ECU can be carried out the “after-run” procedure • do not use start booster to let start the engine



Introduction

R 750 It should be kept in mind, while working on the product, that the electrical systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Before working on the electrical system, disconnect the (–) battery cable to prevent short circuits. CAUTION Make sure the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. Semiconductor components may otherwise be damaged. When separating connectors, grasp the connectors themselves rather than the harnesses.To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them together until they click.

Before washing the engine, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.

When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily operate on the battery voltage. CAUTION

Introduction



R 750 • Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can, particularly with the chassis harness, hasten corrosion. Inspection of harnesses Inspections with connectors fitted together Waterproof connectors • Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust. Non-waterproof connectors Perform the inspection by inserting a test probe C into the wireentry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage.

Inspections with connectors separated Inspections on female terminals Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections.

Inspections on male terminals Perform the inspection by applying test probes directly to the pins. CAUTION . • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuitry.

When using a multimeter to check continuity, do not

10

Introduction

R 750 allow the test probes to touch the wrong terminals

Inspection of connectors Visual inspection Check that the connectors are fitted together securely

Check whether wires have been separated from their terminals due to pulling of the harness

Check that male and female terminals fit together tightly Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances.

Checking for loose terminals • If connector terminal retainers become damaged, male and female terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings.

Introduction

11

R 750 Precautions for Arc Welding

When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless appropriate steps are taken, this current can damage engine control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be largely damaged. REMOVE THE ELCTRONIC ENGINE CONTROL UNIT FROM THE VEHICLE Current flows backward as shown nearby From battery (–) cable To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery’s (–) cable. Procedure Turn the starter switch to the LOCK position. Disconnect the battery’s (–) cable. Cover all parts of the vehicle that may be damaged by welding sparks. Connect the welder’s (–) cable to the vehicle as close as possible to the area being welded. Do not connect the welder’s (–) cable to the cab if the frame is being welded, and vice versa. Set the welding current in accordance with the part being welded.

12

Introduction

R 750 service manual - Updating Edition 0 _ 07 - 2007 Date

Chapter / Paragraph

Action Description

dd/mm/yyyy 04/07/2007

First Issue

Edition 1 _ 11 - 2007 Date

Chapter / Paragraph

Action Description

Maintenance / Engine Specifications

updating: API and ACEA engine oil specifications regarding all engine models of R750 family

gg/mm/aaaa 28/11/2007

modification: engine oil change quantity (oil filter cartridge included), concerning all engine versions, with counter balancer shaft and oil pan with major capacity Insertion: new DPF particulate filter cleaning procedure using an electrical oven Engine Block / Crankshaft

Insertion: crankshaft tech drawing about R756

Edition 2 _ 03 - 2008 DATE

Chapter / Paragraph

Action Description

Maintenance / Engine Oil

Added important note about 2 different oil pan capacities on R750 engines. Take care during engine oil change and filling.

Basic Engine / Fractured connecting Rod

New paragraph “Fractured Connecting Rod”

Specia Tools

Added spare parts code about socket for removal alternator pulley

Labour Time Guide

Added labour time for cleaning DPF filter with compressed air

Exhaust Side / Turbocharger

Added note about failure of turcharger: with an important oil leakage into exhaust side evaluate a cleaning of DPF Filter

gg/mm/aaaa 14/03/2008

Edition 3 _ 04 - 2008 Date

Chapter / Paragraph

Action Description

Special Tools

Inserted: Electrical Owen for DPF Filter cleaning, Engine test harness.

dd/mm/yyyy 23/04/2008

Updated the Diagnostic Tool P/N Introduction

Inserted: Handling Precautions for Electric Circuits, Precautions for Arc Welding

Introduction

13

R 750 Edition 4 _ 07- 2008 Date

Chapter / Paragraph

Action Description

Special Tools

Inserted: Compression Tester Adapter Tool.

dd/mm/yyyy 23/07/2008

Inserted: Break out Box Tool. Timing Side / Crankshaft gear

Heating of crankshaft gear before installing it on crankshaft

Introduction

Warning about ECU safeguard

Edition 5_ 09 - 2008 Date

Chapter / Paragraph

Action Description

Engine Block

Inserted: new chapter “Crankcase”,

dd/mm/yyyy 08/09/2008

inspection procedure of balance shaft assembly plugs and their caulking.

Edition 6 _ 12- 2008 Chapter / Paragraph

Action Description

17/12/2008

Introduction

Inserted: indication DO NOT use STARTBOOSTERS to let start the engine

17/12/2008

Maintenance

Inserted: required conditions about:

Date dd/mm/yyyy

14

Introduction

•

DPF filter cleaning with electrical oven

•

service regeneration through diagnostic tool

R 750 Edition 7 _ 03- 2010 Date

Chapter / Paragraph

Action Description

General Information

Updating of engine codes about R750 EURO5 engines family

Maintenance

ENGINE SPECIFICATIONS: updating of R754EU5 R756EU5 engine models

dd/mm/yyyy 22/01/2010

MAINTENANCE SCHEDULE: updating of maintenance chart about engines model EURO5 ENGINE OIL: •

updating of ACEA oil specifications about engines EURO 5

•

added delete procedure about ENGINE OIL DILUTION function

AIR FILTER: maintenance procedure about engines EURO5 DPF DIESEL PARTICULATE FILTER : description of DPF filter about engines EURO 5. Timing Side

“PTO” IDLER GEAR: updating of Loctite 572 on PTO cover gears bolt threads OIL PUMP: updating of dimensions about R750 EURO 5 engine models

Basic Engine

CYLINDER HEAD VALVE SEAT: updating of dimensions about R750 EURO 5 engine models

Injection Side

low pressure system requirements: updating of specifications as from installation manual

Electrical System

Electrical Schematic Diagrams , engine Wiring harness, installation electric diagram: updating in relation to EURO 5 engine models

Special Tools

updating of injector extractor fork for R750 EURO 5 engine models, VM code 68400045G

Engine Block

CRANKCASE: updating installation plugs for closing counter balance shaft oil lubrication passages

Basic Engine

HYDRAULIC TAPPET: insert new tappet 40432003F

Timing Side

IDLER GEAR (between crankshaft and camshaft gear): insert new idler gear

Edition 8 _ 04- 2010 Date

Chapter / Paragraph

Action Description

Maintenance

OIL CHANGE/OIL DILUTION CALULATION: updating of reset procedure

Maintenance

DPF FILTER EURO 5: updating of cleaning procudure through compressed dry air

Electrical System

INSTALLATION ELECTRICAL DIAGRAM “K SIDE”: updating electrical diagram R750EU5 engines

dd/mm/yyyy 07/04/2010

INSTALLATION ELECTRICAL DIAGRAM “K SIDE”: new electrical diagram R750IE3 engines Labout Time Guide

Insert ECU diagnosis time

General Information

15

R 750 Edition 9 _ 10 - 2010 Date

Chapter / Paragraph

Action Description

Maintenance

ENGINE SPECIFICATIONS: updating of exhaust back pressure about R750IE3 - EU4 - EU5 engine models

dd/mm/yyyy 08/10/2010

DPF FILTER EURO 4: cleaning procedure of pressure lines (from pressure sensor and DPF filter) every time the DPF filter comes cleaned ENGINE SPECIFICATIONS, ENGINE OIL: updating of engine oil specifications and oil pan capacities

16

General Information

R 750 General Information Introduction

This comprehensive overhaul and repair manual is designed as a service guide for the VM common rail diesel engines belonging to R750 family models. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. Before attempting repairs, read through the procedures to understand the methods and tools used and the cautions and warnings required for safety.

How To Order This Manual

This manual can be order through your normal literature ordering procedure (refer to front page to identify the order number). A copy of this manual is available from VM Motori web site Customer Reserved Area “Extranet”

Engine Serial Number and engine plate identification Engine Serial Number

P

1 - VM serial number stamped in the crankcase 2 - VM serial number and specification plate

q r XXC 01001

P) Engine serial number (punched on the crankcase) q) Engine code r) Consecutive number The table helps you to identify the model through the engine code. Engine code

Engine model

56C

R754EU4

79C

R756EU4

80C

R756IE3

05D

R754EU5

06D

R756EU5

1

General Information

17

R 750 engine plate identification

FLYWHEEL SIDE

2

A) Manufacturer identification G) Version

2

B) Serial number

H) Maximum power (kW)

C) Weight

L) Maximum number of revolutions

D) Type E) Family F) Model

TIMIMG SIDE

2

18

General Information

M) Homologation number N) Lubricating oil features

R 750 Maintenance Engine Specifications r 754 eu4, r 756 eu4, r 756 ie3 GENERAL SPECIFICATIONS Engine Model R754 IE3/EU4 Engine

Engine Type

R756 IE3/EU4

In–line 4 cylinder

Cylinder

In–line 6 cylinder

Bore

94 mm

Stroke

107 mm

Firing order

1‑3‑4‑2

1-5-3-6-2-4

Displacement

2.970 liters

4.455 liters

Compression Ratio

17,5 ± 0.5 : 1

17,5 ± 0.5 : 1

Injection System Type

Direct - Common Rail

Cooling System Type

Forced Water Cooling

Intake System Type Maximum Power (Ratings are based upon ECE Directive R120) Nm (CV) Maximum Torque Engine Rotation (Looking at flywheel) Idle Speed

Turbocharger/Intercooler

Weight (Dry) Maximum permanent lengthwise inclination (with flywheel up) Maximum permanent lengthwise inclination (with flywheel down)

74 (100) @ 3000 rpm

121 (165) @ 3000 rpm

340 Nm @ 1350 rpm

535 Nm @ 1350rpm

counterclockwise 800 ± 50 rpm

750 ± 50 rpm

269 kg

335 kg

35°

30° 35°

Maximum permanent crosswise inclination

30°

Valve clearance ‑ intake and exhaust

Hydraulic

Maximum pressure difference between cylinders

500 kPa ( 72 PSI)

Maintenance

19

R 750 R754 IE3/EU4

Engine Model

Fuel

Fuel System Low Fuel Pressure Line

Fuel System High Fuel Pressure Line

Specifications

Fuel Pump Type

Gerotor Type

Fuel Flow Rate Fuel Flow Pressure Fuel Filter Type

filtering area filtrante 6300 ± 200 cm2 / filtration efficiency 5 micron @ 95%

Fuel Pump Type

3 – cylinder radial plunger

Delivery/Pump Rotation Common Rail Pressure

max 1400 bar

Injection Pressure

max 1350 bar

Injector Type

solenoid type

Standard

SAE 10W 40 API CI-4

Oil Change (Including Filter) STANDARD OIL PAN Oil Change (Including Filter) more OIL PAN CAPACITY

Engine Systems

Engine Oil

R756 IE3/EU4

The engine has been designed to be powered by standard fuels (conforms to specifications DIN EN 590) available on the European market. If it is to be powered by BIODIESEL fuels (conforms to specifications UNI EN 14214), it can be mixed, up to 5%, with fuel (conforms to specifications DIN EN 590) available on the European market. About R750 engine models use only fuel with low sulphur content (not above 10-50 ppm)

Oil Change (Including Filter) COUNTER BALANCER SHAFT IN OIL PAN

MAX 8.7 Kg

MAX 12 kg

/

/

MAX 7.9 Kg

/

Oil Pump Type

Internal Rotor

Thermostat Consumption

0.5 - 1 (gr/CVh)

Oil temperature (alarm)

128°C

Oil pressure (with hot engine)

1.2 bar (idle 800±50 rpm) / 3.2 bar (rating 3000 rpm)

1.2 bar (idle 750±50 rpm) / 3.2 bar (rating 3000 rpm)

Normal operating temperature Thermostat

start opening 80 ± 2 °C / 90°C fully open

start opening 80 ± 2 °C / 90°C fully open

Capacity

5 liters (without radiator and pipes)

7.5 liters (without radiator and pipes)

Coolant System

20

80‑85° C

Water Circuit Pressure

0.9 - 1.1 bar

Standard

ASTM D 3306

Maintenance

R 750 Engine Model Engine Systems

Electric System

Intake System

R754 IE3/EU4

R756 IE3/EU4

Battery

12 V

12 V

Alternator

2.3 Kw - 105 A

2.3 Kw - 110 A

Starter

12V, 2.4 kW

Admittable depressure

MAX 70 mbar with new air filter <35mbar

Air Cosumption m3/h

Max. Exhaust backpressure

Engine Systems Exhaust System

365 @ 3000 rpm

673 @ 3000 rpm

(R750EU4) 350 mbar with DPF (Diesel Particulate Filter) new, clean or regenerated (R750IE3) 250 mbar

Exhaust Gas Temperature (in accordance with ECE Regulation R120)

625°C @ 3000 rpm

Maintenance

637°C @ 3000 rpm

21

R 750 r 754 eu5, r 756 eu5 GENERAL SPECIFICATIONS Engine Model R754 EU5 Engine

Engine Type

In–line 4 cylinder

Cylinder

In–line 6 cylinder

Bore

94 mm

Stroke

107 mm

Firing order

1‑3‑4‑2

1-5-3-6-2-4

Displacement

2.970 liters

4.455 liters

Compression Ratio

17,8 ± 0.5 : 1

17,8 ± 0.5 : 1

Injection System Type

Direct - Common Rail

Cooling System Type

Forced Water Cooling

Intake System Type

Turbocharger/Intercooler

Maximum Power - Nm (CV)

74 (100) @ 3000 rpm

121 (165) @ 3000 rpm

Maximum Torque Engine Rotation (Looking at flywheel) Idle Speed

340 Nm @ 1400 rpm

500 Nm @ 1400 rpm

800 ± 50 rpm

750 ± 50 rpm

Weight (Dry)

260 kg

335 kg

Maximum permanent lengthwise inclination (with flywheel up) Maximum permanent lengthwise inclination (with flywheel down)

22

R756 EU5

counterclockwise

30°/57%

30° 35°/70%

Maximum permanent crosswise inclination

30°/57%

Valve clearance ‑ intake and exhaust

Hydraulic

Maximum pressure difference between cylinders

500 kPa ( 72 PSI)

Maintenance

R 750 Engine Model

Fuel

Specifications

R754 EU5 R756 EU5 The engine has been designed to be powered by standard fuels (conforms to specifications DIN EN 590/2004) available on the European market. If it is to be powered by BIODIESEL fuels (conforms to specifications UNI EN 14214), it can be mixed, up to 5%, with fuel (conforms to specifications DIN EN 590) available on the European market. About R750E engine models use only fuel with low sulphur content (not above 10-50 ppm)

Fuel Pump Type Fuel System Low Fuel Pressure Line

Fuel System High Fuel Pressure Line

Gerotor Type

Fuel Flow Rate Fuel Flow Pressure Fuel Filter Type

Filter efficiency in according Bosch std KM 45 110 004_ en / Water separation in according ISO 16332

Fuel Pump Type

3 – cylinder radial plunger

Delivery/Pump Rotation Common Rail Pressure

max 1600 bar

Injection Pressure Injector Type

solenoid type SAE 10W 40

Standard Oil Pan Capacity Engine Systems

STANDARD OIL PAN Oil Change (Including Filter) more OIL PAN CAPACITY Engine Oil

Oil Pan Capacity COUNTER BALANCER SHAFT IN OIL PAN

ACEA E6 - API CJ4

8.7 Kg

12 kg

/

/

7.9 kg

/

Oil Pump Type

Internal Rotor

Thermostat Consumption

0.2 (gr/KWh)

Oil temperature (alarm)

135°C

Oil pressure (with hot engine)

> 1.5 bar / 120°C (rpm engine idle) 4 - 4.5 bar / 80°C (max 3000 rpm)

Normal operating temperature

80‑85° C

Thermostat

start opening 80 ± 2 °C / 90°C fully open

start opening 80 ± 2 °C / 90°C fully open

Capacity

5 liters (without radiator and pipes)

7.5 liters (without radiator and pipes)

Coolant System

Water Circuit Pressure

0.9 - 1.1 bar

Standard

ASTM D 3306

Maintenance

23

R 750 Engine Model

Engine Systems

R754 EU5

Battery Electric System

Intake System

R756 EU5

12 V Cold Cranking Amps (CCA) 950 A EN Capacity 140 Ah

Alternator

14V - 2.3 Kw - 105 A

Starter

12V, 2.5kW

Admittable depressure

max 40 mbar with new air filter

Air Cosumption m3/h Max. Exhaust backpressure

Engine Systems Exhaust System

24

Exhaust Gas Temperature after turbocharger

(R754EU5 350 mbar) - (R756EU5 - 450 mbar) with DPF (Diesel Particulate Filter) new, clean or regenerated

569 °C

Maintenance

R 750 Maintenance Intervals WARNING

Avoid injury or death, product damage, fire or explosion. The electrical system is capable of violent and damaging short circuits or severe electrical shocks. When performing any activity where any electrical terminals could possibly be grounded or touched, the battery cables should be disconnected at the battery. Always disconnect battery cables from the battery before working around electrical system components to prevent injury to yourself and damage to the electrical system should a wire be accidentally shorted.

Maintenance Schedule - R750 EURO 4 - IE3 AFTER FIRST 50 HOURS

• Replace the engine oil filter (If the engine has not been in operation, the filter must be replaced once every 12 months)

EVERY 10 HOURS or every day

• Check the engine oil level. (This task interval can be extended based on operator experience with the product.) • Check the coolant level • Check the air filter element cleaning and possible replacement if dirty • Check the radiator cleaning

EVERY 300 HOURS

• Change the engine oil. (Or every year, whichever occurs first.) In particulary severe operating conditions, in dusty environments and when operating under extreme loads, the engine oil must be replaced every 150 working hours. • Replace the engine oil filter (Or every year, whichever occurs first.) • Replace the fuel filter (every 300 hours or 30.000 km.) (Or every year, whichever occurs first.)

EVERY 900 HOURS

• Replace the Poly-V alternator belt (Or every 2 years, whichever occurs first.)

EVERY 1200 HOURS

• Replace engine coolant (Or every 2 years, whichever occurs first.)

EVERY 1500 HOURS or 50.000 km

• Diesel particulate filter cleaning • Partial engine overhaul

• Total engine overhaul

EVERY 4000 HOURS

EVERY 8000 HOURS

Maintenance

25

R 750 Maintenance Schedule - R750 EURO 5

AFTER FIRST 50 HOURS

• Replace the engine oil filter (If the engine has not been in operation, the filter must be replaced once every 12 months)

EVERY 10 HOURS or every day

• Check the engine oil level. (This task interval can be extended based on operator experience with the product.) • Check the coolant level • Check the air filter element cleaning and possible replacement if dirty • Check the radiator cleaning

EVERY 300 HOURS

• Change the engine oil. (Or every year, whichever occurs first.) IMPORTANT: Whenever the engine oil is changed it is necessary to reset the OIL DILUTION CALCULATION function (refer to paragraph OIL DILUTION CALCULATION). In particulary severe operating conditions, in dusty environments and when operating under extreme loads, the engine oil must be replaced every 150 working hours. • Replace the engine oil filter (Or every year, whichever occurs first.) • Replace the fuel filter (every 300 hours or 30.000 km.) (Or every year, whichever occurs first.) • REPLACE AIR FILTER CARTRIDGE • CHECK THE CLEANING OF Air intake circuit • CHECK THE CLEANING AND TIGHTNESS OF intercooler pipeS • CHECK THE TIGHTNESS OF OIL SEPARATOR PIPES AND RELATED SYSTEM • CHECK THE TIGHTNESS OF VACUUM PUMP PIPES AND RELATED SYSTEM • CHECK THE CLEANING OF EXHAUST circuit FROM DUST

EVERY 900 HOURS

• Replace the Poly-V alternator belt (Or every 2 years, whichever occurs first.) • CHECK THE CLEANING OF FUEL TANK AND RELATED FILLING PLUG • REPLACE THE SERVICE INDICATOR ON AIR FILTER

EVERY 1200 HOURS

• Replace engine coolant (Or every 2 years, whichever occurs first.)

EVERY 4000 HOURS

• Partial engine overhaul • Diesel particulate filter REGENERATION • Total engine overhaul

26

EVERY 8000 HOURS

Maintenance

R 750 Engine External Views Exhaust Side View

10

7 3 6

9

5 4

8

2

11

1

.

Oil pan

.

Hydraulic pump

3.

EGR valve and Intake Throttle

4.

Turbocharger

5.

Exhaust manifold

6.

Intake manifold

7.

Rear Engine lifting eye

.

EGR cooler

9.

Water pump pulley

0. Injector . Crankshaft speed sensor / crankshaft position sensor

Maintenance

27

R 750 Timing Side View

10

9

8

3 7 6

5

2

4

1

.

Crankshaft pulley

.

Timing cover

3.

Turbocharger

4.

Oil filter

5.

Automatic belt tensioner

6.

Alternator Poly V Belt

7.

Water pump pulley

.

Alternator

9.

Injector

0. Coolant manifold (thermostatic valve housing)

28

Maintenance

R 750 Injection Side View

9

10

8 7

6

5

1

4

12 3

2

.

High pressure pump

.

Oil filter

3.

Oil heat exchanger

4.

Starter

5.

Rail

6.

Oil separator

7.

Oil dipstick tube

.

Injector

9.

Alternator

11

0. Vacuum pump . Camshaft sensor . Oil pressure & temperature sensor

Maintenance

29

R 750 Top Side View

4

3

2

1

14

13

5 12

11

6

7 10

8 .

Intake temperature & pressure sensor

.

Intake manifold

3.

Oil filler cap

4.

Coolant temperature sensor

5.

Thermostatic valve housing

6.

Poly V belt alternator

7.

Alternator

.

Vacuumm pump

9.

Oil filter housing

9

0. Oil separator . Oil dipstick tube . Injector 3. Rocker arm valve cover 4. Coolant manifold

30

Maintenance

R 750 Engine Oil Specifications To help obtain optimum engine performance and to provide maximum protection, the engine requires engine oil with a rating of ACEA-SAE‑API. We strongly recommend the use of the following engine oil specifications: SAE

10W - 40

This oil exceeds requirements for R750 EURO 4 ACEA API

CI-4 R750 EURO 5

ACEA API

E6 CJ-4

IMPORTANT: the engine oil used on R750 EURO 5 engine models is valid on engines EURO 4 too.

Oil Level

IMPORTANT

Two (2) different oil pans, with different oil capacity, are installed on R750 engines.(Refert to Section “Engine Specifications” to determine oil pans capacities”). During oil change use the lowest oil quantity for filling the engine until the MIN level is reached, indicated by oil dipstick MIN mark. If the MIN oil level is not reached, add oil, 100 - 200 ml at a time for reaching the MIN oil level. Add further oil quantity (100 - 200 ml at a time) for reaching the MAX oil level.

CAUTION

ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your engine. Contain and dispose of oil or oil waste as directed by local authorities. An overfilled engine crankcase or block can cause a fluctuation or drop in oil pressure. The over‑full condition results in the engine crankshaft splashing and agitating the oil, causing it to become aerated. The aerated oil causes a loss of engine performance and an increase in crankcase back pressure. An extreme overfill condition could result in large amounts of oil being drawn into the intake. Checking engine oil level must be done carefully. The oil level must be maintained between the minimum and the maximum oil level mark on the dipstick. To ensure that you are not getting a false reading, observe the following before checking the oil level. • Ensure that the vehicle or the engine at rest in a flat surface. • Allow five minutes for the oil to drain into the oil pan if the engine has just been operated or oil has just been added.

Maintenance

31

R 750 Checking IMPORTANT: Engine crankcase oil must be checked at intervals specified in Maintenance Schedules. 1. Check the engine oil daily before the first start‑up.

CAUTION

Avoid possible injury or damage to the crankcase oil dipstick and internal engine components. Do not remove the oil dipstick when the engine is running. Stop the engine completely before removing or inserting the dipstick. 2. If the engine is operating, stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. 3. Remove the dipstick. Wipe the dipstick clean and reinstall it fully into the dipstick tube. a - Dipstick b - dipstick tube

a

b

4. Remove the dipstick and observe the oil level. Oil level must be between the marks on the dipstick. 5. Add specified oil to bring the level up to, but not over, the maximum mark on the dipstick. Refer to “Engine Specifications - Engine oil Capacities” for the oil quantity and oil specifications for quality.

IMPORTANT

Two (2) different oil pans, with different oil capacity, are installed on R750 engines.(Refert to Section “Engine Specifications” to determine oil pans capacities”). During oil change use the lowest oil quantity for filling the engine until the MIN level is reached, indicated by oil dipstick MIN mark. If the MIN oil level is not reached, add oil, 100 - 200 ml at a time for reaching the MIN oil level. Add further oil quantity (100 - 200 ml at a time) for reaching the MAX oil level.

32

Maintenance

R 750 Filling IMPORTANT: Do not overfill. Refer to “Engine Specifications - Engine oil Capacities” for the oil quantity and oil specifications for quality. Two (2) different oil pans, with different oil capacity, are installed on R750 engines.(Refert to Section “Engine Specifications” to determine oil pans capacities”). During oil change use the lowest oil quantity for filling the engine until the MIN level is reached, indicated by oil dipstick MIN mark. If the MIN oil level is not reached, add oil, 100 - 200 ml at a time for reaching the MIN oil level. Add further oil quantity (100 - 200 ml at a time) for reaching the MAX oil level. 1. Remove the oil filler cap.

a - Oil filler cap

a

NOTE: Always use the dipstick to determine the exact quantity of oil or fluid required. 2. Add the specified oil to bring the level up to, but not over, the maximum mark on the dipstick. 3. Install the oil filler cap.

Maintenance

33

R 750 Changing—Oil and Filter Refer to the Maintenance schedule for the change interval. IMPORTANT: Whenever the engine oil is changed it is necessary to reset the OIL DILUTION CALCULATION function (refer to following paragraph OIL DILUTION CALCULATION). IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only specified engine oil (refer to Engine Specifications - Engine Oil Specifications). 1. Start the engine and allow it to reach normal operating temperature. 2. Stop the engine and allow approximately 10 minutes for the oil to drain into the oil pan. 3. remove the oil dipstick and remove oil filler cap 4. Remove the threaded plug from the oil pan.

a

CAUTION

ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill or discharge oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. a - Oil filler cap b - Threaded plug

b

oil dilution calculation Whenever you change the engine oil, you must reset the “Oil dilution calculation” function. Important: The Oil Dilution Calculation function can be reset with the Diagnostic Tool To reset of Oil dilution calculation function restored is necessary to use the diagnostic tool. In the absence of diagnostic tool it is possible to reset the function through the following procedure: . With engine turned off bring the engine start key to ON position . Fully press the accelerator pedal (from 0% to 100%) 3. Wait for 3 secs before leaving it 4. Leave the accelerator pedal up to original position (0 %) and wait for 3 secs before pressing it again. The above procedure to points 2, 3, 4 must be carried out 5 times. On some vehicles the accelerator pedal procedure is not feasible: in place of pedal accelerator

34

use the potentiometer accelerator. VERIFICATION: if the procedure has been correctly carried out the engine oil low pressure pilotlight blinks 3 times by 1 second spaced by 0.5 seconds. On some vehicles the verification is not feasible.

Maintenance

R 750 5 Install the plug with the washer in the oil pan. Oil sump threaded plug

78.5 Nm

6 Use an appropriate device to loosen the oil filter cartridge. 7 Remove the oil filter cartridge. 8 Disconnect and properly dispose of the old oil filter element. Discard the old O‑ring from the oil filter.

a - Device b - O‑ring c - Filter element

9. Install the new O‑ring. Apply lubricant engine oil to the O‑ring. 10. Thread the new filter element into the oil filter housing. IMPORTANT: Over tightening the oil filter will cause deformation resulting in oil leakage. Oil filter cartridge

b

12.7 Nm

c

11. Turn the oil filter until the sealing surface contacts the housing. 12. Torque the oil filter using an appropriate socket. 13. Refill the engine with new engine oil. Refer to Filling. 14. Start the engine and check for leaks

a

Maintenance

35

R 750 Coolant Specifications

CAUTION

Propylene glycol, alcohol or methanol based antifreeze is not recommended for use in the closed cooling system. Use only de‑ionized or distilled water to dilute the antifreeze if it is not pre‑diluted. Diesel engines are high compression engines and create higher engine operating temperatures. The closed cooling system and engine must remain as clean as possible to provide adequate engine cooling. Adequate engine cooling can only be assured by using the proper antifreeze and water. VM Motori recommends that the closed cooled section of the closed cooling system must be filled with a low‑silicate formula of ethylene glycol antifreeze in solution with deionized or distilled water. A low‑silicate formula prevents antifreeze separation, which causes a silicate gelatin to form. This gelatin will block engine and heat exchanger passages causing the engine to overheat. The coolant, if not premixed, should be mixed, using antifreeze and deionized water, before being added to the closed cooling system. Common tap water or softened water contains unwanted minerals, which can leave deposits in the system that reduce the efficiency of the cooling system. The closed cooled section of the closed cooling system should be kept filled year‑round with an approved antifreeze‑coolant solution. Do not drain the closed cooled section for storage because draining will promote rusting of internal surfaces. If the engine will be exposed to freezing temperatures, ensure that the closed cooled section is filled with a properly mixed antifreeze‑coolant solution to protect the engine and the closed cooling system to the lowest temperature to which they will be exposed. IMPORTANT: The antifreeze‑coolant used in these engines must be a low‑silicate ethylene glycol, containing deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer also to the coolant manufacturer’s instructions. VM Motori approves this type of antifreeze-coolant solution: Solution

50% Antifreeze + 50% de‑ionized or distilled water

Antifreeze meets the following industry specifications: ASTM D 3306

Refer to Maintenance Schedules for change intervals. Refer to Engine Specifications - Coolant System/Capacities for capacity

36

Maintenance

R 750 Checking the level

CAUTION

Avoid serious injury from burns. Do not remove the coolant cap when the engine is hot. Coolant may discharge violently. IMPORTANT: Check engine coolant before starting the engine, when the engine is cold. 1. Allow the engine to cool. 2. Remove the pressure cap from the coolant expansion tank or radiator and observe the coolant level. 3. The coolant level in the radiator should be kept at the bottom side of the pressure cap neck. If the vehicle is equipped with an expansion tank the coolant level should be kept between the upper (MAX) and lower (MIN) marks.Please refer to the user manual of the vehicle. 4. If the coolant level is correct, install the pressure cap. 5. If the coolant level is low, add the specified coolant. Refer to Filling or Capacities for coolant quantity. 6. Install the pressure cap.

a - Pressure cap d - Radiator

a

b

Filling the Closed Cooling System 1. Remove the pressure cap with the engine is cold. IMPORTANT: Use only the specified coolant. (Refer to Coolant specifications) 2. If the coolant is being replaced or the level is low, slowly add the specified coolant to the level indicated in section “Checking Level”.

CAUTION

Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient coolant always available before operating the engine every day. 3. Do not install the pressure cap. Start and operate the engine at fast idle (1500‑1800 RPM). Add coolant if necessary to maintain the coolant at the level specified previously. IMPORTANT: When installing the pressure cap, be sure to tighten it securely to avoid coolant loss. 4. Install the pressure cap after the engine has reached normal operating temperature (thermostat fully open), and the coolant level remains constant, as specified previously (Refer to Engine Specifications). 5. Test the engine operation. Observe the temperature gauge and check the engine for coolant leaks. If the temperature gauge indicates excessive temperature or coolant leaks exist, stop the engine immediately and inspect for the cause. 6. After the first operation, allow the engine to cool. 7. Remove the pressure cap and add the specified coolant to the level indicated in section “Checking Level” . 8. Install and securely tighten the pressure cap.

Maintenance

37

R 750 Draining the Closed Cooling System

CAUTION

ENVIRONMENTAL HAZARD! Discharge or oil, coolant, and other engine and drive fluids into the environment is restricted by law. Do not spill or discharge oil, coolant, and other engine and drive fluids into the environment when using or servicing your vehicle. Contain and dispose of oil, coolant, and other engine and drive fluids as defined by local authorities.

WARNING

Avoid personal injury and burns from hot engine coolant. Allow the engine to cool down before removing the coolant pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. 1. Allow the engine to cool. 2. Remove the pressure cap from the coolant expansion tank or radiator. NOTE: Drain coolant into a suitable container. Dispose of old coolant properly. 3. Loosen the radiator drain plug or tap. If the plug/tap is not present, remove lower rubber pipe from radiator.

a

a - Coolant pressure cap b - Drain plug/tap

b

4 After the coolant has drained completely, close the radiator drain valve or install the rubber pipe in the radiator. Tighten all drain plugs and drain valves securely. 5. If required, clean the closed cooling system. Refer to Cleaning the Closed Cooling System. 6. Fill the system with the specified coolant. Refer to Filling.

Cleaning the Closed Cooling System Closed cooling section of closed cooling system must be cleaned in accordance with the maintenance scheduled intervals or whenever decreased cooling efficiency is experienced.

38

Maintenance

R 750 Air Filter Element r 750 eu4 NOTE: To remove the air filter element, refer to the vehicle manufacturer’s instructions.

r 750 eu5

A air filter box B air mass flow meter

a

b

Slacken the clamps C.

c

Remove the cover D.

d

Maintenance

39

R 750 Replace the main air filter cartridge A.

a

R 754 EU5

On R 756 EU5 engine model it is needed to pull the orange handle as shown in the picture. Remove the air filter cartdridge from the box.

R 756 EU5

UNLOCK

R 756 EU5 Replace the main air filter cartdridge A.

40

Maintenance

a

R 750 Replace the secondary (pre-filter) air filter cartridge B. NOTE: After having replaced the main cartridge (A) two or three times, it is important to replace the cartridge (B), as well.

b

Clean the CYCLON area.

b

CYCLON area

Maintenance

41

R 750 Fuel System General Information

WARNING

Always disconnect battery cables from battery before working on fuel system to prevent fire or explosion.

WARNING

FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components should be inspected for leakage, softening, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation.

WARNING

IMPORTANT: Use of improper or water‑contaminated diesel fuel can cause serious engine damage. Use of improper fuel is considered misuse of the engine, and the resulting damage will not be covered by warranty.

specifiCations The engine has been designed to be powered by standard fuel (conforms to specifications DIN EN 590) available on the European market. If it is to be powered by BIODIESEL fuels (conforms to specifications UNI EN 14214), it can be mixed, up to 5%, with fuel (conforms to specifications DIN EN 590) available on the European market. About R750 engine models use only fuel with low content of sulphur (not above 10-50ppm)

Diesel Fuel in Cold Weather Unaltered diesel fuels thicken and gel in cold temperatures unless they are treated. Virtually all diesel fuels are climatized to allow their use in a particular region for that time of the year. If it becomes necessary to treat the diesel fuel further, it is the owner’s and operator’s responsibility to add a commercial standard brand anti‑gel diesel fuel additive according to product directions. No liability can be accepted by the VM Motori for any malfunction or engine damage, caused by the use of diesel fuel additive and the resulting damage will not be covered by warranty.

42

Maintenance

R 750 Fuel Filter Draining The water‑separating fuel filter can be drained of water and small dirt particles by opening the water drain cap (bleed valve). IMPORTANT: To ensure complete draining in warm weather, open the water drain cap before starting daily operations. In cold weather, when there is a possibility that the condensed water will freeze, drain the filter shortly after the end of daily operations. NOTE: Place a suitable container under the fuel filter to catch contaminated fuel or water. 1. Using a suitable container to catch contaminated fuel or water, open the drain cap at bottom of the filter. 2. Drain the fuel filter until the fuel is clear in appearance. 3. Close the drain cap 4. Fill the water‑separating fuel filter if the fuel has heen completely drained from the filter. Refer to Filling. a - Fuel filter b - Drain cap a

b

Filling & air bleeding Follow this procedure after installing a new filter or after the fuel has been completely drained from the filter when checking for water. 1. Loosen the air vent (bleed) screw on fuel filter header assembly. NOTE: The fuel filter is equipped with a primer plunger on the fuel filter header to assist in filling the fuel filter. 2. Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw. 3. Securely tighten the air vent screw. 4. Start the engine and check for fuel leaks. Stop the engine immediately if a fuel leaks exist. Recheck the installation of the fuel filter.

b a

WARNING

Ensure that no fuel leaks exist before closing the engine hatch.

a - Air vent (bleed) screw b - Primer Plunger

Maintenance

43

R 750 Removal

CAUTION

Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system. 1. Disconnect both battery cables from the battery. 2. Unplug the Water In Fuel ( WIF) sensor wire from the drain cap. a - Drain cap b - WIF sensor wire

a

b

IMPORTANT: The water‑separating fuel filter must be replaced; it cannot be cleaned and reused. 3. If the locking ring is present, loosen it and remove the filter. If is not present, remove by hand or using a commercial device the water‑separating fuel filter.

a - Water separating fuel filter b - Locking ring

a

Installation 1. Lubricate the fuel filter seal with engine oil. 2. Fill the new water‑separating fuel filter pouring new fuel. 3. Align the fuel filter to the fuel filter header assembly. Hand tighten the filter to secure the filter to the header assembly. Do not use a filter wrench. Continue with Filling and Air Bleeding of fuel Filter. 4. Connect the water in the fuel sensor connector and the battery cables. 5. Start the engine and check for fuel leaks. Stop the engine immediately if fuel leaks exist . Recheck the fuel filter installation.

44

Maintenance

R 750 alternator Belt / Poly - V (Serpentine) Inspection 1. Inspect the belt for proper tension and for the following: • Excessive wear • Cracks • Fraying • Glazed surfaces NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable.

2. Check the operation of the automatic tensioner and associated components. a. Position a suitable tool in the automatic tensioner release slot. b. Rotate the automatic tensioner, in the direction of the arrow. c. Release the automatic tensioner and allow it to glide back slowly. d. The automatic tensioner must return to the initial position and hold tension on the serpentine belt.

b a - Automatic tensioner b - Release slot

Maintenance

a

45

R 750 Replacement - Installation

b

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as when first used. 1. Position a suitable tool in the automatic tensioner release slot. 2. Rotate the automatic tensioner, in the direction of the arrow, to remove the tension on the serpentine belt.

c

a - Serpentine belt b - Tensioner release slot c - Hole d - pin

a

d 3. Install a pin into the tensioner hole to block the tensioner rotation. 4. Before removing the serpentine belt note its position on the alternator, and idler pulleys. 5. Replace the serpentine belt. 6. Install a new belt if required. IMPORTANT:Carefully remove the pin and release the automatic tensioner with the breaker bar, ensuring that the belt stays positioned properly on the alternator and idler pulleys races. IMPORTANT: For a correct alignment of the serpentine belt it must be stay positioned on the inner races of the alternator and idler pulleys

a a1

a - alternator pulley b - idler pulley a1 - alternator pulley outer races remaining b1 - idler pulley outer race remaining

a1

b1

46

b b1

Maintenance

R 750 Diesel Particulate Filter (DPF) - r 750 euro 4 Introduction

Diesel particular filters remove particulate matter and inorganic ash from diesel exhaust. Under normal operating conditions the filters collect and burn particulate matter. However, inorganic ash, from the oil does not burn, so it slowly accumulates in the filter. This necessitates periodic ash removal from the filter. This document provides guidelines for ash removal from DPF particulate filter. Following these guidelines maintains filter performance, and trouble free operation.

Cleaning Interval

Refer to Maintenance scheduled intervals. Some applications, including older higher emission engines, may require more frequent cleaning. Customers utilizing a backpressure monitor / dashboard MIL will be notified by the alarm system that cleaning of a DPF filter is required.

Service Record

Customers are required to maintain proper record of the DPF filter service and cleaning. This record should include the following information: - Date of installation of filter - Vehicle operating hours at the time of installation - DPF filter part number and serial number - Date and vehicle operating hours for each filter cleaning

IMPORTANT: every time the DPF filter comes cleaned it is necessary to clean the pressure sensor lines (lines between pressure sensor and DPF filter). Clean the lines as follows: 1. mark each line (the pressure lines have different diameter) 2. disconnect the lines 3. blow with compressed aria in the lines (blow towards DPF filter, see arrows for orientation)

Maintenance

47

R 750 Cleaning Process through “dry compressed air” safety Equipment Required

- A source of compressed dry air (80-100 psi / 5.5-7 bar) with a standard shop air-gun - Dust mask, gloves, safety glasses should be worn during the cleaning. - An industrial vacuum cleaner or a dust/ash collecting device Cleaning Process through “heating in electrical oven”: - Electrical Oven (see specific technical procedure) Before removing the DPF filter centerbody for cleaning, mark the exhaust side (outlet) of the filter. Remove the centerbody. Using compressed dry air on the outlet side and a vacuum on the inlet side, from a distance approximately of 10 cm blow air (5.5-7 bar) through the filter allowing the vacuum cleaner to collect the ash. Alternatively, connect the inlet side of the filter to a dust/ashcollecting device. Make sure to move the gun slowly, directing air into each individual cell for better results. Continue this process for approximately 30-40 min. Avoid direct contact of the air nozzle with the filter surface. Larger filters generally require longer cleaning time. Install the DPF filter centerbody on the vehicle in the reversed flow direction from which it was removed. The side with the mark should become the inlet side. It is not recommended cleaning of DPF filters with steam and / or other detergents. Use of these products may damage and / or deactivate the filters.

CLAMP

CLAMP

CENTER BODY INLET

CENTER BODY

CORPO CENTRALE

OUTLET

INLET

CENTER BODY

OUTLET

30 Nm

CENTER BODY ~ 10 cm

48

Maintenance

R 750 Cleaning Process using an “electrical oven” Before removing the DPF filter centerbody for cleaning, mark the exhaust side (outlet) of the filter. Put the DPF center body into the electrical oven. Follow the heating steps, shown in this chart: STEP

TEMPERATURE °C

DURATION (min)

RAMP SHAPE

start

ambient into oven

/

/

increasing 10°C / min

1

0 - 200

60 min

linear

2

200 - 500

120 min

linear

5°C / min

3

500 - 600

30 min

linear

2°C / min

4

600

360 min

constant

5

600 - 500

30 min

linear

6

500 - 200

120 min

linear

7

200 - 120

60 min

linear

8

120

60 min

constant

9

switch off

/

/

WARNING In certain conditions it could be necessary to clean the filter earlier than normal scheduled maintenance interval filter cleaning, as in event of faster soot accumulation with consequent clogging of the filter. This higher soot accumulation can happen in case of failure of some engine component (i.e. EGR locked open) or in case of engine particular use: always very low load duty cycle, low idle for very long time, etc. In this case the MIL lamp will switch on. The DPF diesel particulate filter may result in a faster clogging and higher soot accumulation if the outlet pneumatic connections or actuators electrical connections of the intake throttle valve and EGR valve are exchanged (see “Intake Throttle Valve Section”). Before removing any connections from above mentioned components, it is recommended to apply a label on them.

Ash Removal Disposal of ash should be in accordance with all local laws and regulations.

Remove the DPF center body from the oven. Install the DPF filter centerbody on the vehicle in the reversed flow direction from which it was removed. The side with the mark should become the inlet side. It is not recommended cleaning of DPF filters with steam and / or other detergents. Use of these products may damage and / or deactivate the filters. IMPORTANT The DPF filter cleaning carried out by electrical oven is deeper that compressed air cleaning. On engine models EURO 4, at the end of every DPF cleaning process (compressed air or electrical oven), is necessary to let start the process “service self regeneratio” through the diagnostic tool (Refer to the Special Tools section). Whenever exist: • un evident damage of the turbocharger with consequent engine oil at the exhaust or • engine oil in intake system it is required to clean the DPF filter with electrical oven. IMPORTANT DPF Diesel Particulate Filter does not require any additional maintenance other than routine cleaning. If the unit does become plugged, the centerbody can be removed and cleaned or replaced. Engine maintenance procedures must be followed to ensure proper DPF filter operation. Oil consumption that exceeds engine specification will increase the required cleaning frequency. Whenever the DPF is disassembled replace the clamps and ring spacers. DPF Filter Clamp torque screws

30 Nm

Maintenance

49

R 750 Diesel Particulate Filter (DPF) - r 750 euro 5 IMPORTANT: the DPF filter is not serviceable. It is necessary to launch the service regeneration through the diagnostic tool in order to clean the DPF filter. It is possible to clean the DPF filter also through compressed air: refer to Section DIESEL PARTICULATE FILTER R 750 EURO 4 - CLEANING PROCESS USING COMPRESSED DRY AIR

GAS INLET ENTRATA GAS

delta p sensor point SENSORE DIFFERENZIALE DI PRESSIONE SCARICO

Exhaust gas tempemperature sensor point SENSORE TEMPERATURA GAS SCARICO

R 754 EU5

GAS OUTLET USCITA GAS SCARICO

R 756 EU5 delta p sensor point SENSORE DIFFERENZIALE DI PRESSIONE SCARICO GAS INLET ENTRATA GAS

Exhaust gas tempemperature sensor point SENSORE TEMPERATURA GAS SCARICO

50

Maintenance

GAS OUTLET USCITA GAS SCARICO

R 750 Extended Storage Storage Information VM Motori engines are shipped from the factory with a sufficient preservation for a 6 (six) months shelf life. Each time the storage procedure is performed the “shelf life” will be extended for six months. The procedure should be performed 30 days of the expiration of VM Motori’s preservation or the current protection. When the engine is being not operated for short periods of time, less than one month, it is advisable to start the engine and operate until it reaches normal operating temperature at least once per month. The engine must always be started and operated until it reaches normal operating temperature once per month if it is installed for emergency purposes. When the engine is being not operated for long periods of time, such as one month or more, up to six months, it is needed to carry out a specific treatment to protect it for 6 months. If the engine remains not operating for a further period of time, check the need to repeat the protective treatment to extend the protection for other 6 months. (Refer to Preparing the Engine for Extended Storage - Engine Protective Treatment)

Preparing Engine For Extended Storage * To prepare the engine for extended storage, follow this procedure: 1. Check for external damages. 2. Remove any cap or protection tape. 3. Check alternator belt tension. 4. Check the air cleaner. 5. Fill the engine to the proper level with preservative lubricating oil MIL-L-21260C, Grade 2. 6. Connect the engine (not for air cooled type *) to an auxiliary radiator, if not existing, and fill with specific solution, water and antifreeze (see coolant specification). 7. Prepare in a portable container a mixture of regular fuel and 10 % preservative oil type Castrol Safecoat DW30X or Rustilo 181 or DWX31 8. Prepare an auxiliary battery and connect to the engine. 9. Start the engine. 10. Operate the engine for five minutes at idle and then at about ⅓ of max rpm until normal temperature is reached (70°C ÷ 80°C or 158°F ÷ 176°F) for water cooled engines; in the case of air cooled engine operation, perform the same test for twenty minutes. 11. Stop the engine. 12. Drain the cooling system. 13. Drain the preservative oil from the engine. 14. Drain the fuel system. 15. Loosen the v-belt driving the alternator. 16. Disconnect the engine from all auxiliary devices useful to the test. 17. Seal all engine openings including the exhaust outlet, with moisture resistant tape. Use cardboard, plywood or metal cover where practical. 18. Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile body wax, a synthetic resin varnish or rust preventive compound. 19. Apply a rust preventive compound to all exposed engine part and to the flywheel. 20. Protect the engine with a good weather-resistant tarpaulin and store under cover, in a dry building. NOTE: Plastic may be used for indoor storage. Moisture absorbing chemicals are available commercially for use when dampness prevails in the storage area. Outdoor storage of engines is not recommended. *) Coolant related procedures not to be applied for air-cooled engines.

Restoring An Extended Storage Engine

Use the following procedure to restore an engine that has been in extended storage. 1. Remove the covers and tape from all of the openings of the engine and electrical equipment. 2. Remove the plugs from the inlet and outlet fuel lines and connect the lines to their proper position. 3. Wash the exterior of the engine with fuel oil to remove the rust preventive. (Do NOT wash the electrical components.) 4. Remove the rust preventive from the flywheel. 5. Tighten the belt to proper tension. 6. For fluid filling, installation and preparing the engine for the use, refer to herein instruction. 7. Check for any coolant or oil leakage at the first running in.

Maintenance

51

R 750 REMOVAL AND INSTALLATION ENGINE lifting eye bracket Place the lifting device as shown in the figure. Loosen the screws (A) and disassemble the side supports (B). Move the engine to the installation area. Further information are available inside the owner manual or installation manual.

B

A

a - lifting eye bracket screw (front side) lifting eye bracket (front side)

27.5 Nm

a

b

b - lifting eye bracket nut (rear side) lifting eye bracket (rear side)

52

32.4 Nm

a

Removal and Installation

R 750 FASTENER TIGHTENING SPECIFICATIONS COMPONENT

Nm

SYSTEM

center main bearing carrieRs - bolts

44,1

ENGINE BLOCK

OIL DELIVERY TO main bearing carrieRs - SPECIAL SCREW ON BLOCK

53,9

ENGINE BLOCK

CAMSHAFT FLANGE - SCREW

27,5

ENGINE BLOCK

OIL PISTON COOLING JET - SCREW

12,7

ENGINE BLOCK

IDLER GEAR (BEETWEN CAMSHAFT AND CRANKSHAFT GEARS) - BOLT

32,4

TIMING SIDE

IDLER GEAR (BEETWEN CAMSHAFT AND INJECTION PUMP GEARS) - SCREW

35

TIMING SIDE

OIL PUMP - SCREW

27,5

TIMING SIDE

COOLANT PUMP - SCREW

32,4

TIMING SIDE

CRANKSHAFT FRONT HUB - NUT

SEE PROCEDURE

TIMING SIDE

CRANKSHAFT FRONT PULLEY - SCREW

45,1

TIMING SIDE

RAIL - SCREW

SEE PROCEDURE

INJECTION SIDE

RAIL BRACKET - SCREW

SEE PROCEDURE

INJECTION SIDE

INJECTOR - CLAMP SCREW

SEE PROCEDURE

INJECTION SIDE

HIGH PRESSURE INJECTION PUMP - FLANGE NUT

27,5

INJECTION SIDE

HIGH PRESSURE INJECTION PUMP GEAR - NUT

86,3

INJECTION SIDE

ENGINE OIL HEAT EXCHANGER (MODINE) - BOLT

60

INJECTION SIDE

OIL FILTER HOUSING - BOLT

39,2

INJECTION SIDE

COOLANT MANIFOLD - SCREW

11,8

INJECTION SIDE

OIL DELIVERY PIPE TO ROCKER ARM - HOLLOW BOLT ON CYL. HEAD

14

INJECTION SIDE

OIL DELIVERY PIPE TO ROCKER ARM - HOLLOW BOLT ON CRANCASE

23,5

INJECTION SIDE

EXHAUST MANIFOLD - NUT

32,4

EXHAUST SIDE

INTAKE MANIFOLD - NUT

27,5

EXHAUST SIDE

TURBOCHARGER - NUT

32,4

EXHAUST SIDE

OIL DELIVERY PIPE TO TURBOCHARGER- HOLLOW BOLT ON TURBO FLANGE

24,5

EXHAUST SIDE

OIL DELIVERY PIPE TO TURBOCHARGER - NUT ON BLOCK

32,4

EXHAUST SIDE

EGR HEAT EXCHANGER (INSTALLED ON HOUSING) - SCREW

10,8

EXHAUST SIDE

EGR HEAT EXCHANGER (INSTALLED ON BLOCK) - SCREW

32,4

EXHAUST SIDE

EGR HOUSING HEAT EXCHANGER (INSTALLED ON EXHAUST MANIFOLD) - NUT

32,4

EXHAUST SIDE

ASSEMBLY EGR & INTAKE THROTTLE VALVE - SCREW

10,8

EXHAUST SIDE

ELBOW ASSEMBLY EGR & INTAKE THROTTLE VALVE - SCREW

10,8

EXHAUST SIDE

VACUUM PUMP OIL DELIVERY PIPE - HOLLOW BOLT (ON BLOCK)

27,5

ENGINE ELECTRICAL

ALTERNATOR - NUT

45,1

ENGINE ELECTRICAL

ALTERNATOR IDLE PULLEY

80 ± 5

ENGINE ELECTRICAL

STARTER MOTOR - BOLT

83,4

ENGINE ELECTRICAL

VACUUM PUMP OIL DELIVERY PIPE - HOLLOW BOLT (ON VACCUM PUMP)

24,5

ENGINE ELECTRICAL

REAR MAIN BEARING CARRIER - NUT

24,5

FLYWHEEL SIDE

FLYWHEEL HOUSING - SCREW

68,6

FLYWHEEL SIDE

FLYWHEEL

SEE PROCEDURE

FLYWHEEL SIDE

OIL FILTER

12,7

MAINTENANCE

CONNECTING ROD - SCREW

SEE PROCEDURE

BASIC ENGINE

CYLINDER HEAD

SEE PROCEDURE

BASIC ENGINE

ROCKER ARM - NUT

29

BASIC ENGINE

GLOW PLUG OR PLUG

14,2

BASIC ENGINE

ALTERNATOR BRACKET - SCREW

68,6

REMOVAL & INSTALLATION

FRONT ENGINE LIFTING BRACKET (INSTALLED ON ALTERNATOR BRACKET)

27,5

REMOVAL & INSTALLATION

REAR ENGINE LIFTING BRACKET (INSTALLED ON EXHAUST MANIFOLD)

32,4

EXHAUST SIDE

Fastener Tightening Specifications

53

R 750 special tools VM code

Description

68400012A

Cylinder liner extractor

68400015A

Crankshaft and camshaft bearing remover/installer

68410006A

Crankshaft assembly tool

68410012F

Assembly/disassembly Hydraulic tappets tool

68420016F

XZN wrench for cylinder head bolt (12 mm)

68420015F

XZN wrench for cylinder head bolt (14 mm)

68420019F

Angular torque wrench

68460003A

Cylinder head assembly dowels

54

Picture

Special Tools

R 750 68480003A

Flywheel ring gear clamp (to be installed in place of starter motor)

68490007A

Cylinder liner protusion gauge

68460005F

Pins for flywheel assembly

68400038F

Crankshaft gear extractor for engines with cylindrical crankshaft end

68500010F

R750 EURO 4 R750 EURO 5 R750 IE3 Diagnostic tool -------------------------------------- The software updating is available on VM Motori web site, Customer Reserved Area “EXTRANET”

Special Tools

55

R 750 68410013G

Front Oil Seal Installer

68400040F 68400046F 68400044F 68400045F 68400045G

Injector Remover (Complete) Body Stud Fork R750 EURO 4 / IE3 Fork R750 EURO 5

68410010F

Rear Oil Seal Installer

68480013F

Counter balancing crankshaft pins (only for engines where the counter weight balance is installed)

6844009F 68440010F

Cylinder head seal hydraulic test Cylinder head seal test with hydraulic O-rings

56

Special Tools

R 750 68420022F

Alternator idle pulley remover

68490038F ONLY FOR R750 EURO 4 Owen for DPF Filter cleaning 3kW - 220V

Test Engine harness 68490035F

(without potentiometer accelerator and ECU)

68490036F

(with potentiometer accelerator and without ECU)

68490037F

(with potentiometer accelerator and with ECU)

68490034F

engine compression adapter tester tool

Break out box 68500017F 68500016F

(without jumpers) (complete of jumpers)

Special Tools

57

R 750 Timing Side .

Timing cover (metal sheet)

.

Crankshaft pulley

3.

Belt Tensioner

4.

Plastic Idler pulley

5.

Coolant pump pulley

6.

Metal idler pulley

7.

Alternator

.

Poly - V alternator belt

7 8 6 5

1

2

58

Timing Side

3

4

R 750 Timing Gears .

Crankshaft gear

.

Oil pump gear

3.

Idler gear

4.

Camshaft gear

5.

Idler gear

6.

Injection pump gear

7.

Hydraulic pump gear

6

5 7

4 3

1 2

.

Gear driving oil pump gear (crankshaft gear not visible)

.

Oil pump gear

3.

Idler gear

4.

Camshaft gear

5.

Idler gear

6.

Injection pump gear

7.

Hydraulic pump gear

6

5

7

4 3

1

2

Timing Side

59

R 750 Timing gears with cylinder number 1 piston is at compression stroke TDC.

Timing reference punched dots camshft gear hydraulic pump gear

idler gear

crankshaft gear

camshft gear

idler gear idler gear

crankshaft gear

60

Timing Side

R 750 1 - Oil pump gear 2 - Crankshaft gear 3 - Idler gear 4 - Camshaft gear 5 - Idler gear 6 - High pressure injection pump gear

timing reference marks - punched dots on the gears segni di riferimento per la fase - punti punzonati sugli ingranaggi

6

4

5

3

2

1

Timing Side

61

R 750 Oil pump Removal •

Remove the gear driving the oil pump gear.

•

Remove the 3 screws with washers (Note bolts position).

•

a - gear driving the oil pump gear

•

b - oil pump and its gear

•

c - screws with washers

a

Cleaning 1. Disassemble and wash all parts in cleaning solvent.

b

2. Put on safety glasses and dry parts with compressed air.

c

Inspection 1. Inspect the oil pump shaft, rotors, and housing for excessive wear or damage. Replace the oil pump assembly if excessive wear or damage is found.

a

2. Check clearance between the inner and outer oil pump rotors. 3. Check clearance between the outer rotor and housing. 4. Check the outer and inner rotor end float (reentering of outer rotor from oil pump body). 5. If the measured values are greater than specified, the pump is faulty and must be replaced as a complete unit. 6. Check the rotor and gear coupling rolling torque.

62

Timing Side

b

c

R 750 Specifications a - Shaft

f - Difference between height of inner rotor and outer rotor seat (Reentering of outer rotor from pump body - see picture below)

b - Inner rotor c - Outer rotor

g - Rotor housing

d - Clearance between rotors (see outer rotor) e - Clearance between housing and outer rotor (see pump housing)

0.030 - 0.087 mm

1 - Oil pump gear 2 - Rotor housing 3 - Outer rotor 4 - Inner rotor 5 - Shaft

Axial clearance between gear and pump body

0.150 ‑ 0.250 mm

Rotor and gear coupling rolling torque resistance

9 kgm

Difference between height of inner rotor and outer rotor seat

0.030 - 0.087 mm

Timing Side

63

R 750 Outer rotor

R754 EURO 4-5 a-

57.95 - 58 mm

b-

49.3 - 49.4 mm

Heigh of outer rotor:

32.483 - 32.5 mm

b

R756 EURO 4-5 a-

57.95 - 58 mm

b-

49.3 - 49.4 mm

Heigh of outer rotor:

37.983 - 38 mm

a

c - Clearance between rotors

0.07 - 0.20 mm

c

Inner rotor

a a

25.92 - 25.97 mm

b

41.12 - 41.15 mm

c

32.045 - 32.075 mm

Heigh of inner rotor: R754

32.483 - 32.5 mm

R756

37.983 - 38 mm

b

c

64

Timing Side

R 750 oil Pump body R754 EURO 4-5 a - Inside diameter of rotor housing

58.13 - 58.18 mm

Clearance between housing and outer rotor

0.13 - 0.23 mm

b - Rotor seat depth in housing

32.53 - 32.57 mm

c - depth

22.06 - 22.10 mm

R756 EURO 4-5 a - Inside diameter of rotor housing

58.13 - 58.18 mm

Clearance between housing and outer rotor

0.13 - 0.23 mm

b - Rotor seat depth in housing

38.03 - 38.07 mm

c - depth

22.06 - 22.10 mm

a

c

b

oil Pump housing into crankcase

Timing Side

65

R 750 Installation •

Lubricate the oil pump rotor housing and the inner and outer rotor surfaces with engine oil.

•

Install the bevelled (chamfered) end of the outer rotor towards the seat (the inside) of the rotor housing.

•

Install the 3 screws and spring washers into the mounting holes in the oil pump. Install the oil pump in the cylinder block.

•

Torque the 3 oil pump screws evenly in a diagonal pattern.

Oil pump screws

27.5 Nm

•

Install the gear driving the oil pump gear by aligning the keyway gear with the crankshaft key and the side with flange must be pointed toward the crankshaft gear. The flat surface of the gear must be pointed towards outside.

•

Check that the oil pump gear is not in a bind by ensuring that there is some clearance (backlash) between the crankshaft sprocket and oil pump gear. Verify the installation if no backlash exists between the gears.

•

Install the timing gear cover.

•

Complete the engine assembly.

•

Verify oil pressure and check for leaks when you start the engine.

a - Bevelled (chamfered) end b - Rotor housing c - Oil pump screws

flange

keyway gear flange

c

66

Timing Side

R 750 Crankshaft gear Removal

a

NOTE: Replace the timing gear only if worn or damaged. Before removing the gear make the reference marks on it and idler gear, so that its installation results easier in order to mantain the gears timing. Take the oil pump driving gear off. Remove the oil pump and the idler gear if nedeed. Install the Crankshaft Gear Puller onto the gear. Tighten the four clamping screws securely. Turn the Crankshaft Gear Puller screw and remove the timing gear.

b

a - Crankshaft gear puller with clamping screws b - crankshaft gear

INStallation Install the gear by aligning the keyway sprocket with the crankshaft spline. Remark new gear making the same reference previously made on replaced gear and align the reference marks on the gear with idler gear reference marks, or if necessary, time the crankshaft gear with the idler gear and camshaft gear (Refer to Timing gears with cylinder number 1 piston is at compression stroke TDC.). NOTE: Before installing the crankshaft gear on the crankshaft, heat the gear at 70°C and istall it against crankshaft shoulder keeping it in position for 10 seconds.

Timing Side

67

R 750 Hydraulic pump Idler gear (between the crankshaft and camshaft gears) removal Remove the 2 idler gear bushing screws.. Before removing the gear make a reference mark on all 3 gears, crankshaft, idler and camshaft gear or align the 3 gears as shown in the picture so that the timing dots (punched on each gear) are properly aligned, timed. Remove the idler gear bushing and idler gear assembly. a - Idler gear bushing b - Idler gear assembly c - Idler gear bushing screw

d - crankshaft gear and idler gear assembly timing dots aligned (dots punched on the gear) e - Idler gear assembly and camshaft gear timing dots aligned (dots punched on the gears) f - timing reference dots punched on the gears (facing outside) Separate the idler gear bushing from the idler gear assembly. Timing gears with cylinder number 1 piston is at compression stroke TDC.

e

timing reference punched dots on the gears coated by a dot of felt-tip pen, carried out during assembling process.

a c d

a c

d

f e

d

68

Timing Side

R 750 Installation

a

Lubricate the idler gear assembly (bearing and idler gear bushing and pin shim C). Install the idler gear bushing into the idler gear assembly. Verify that the bushing rotates freely. Ensure that the timing reference dots on the gear are facing outside, not towards the block. Install the idler gear assembly. Ensure the timing dots on the adjacent gears (crankshaft and camshaft gear) are properly aligned or that the reference marks carried out previously are properly aligned. Verify that the cut area of the bushing is towards the crankshaft sprocket so that the oil pump driving gear fits properly. Ensure that the tapered side C1 of pin shim ring C faces the gear, inside engine (only on EURO 5 engine model).

b

Torque the 2 idler gear bushing screws X = Idler gear bushing screws

32.4 Nm

c1 c

specifications Inner diameter - Idler gear bushing

53.465 - 53.480 mm

Inner diameter - Idler gear

53.500 - 53.519 mm

Clerance - Installation

0.02 - 0.054 mm

Wear Limit

0.2 mm

x - idler gear bushing screws a - Idler gear bushing b - Idler gear c - pin shim ring for idle gear (on EURO 5) c1 - tapered side of pin shim ring

a b

f - timing reference dots punched on the gear (facing outside) g - cut area of the bushing is towards the crankshaft sprocket. h - oil pump driving gear

Timing Side

69

R 750 x - idler gear bushing screws a - Idler gear bushing b - Idler gear c - pin shim ring for idle gear (on EURO 5) c1 - tapered side of pin shim ring f - timing reference dots punched on the gear (facing outside) g - cut area of the bushing is towards the crankshaft sprocket. h - oil pump driving gear

x g

g

h

70

g

Timing Side

f

R 750 injection pump Idler gear (between the camshaft and injection pump gears) removal

c

Remove the idler gear fixing screw, at the bottom of the injection pump. a - Idler gear (between the camshaft and injection pump gears) b - camshaft gear c - injection pump gear d - injection pump e - idler gear fixing screw

b

a

installation Install the gear between the camshaft gear and injection pump gear.

d

This gear must not to be timed. Thread the bolt with a new O-ring, grease it with Moliykote 111 grease, and torque the bolt as follows: 1st Step - tightening

35 Nm

Loosen the bolt by an angle between

30° ÷ 90°

2nd Step - re-tightening

35 Nm

e

f - O-ring g - screw

a

a f f

e g

g

Timing Side

71

R 750 hydraulic pump gear assembly removal

Loosen the rear allen screws and remove the rear flange.

Loosen the front allen screws and remove the cover.

72

Timing Side

R 750 Remove the hydraulic pump sprocket assembly (driving gear + ball bearing)

Remove the hydraulic pump idler gear

Timing Side

73

R 750 installation Install the idler gear into the block. Oil the idle gear shaft Ensure that the grooves are towards the block a - groove

a Install the hydraulic pump sprocket assembly (gear + ball bearing) into the block bore. Oil the outer surface of ball bearing.

Install the front cover by aligning the pins with block holes. a - pin b - Hydraulic pump cover fixing screws Apply Loctite 572 on the allen screws thread and torque them. Hydraulic pump cover fixing screws

24.5 Nm

a

b

74

Timing Side

R 750 Install rear flange. Apply Loctite 572 on threads bolts and torque them. Rear flange Fixing Screws

19.6 Nm

Note: install the gasket with the cut side as showed in the picture

Timing Side

75

R 750 belt tensioner - (automatic type) removal

b

Remove the alternator belt (Refer to Altenator Belt) Position a suitable tool in the automatic tensioner release slot. Move (rotate) in direction of the arrow the tensioner and align 2 holes. Insert a pin into to 2 holes to block the tensioner. Remove the tensioner bolt.

c

a - Serpentine belt b - Tensioner release slot c - Hole d - pin

a

d Installation Align the pin with the drilling in the bracket and install the automatic tensioner assembly. Torque the automatic tensioner mounting screw. Tensioner bolt

a

b

78.5 Nm

a - drilling b - pin c - screw

c

76

Timing Side

R 750 belt tensioner bracket removal Remove the alternator belt and belt tensioner (Refer to proper section). Remove the bolts from the bracket.

b

installation Install and torque the bolt at: a

78.5 Nm

b

44.1 Nm

a

a

b

Timing Side

77

R 750 idler pulleys removal Remove the alternator belt. (Refer to alternator belt section) Remove the left-hand therad bolt. a - metal pulley

Installation Install the bolt (left-hand therad) and torque it Idler pulley screw

53 Nm

a

Remove the right-hand therad bolt. Install the bolt and torque it.

b

b - Plastic Pulley Idler pulley screw

78

53 Nm

Timing Side

R 750 crankshaft hub and pulley removal Remove the alternator belt (Refer to Alternator Belt section). Install the Flywheel ring gear clamp tool in place of starter to block the crankshft rotation. Remove the 6 crankshaft pulley bolts and take the pulley off. Using a suitable 46 mm socket, remove the left‑hand thread crankshaft hub nut.

a b c

IMPORTANT: It is also possible take the crankshaft pulley and hub off as assembly without removing crankshaft pulley from the hub.

d

a - crankshaft hub nut b - crankshaft pulley c - crankshaft hub d - Flywheel ring gear clamp tool

a

c crankshaft hub and pulley as assembly

b c

Timing Side

79

R 750 installation If the pulley has been removed from the hub, install the hub on the pulley as shown in the picture. Make sure that the pulley rim is towards outside.

a

a - crankshaft pulley b - crankshaft hub c - pulley rim

b

b c

80

Timing Side

R 750 Clean contact surfaces between the crankshaft hub and crankshaft nut with cleaning solvent and dry with compressed air. Clean the crankshaft threads. Clean the crankshaft hub surface in contact with the oil pump gear driving. If the timing gear cover oil seal has been removed for replacement, clean the seating surface in the cover.

c

a

Front Oil seal and the sealing lip of an oil seal can be damaged by grease on your hands or the dirt from gloves. A damaged oil seal or oil seal lip could result in an oil leak. When fitting or replacing crankshaft hub, do not touch inside the oil seal or touch the oil seal lip with your bare hands or with dirty gloves. Install the Flywheel Holder Tool in place of the starter motor to block the crankshaft rotation.

a

Apply lubricant “Molykote G Rapid Plus Paste” to the left‑hand thread crankshaft hub nut threads and on the crankshaft hub contact side. Align the keyway of crankshaft hub with crankshaft spline and finger tighten the left‑hand thread crankshaft hub nut. WARNING: the left‑hand thread crankshaft hub nut must be installed with flange-side towards crankshaft gear (the inside of engine).

b

TIGHTENING PROCEDURE Torque the nut at 400 Nm. Loosen and retorque it at 600 Nm a - crankshaft hub contact surface (oil pump gear driving) b - crankshaft hub keyway c - crankshaft spline d - crankshaft hub contact surface (crankshaft nut) e - left‑hand thread crankshaft hub - flange-side Install fixing pulley bolts with proper washers and torque them. Crankshaft pulley bolt

45.1 Nm

d

Remove the Flywheel Holder Tool. x - identification mark for left-hand thread nut

e

x

Timing Side

81

R 750 water pump and pulley

a

removal Remove any pipes or rubber hoses from the pump. Remove the alternator belt (Refer to Alternator Belt Section). Remove the water pump pulley screws or water pump housing screws to take the water pump assembly off.

b

a - water pump housing b - water pump housing screws c - water pump pulley screws

c

Remove the old gasket from the pump housing and block. Be careful not to gouge or nick the sealing surfaces.

installation Inspect the water circulating pump body for blockage, cracks, sand holes, corrosion or other damage. Inspect the impeller for cracks, corrosion, or damage. Inspect the impeller shaft and bearings for excessive side play, abnormal noise when turning, or wear. Inspect the pulley for bends, cracks, corrosion, improper runout, or other damage. Apply sealant Loctite to both sides of the new water circulating pump gasket. Install the new water circulating pump gasket on the engine block. Torque the 6 water circulating pump flange screws as shown in the picture. Torque 3 water pump pulley screws. water circulating pump flange screws

32.4 Nm

water circulating pump flanged support (upper position) fixing screws

32.4 Nm

water pump pulley screws

27.5 Nm

x x

x - water pump - upper position

82

Timing Side

R 750 timing gear cover metal sheet cover removal Remove any component that hinder the cover removal. Remove the fixing bolts around the cover perimeter. Use a knife to cut the sealant silicon. Detach the cover from crankcase by ensuring do not bend it.

installation Check the front oil seal for wear or damage. Replace the oil seal if needed. (Refer to Front Oil Seal section). Remove the old silicon material from the cylinder block and timing gear cover. Be careful not to gouge or nick the sealing surfaces. Apply a continuous bead of sealant (silicon type Dow Corning 7091) (as shown in the pictures) along the cover perimeter, following the races and on the inside of hole bolts as shown. Align the cover with the pins installed in the block. Torque the timing gear cover flange screws evenly, in a cross pattern to: timing gear cover flange screws

12.7 Nm

a - holes b - races c - bead of sealant

c a

c

b

Timing Side

83

R 750 front oil seal removal IMPORTANT: Oil seals and the sealing lip of an oil seal can be damaged by grease on your hands or the dirt from gloves. A damaged oil seal or oil seal lip could result in an oil leak. When fitting or replacing an oil seal, do not touch inside the oil seal or touch the oil seal lip with your bare hands or with dirty gloves. The seal is made of special compounds; do not touch or handle the lips of the seal. Do not attempt to install front main seal using a hammer or mallet. Damage to the seal or timing cover could result. Lubricate the oil seal outer surfaces. Do not touch or handle the lips of the seal. Install the new front oil seal in the Front Oil Seal Installer. Torque the screw and the seal will stop when seated.

84

Timing Side

R 750 ExHaust Side turbocharger removal IMPORTANT: In case of failure of turbocharger (seized bearings, broken shaft, etc.) with consequent oil leakage from turbocharger exhaust side, evaluate the DPF filter cleaning (Refer to Section “Maintenance - DPF Filter”)..

d a

Loosen the hollow bolt and hex nut of the oil delivery pipe and remove oil delivery pipe. Loosen the clamp of the oil drain pipe and take it off. Remove mounting nuts.

c

Remove the old gasket.

b

a - oil delivery pipe b - oil drain pipe (clamp) c - mounting nuts d - hollow bolt e - hex nut

a Installation Install a new gasket on the exhaust manifold. Install the turbo and torque the nuts evenly, in a diagonal pattern. Turbocharger flange nuts

e

32.4 Nm

Install the oil drain pipe. Finger tighten the hollow bolt with new washers on the turbo and hex nut on the block. Torque the hollow bolt and the hex nut. Oil delivery pipe hollow bolt

24.5 Nm

Oil delivery pipe hex nut

32.4 Nm

Exhaust Side

85

R 750 egr cooler removal Loosen the clamps of the rubber hoses and remove them from EGR cooler.

b

Loosen the clamps of the pipe connected to EGR cooler housing and throttle valve. Remove the pipe. a - rubber hose (clamp)

c

b - pipe (clamp) c - EGR cooler d - EGR cooler housing e - bolts fixing the EGR cooler assembly to cranckcase f - nuts fixing EGR housing to exhaust manifold and the old gasket.

a

g - spacer between EGR cooler and crankcase

Loosen and remove the bolts fixing the EGR cooler assembly to cranckcase. IMPORTANT: Between the EGR cooler and crankcase a spacer is inserted. Do not forget it during assembling. Remove nuts fixing EGR housing to exhaust manifold and old gasket.

d

e f

d

86

d

Exhaust Side

e

R 750 Loosen the 5 fixing screws and remove the housing from EGR cooler. IMPORTANT: Never use a caustic cleaning solution, as it may attack aluminum. Also, never use a wire brush which could damage blade or mating surfaces.

c

c - EGR cooler d - EGR cooler housing with gasket.

d

Installation Assemble the EGR cooler assembly by using a new gasket. x - EGR cooler fixing screw to housing x = EGR cooler fixing screw to housing

10.8 Nm

x

a

Install a new gasket on mating surface of EGR housing cooler and install it in the exhaust manifold studs. Finger tighten 2 nuts fixing the EGR cooler assembly to exhaust manifold and bolt fixing EGR cooler assembly to crankcase.

b

IMPORTANT: Mind to install the spacer between the EGR cooler and crankcase. a - nuts fixing EGR cooler assembly to exhaust manifold with new gasket. b - bolts fixing the EGR cooler assembly to cranckcase Torque nuts and bolts as indicate in the table.

a = nuts fixing EGR cooler assembly to exhaust manifold

32.4 Nm

b = bolts fixing the EGR cooler assembly to crankcase

32.4 Nm

Install a new washers in the collars of the metal pipe clamps.

e

Install the pipe and torque the screw of the clamps. e - washer Install the rubber hoses and proper clamps.

Exhaust Side

87

R 750 intake Throttle / EGR valve & PROPER actuators removal WARNING The DPF diesel antiparticulate filter may result in a FIRE HAZARD if the inlet/outlet pneumatic connections or actuators electrical connections of the intake throttle valve and EGR valve are exchanged. Before removing any connections from above mentioned components, it is recommended to apply a label on them.

a

Label the pneumatic rubber pipes connected to outlet of throttle valve and EGR valve. a - EGR valve (pneumatic oulet)

b

d

b - Throttle valve (pneumatic oulet) These 2 outles are connected to 2 identical modulator vacuum sensors and it results very simple to exchange them. Loosen the bolts fixing throttle valve to intake manifold. Remove the intake throttle valve and old gasket. Loosen bolts fixing the throttle valve to elbow and separate the valve from elbow. c - bolts fixing the throttle valve to elbow d - bolts fixing throttle valve to intake manifold

c

Installation Take a new gasket and install the throttle valve on the elbow. Torque the bolts at: c = bolts fixing the throttle valve to elbow

10.8 Nm

Install a new gasket on elbow mating surface and torque the bolts at: d = bolts fixing the elbow to intake manifold

88

10.8 Nm

Exhaust Side

R 750 a - Vacuum pump

c

b - Pnuematic outlet from vacuum pump c - Actuators (c1: EGR valve / c2: Intake throttle valve) d - Actuators electrical connection (d1: EGR valve / d2: Intake throttle valve

a

e - Intake Throttle valve e1 - Intake Throttle valve - Pneumatic Inlet (in the valve) e2 - Intake Throttle valve Pneumatic Outlet from proper Actuator f - EGR valve f1 - EGR valve - Pneumatic Inlet (NOT VISIBLE) f2 - EGR valve Pneumatic Outlet from proper Actuator

b

x - Actuators Pnuematic Inlet from vacuum pump (VAC=vacuump)

c1 d1

c2 d2

f

y - OUT=pnuematic outlet from actuator to Intake Throttle valve or EGR valve

b

e

x e2

f2 y b

f

x e e1

Exhaust Side

89

R 750 EGR & INTAKE THROTTLE VALVE CONNECTIONS TEST

EGR VALVE - VALVOLA EGR

INTAKE THROTTLE VALVE VALVOLA ASPIRAZIONE A FARFALLA

INTAKE THROTTLE VALVE ACTUATOR

1

1

2

vehicle wiring harness connector Connettore cablaggio veicolo

2

MODULATORE DEL VUOTO VALVOLA ASPIRAZIONE A FARFALLA

EGR VALVE ACTUATOR MODULATORE DEL VUOTO VALVOLA EGR

1 + 12 V from Main Relay + 12 volt da Relé principale

2

engine wiring harness connector Connettore cablaggio motore

VACUUM PUMP POMPA DEL VUOTO

90

Exhaust Side

R 750 INSTRUCTIONS Measure with a tester the continuity between pin 2 of one of two the vehicle wiring harness connectors (connectors that will be connected to proper modulators) and pin 1 of engine wiring harness connector. Once verified the continuity, the electrical connection is related to Intake Throttle valve. Measure with a tester the continuity between pin 2 of remaining engine wiring harness connector and pin 2 of the vehicle wiring harness connector, to establish the electrical connection related to EGR valve. Once verified the electrical connections, carry on with pneumatic hoses connection to proper component. FINAL ENGINE TEST Operate the engine Run the engine at idle RPM for several minutes to allow the vacuum system charges. Stop the engine Verify Intake Throttle Valve drive rod moves, so that it closes intake inlet.

exhaust manifold removal Loosen the 2 bolts fixing the heat shield and remove it. a - heat shield Remove any component wich hinders the turbocharger removal. Loosen and remove fixing flange nuts.

b

a

b

b - flange nuts fixing exhaust manifold Remove all spacers if present from the studs and remove the exhaust manifold and old single gaskets. c - spacer

Installation Install new single gaskets on the studs if necessary. Install the exhaust manifold and proper spacers. Install flange nuts and torque them evenly in a cross pattern. Exhaust flange nut

32.4 Nm

b

Exhaust Side

c

91

R 750 intake manifold removal Remove the exhaust manifold and any component wich hinders the intake manifold removal. If nedeed remove the Intake Throttle Valve and proper elbow fixed to intake manifold. Remove fixing flange nuts and take the intake manifold off. a - flange nut

a

If necessary replace the gaskets.

Installation Install new gaskets on studs if nedeed. Install the flange nuts and torque them evenly in a cross pattern. Intake flange nut

27.5 Nm

a

92

Exhaust Side

R 750 Flywheel Side Crankshaft End Play (Axial Clearance)

Install the Flywheel. Refer to Flywheel. Attach the Dial Indicator to the cylinder block to check the installed crankshaft end play (axial clearance). Measurement can be made from the crankshaft counter weight or flywheel outer surface.. Firmly force the crankshaft rearward. Record the measurement. Firmly force the crankshaft forward. Record the measurement. Subtract the measurements to determine the crankshaft end play (axial clearance).

crankshaft end play

0.080 - 0.230 mm

If the end play (axial clearance) is incorrect, calculate the necessary thickness of the thrust washers needed. Install different thickness thrust washers in rear main carrier and recheck the end play (axial clearance). Refer to Rear Main Bearing Carrier to determine thickness thrust washers. Repeat the steps until the proper end play (axial clearance) is obtained.

Flywheel Side

93

R 750 Flywheel Removal •

Measure and record the crankshaft End Play (Axial Clearance) before removing the flywheel. (Refer Crankshaft End Play - Axial Clearance).

•

Remove the starter and install the special tool, flywheel holder tool, to block the crankshaft rotation.

•

Remove 2 of the flywheel bolts and install the Flywheel Assembly Guide Pins (Refer to special tools).

•

Remove the remaining flywheel bolts and remove the flywheel.

•

a - Flywheel bolts

•

b - Flywheel

b

• •

Take the flywheel off and remove the special tool, flywheel holder tool, blocking the crankshaft rotation

a

94

Flywheel Side

R 750 When taking the flywheel off a crankshaft thrust plate could be installed. If not present, it is melted with the flywheel. In this case verify the O-ring presence. • a - cranckshaft thrust plate (NOT melted with flywheel) • b - cranckshaft thrust plate (melted with flywheel)

• • • •

c - thrust plate o-ring groove d - engine without crankshaft thrust plate e - thrust washers f - rear oil seal

e

d

f

a

f

c c

b

a

Flywheel Side

95

R 750 Installation Install a new O-ring in thrust plate groove. A small amount of grease, such as Molykote, may be used to hold the O‑-ring in position during installation. Whenever the flywheel is removed, replace the O‑ring. Install the thrust plate with O-ring towards the crankshaft. Ensure that there are no scratches, nicks, cracks, or seizure marks on the flywheel mating surface. Only minor scratches, nicks, or seizure marks can be removed. Replace the flywheel if damaged. When installing the flywheel, do not touch or handle the lips of the rear oil seal. Ensure that the rear oil seal is in good conditions. Replace it if any doubt exists. (Refer to Rear Main Bearing Carrier). Ensure that thrust washers are not damaged or worn and are properly seated into the rear main bearing carrier. Replace them if any doubt exists (Refer to Rear Main Bearing Carrier). Install the 2 Flywheel Assembly Guide Pins in the crankshaft.. Install the flywheel with O‑ring (if the cranckshaft thrust plate is melted with flywheel ) onto the crankshaft using the Flywheel Assembly Guide Pins. Lubricate the threads and underside of the head of the flywheel bolts. NOTE: The flywheel bolts may be installed as many as three times, and then must be replaced with new bolts. Replace the bolts if any doubt exists about reuse. New bolts must not be lubricated. Install and hand tighten four of the flywheel bolts. Remove the Flywheel Assembly Guide Pins and install the remaining flywheel bolts. Remove the starter and install the special tool, flywheel holder tool, to block the crankshaft rotation. Torque the flywheel bolts evenly in a clockwise direction, cross pattern at 50 Nm.. Loosen completely one flywheel bolt at a time, and tighten the bolts evenly in a clockwise direction, cross pattern at 20 Nm + 75° . NOTE:Verify the Crankshaft End Play (Axial Clearance). Refer to Crankshaft End Play (Axial Clearance) to set the crankshaft end play. Remove the special tool, flywheel holder tool, to block the crankshaft rotation and install the starter.

Bolt specifications a

70 mm

b

58.75 - 60.25 mm a b

96

Flywheel Side

R 750 FLYWHEEL RING GEAR

1. Heat the ring gear with a torch on the engine side of the ring gear. 2. Once heated, knock the ring gear off the flywheel. Do not strike the flywheel when removing the ring gear.

CAUTION

Some components are made of steel that has been heat treated to increase hardness.

Applying excessive heat to the hardened steel will alter the hardness and make the steel weaker. Do not heat any portion of these hardened steel components, such as a flywheel ring gear, to a temperature higher than 210 °C. 3. Heat the new ring gear for 20 minutes in an oven preheated to 190 - 210° C , or heat evenly until the gear expands enough to slip onto the flywheel. Do not overheat the ring gear. IMPORTANT: The ring gear must be installed so the bevel on the teeth is toward the crankshaft side of the flywheel. 4. Install the ring gear. Ensure that the ring gear is seated properly against the flywheel shoulder. The ring gear can move away from the flywheel shoulder no more than 0.50 mm.

Flywheel Side

97

R 750 Flywhell housing

a

Removal Remove the flywheel (refer to Flywheel). Remove the crankshaft thrust plate if fitted.

c

Remove the flywheel housing bolts. Using a rubber mallet, tap evenly around the housing. The flywheel housing with rear main bearing carrier, will be pulled from the cylinder block.

b

When removing the flywheel housing, do not touch or handle the lips of the rear oil seal and do not damage the rear main bearing carrier O-ring. a - flywheel housing bolts b - rear oil seal c - thrust washers

a - O‑ring into the groove of the flywheel housing b - Groove c - Flywheel housing

98

a - Rear main bearing carrier flange nuts b - Flywheel housing with detached rear main bearing carrier c - Rear main bearing carrier

Flywheel Side

R 750 Installation IMPORTANT: Whenever the flywheel and flywheel housing are removed, replace all installed O‑-rings.

A

O-ring

Ensure that thrust washers are not damaged or worn and are properly seated into the rear main bearing carrier. Replace them if any doubt exists (Refer to Rear Main Bearing Carrier). Apply silicon Dow Corning 7091 on flywheel housing groove where the O-ring seats. PHOTO A. Install a new O‑-ring into the groove of the flywheel housing. Apply a bead of sealant (thickness 2 mm) around the O-ring as shown in the photo B. Install a new O-ring into the groove around the rear main bearing carrier. Apply a bead of sealant (thickness 2 mm) around the O-ring as shown in the photo C.

B

O-ring

Lubricate the rear crankshaft journal and rear main bearing. Install the flywheel housing. Install and torque the flywheel housing bolts evenly in a diagonal pattern. flywheel housing bolts

68.6 Nm

cordone di silicone - bead of silicon

c

Flywheel Side

99

R 750 rear main bearing carrier Removal Remove the flywheel and flywheel housing. (Refer to proper section). Disassemble the rear main bearing carrier from the flywheel housing by removing the flange nuts

Installation Check the thrust washers condition and that they are properly seated into the rear main bearing carrier. Replace them if any doubt exists. Install a new O‑ring around the groove of the carrier. and apply silicon (Refer to Flywheel Housing). Align the flywheel housing with the rolled pin installed in the rear carrier. Install the flange nut and torque them. Rear Main Bearing Carrier fixing flange nut

24.5 Nm

a - Rear main bearing carrier flange nuts b- Rolled pin install in the rear carrier

b

a

THRUST WASHERS

b

removal Using a suitable device, carefully pry out the washer halves. Do not damage the rear main bearing carrier or rear oil seal.

c

INSTALLATION Ensure that the washer halves are properly seated in the rear main carrier and that the oil passages are towards outside as shown in the picture. Align the tab of a washer half with the notch in the rear main bearing carrier Press the washer halves simultaneously into the carrier. a - tab b / c - washer halves d - oil passages (grooves)

Specifications Thrust Washer Standard

2.310 ‑ 2.360 mm

First oversized (+0.10)

2.410 ‑ 2.460 mm

Second oversized (+0.20)

2.510 ‑ 2.560 mm

100

Flywheel Side

a d

R 750 REAR MAIN BEARING Removal Using a suitable mandrel, press the rear main bearing out of the carrier.

a - hole - oil passage

Installation Align the hole of a new rear main bearing with the oil passage in the rear main bearing carrier and press the new bearing into the carrier.

a

Specifications Rear main bearing inner diameter (installed into the carrier)

80.045 - 80.07 mm

First oversized bearing

0.25 mm

IMPORTANT: Refer to Crankshaft Section to determine the Rear Main Bearing Crankshaft Journal Outside Diameter and Rear Main Bearing Clearance.

Rear oil seal removal Using a suitable device, carefully pry out the old seal. Do not damage the rear main bearing carrier or thrust washers.

INSTALLATION IMPORTANT: The seal is made of special compounds; do not touch or handle the lips of the seal. Do not attempt to install rear main seal using a hammer or mallet. Damage to the seal or rear main bearing carrier could result. Lubricate the rear oil seal outer surfaces. Do not touch or handle the lips of the seal. Install the new rear oil seal in the bearing carrier using the Flywheel Seal Installer. The seal will stop when seated.

cps target wheel bolt removal Remove the flywheel, flywheel housing with rear main bearing carrier.

a

Slacken and remove no. 3 bolts retaining the CPS (Crankshaft Position Sensor) target wheel. a - CPS (Crankshaft Position Sensor) target wheel bolts

installation Usually replace the old bolts. Replace the old bolts and apply loctite 510 on the bolt thread. Install the bolts and torque them. CPS (Crankshaft Position 14.7 Nm Sensor) target wheel bolts

Flywheel Side

101

R 750 BASIc ENGINE cylinder head GASKET IMPORTANT: When cylinder heads are removed for service but pistons and cylinder liners are not disturbed,use the same thickness gaskets that were removed. Refer to Head Gasket Identification. Refer to the following procedures during a complete engine rebuild or when pistons and liners are being replaced. 1. Use the dial indicator and Support Block tool (liner gauge bar) (refer to Special Tools) to measure piston height above the cylinder block with the piston at Top Dead Center (TDC ). 2. Place Support Block on cylinder block surface and set the dial indicator to zero 0. 3. Move the Support Block tool to the piston surface with the piston at TDC point as shown.Record the measurement. 4. Measure the piston protrusion (height) of all pistons. Use the average measurement to determine the gasket thickness required for all cylinders.

a - Support Block tool b - Dial indicator c - piston Piston protrusion (height) above cylinder block - average

Gasket thickness required

0.60 - 0.72 mm

1.42 mm

0.73 - 0.82 mm

1.52 mm

0.83 - 0.95 mm

1.62 mm

5. After determining the head gasket thickness required, identify and select the proper the cylinder head gasket. Note the identification marks (holes or notches) in the lower right hand corner. No mark indicates a thickness of

1.42 mm

Two marks indicate a thickness of

1.52 mm

One mark indicates a thickness of

1.62 mm

102

Basic Engine

Two notches gasket shown a - Notches

R 750 cylinder head INSTALLATION •

Clean out bolt holes in cylinder block. Be certain no contaminants (dirt, old oil or coolant) remain in the holes.

•

Clean the gasket surfaces on block and heads.

•

IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced with new bolts. Replace if any doubt exists or the thread is stretched.

•

NOTE: New cylinder head bolts must not be lubricated. They are already lubricated with an anti‑seizing lubricant from the manufacturer, and do not require additional lubrication.

•

Thoroughly clean all existing cylinder head bolts and washers, including all formed spacer‑washers (terminal bridges, three types) and cylinder head spacers (for ends of first and last cylinder heads).

•

If the bolts are reusable lubricate with Molykote G Rapid Plus Paste the bolt threads and underside of bolt heads of all 12M (12 mm) cylinder head bolts (side bolts) and 14M (14 mm) cylinder head bolts (center bolts)

•

IMPORTANT: Cylinder head gasket must be installed dry. Do not use any sealant or adhesive on the gasket.

•

Position the cylinder head gasket on the cylinder block.

•

Install the Cylinder Head Guide Pins (refer to Special Tools) into the 12 mm bolt holes in the gasket and cylinder block at each cylinder location. These pins will align the gasket and cylinder heads.

•

Beginning with cylinder number 1, install the cylinder heads over the guide pins.

a - Cylinder head gasket b - Guide pin locations (two at each cylinder) c - Cylinder head

Center bolts

Side bolts (injection side)

Basic Engine

Side bolts (intake/exhaust side)

103

R 750 •

One at a time, remove the Cylinder Head Guide Pins and install the 12M cylinder head side bolts previously lubricated is reused, finger tight. Do not disturb the cylinder head placement.

•

Install and finger tighten all lubricated 14M cylinder head center bolts, including the proper formed spacer washers (terminal bridges, three types) and cylinder head spacers, for the ends of the first and last cylinder heads, as shown in the following.

a - Spacer, first and last cylinder head ends b - (b1,b2,b3) - Formed spacer washers (terminal bridges, three types) b1 and b1* have the same shape but b1 is overturned than b1*, the edge is upwards.

b1

b1

b1*

b1

b1* a

a

b3

b2

b2

b1

b3

b2

b3

b2

b3 b1* b1

x

a

b1 and b1* have the same shape but b1 is overturned than b1*, the edge is upwards. x - edge upwards y - edge downwards

104

Basic Engine

y

R 750 •

Using the appropriate tools (refer to Special Tools), lightly hand tighten all bolts.

16

15 1

9

•

13

12

Correctly align the cylinder heads by temporarily installing the exhaust or intake (or both) manifold with gaskets and finger tighten each flange nuts. Slightly loosen the 12M and 14M bolts as needed, to allow the cylinder heads to align.

Max disalignement 0.2 mm (measured on intake/exhaust flanges manifold) •

Hand tighten the exhaust manifold nuts sufficiently to align the cylinder heads to the exhaust manifold.

•

Using the appropriate tools (refer to Special Tools), hand tighten all 14M and 12M cylinder head bolts.

•

Torque the center bolt 14M set as specified and in the sequence shown, following steps a, b, and c. Do not torque the side bolt set at this time.

5

4

8

11 •

7

3

2

10

18

17

6

14

SIDE BOLTS a. First pass and sequence: Torque value - 30 Nm Sequence 11, 12, 13, and 14 (4 cylinder heads engine) 15, 16, 17, 18, 19 and 20 (6 cylinder heads engine) b. Second pass and sequence: Torque angle + 85° Sequence 11, 12, 13, and 14 (4 cylinder heads engine) 15, 16, 17, 18, 19 and 20 (6 cylinder heads engine) c. Third pass and sequence: Torque value 30 Nm

CENTER BOLTS

Sequence

a. First pass torque and sequence:

15, 16, 17, and 18 (4 cylinder heads engine)

Torque Value - 30 Nm

21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)

Sequence 3‑2‑1‑4‑5‑8‑9‑10‑7‑6 (4 cylinder heads engine) 11, 12, 13, 14, 10, 9, 8, 4, 3, 2, 1, 5, 6, 7 (6 cylinder heads engine) b. Second pass torque and sequence:

d. Final pass and sequence: Torque angle + 85° Sequence 15, 16, 17, and 18 (4 cylinder heads engine) 21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)

Torque Angle + 65° Sequence 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine) 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine) c. Final pass and sequence: Torque Angle + 65° Sequence 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine) 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine) •

Now, torque the side bolt numbered sets as specified and in the sequence shown, following steps a, b, c and d.

Basic Engine

105

R 750 Torque Procedure After the First 20‑30 Minutes of Operation IMPORTANT When the cylinder heads are replaced or disassembled an additional angular torque and conventional torque must be applied. Torque the cylinder head mounting bolts as specified after the first 20‑30 minutes of operation and with engine cold.. 1. Operate the engine at a fast idle for few minutes. Then operate the engine at 1/3 RPM of the rated RPM for approximately 20‑30 minutes until water temperature reaches 70-80 degrees °C, normal operating temperature. 2. Let the engine cool down completely, at least less than 40° C, temperature measured on 1st cylinder head.. 3. Follow the sequence one at a time, completely loosen each M14 center bolt and torque as indicated in steps a and b. a. First pass: center Bolts - M14 Slacken completely one bolt at a time and retorque it at 30 Nm + 120° (or 60°+60°) by following the sequence indicated here below. Slackening Sequence 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine) / 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine) Torque Value 30 Nm + Torque Angle 120° (or 60°+60°) Torque Sequence 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine) 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine) SIDE Bolts - M12 NOTE: The 12M side bolts numbered 11 ÷ 18 (4 cylinder heads engine) or 15 ÷ 26 (6 cylinder heads engine) do not require tightening again. If necessary, check the 12M side bolts with a conventional torque wrench, checking the torque on each side bolt as indicated. Torque Value 90 Nm Torque Sequence 11-12-13-14-15-16-17-18 (4 cylinder heads engine) 15-16-17-18-19-20-21-22-23-24-25-26 (6 cylinder heads engine)

106

Basic Engine

R 750 Disassembly Using a valve spring compressor, remove the valve locks, the retainers, the springs, and the spring plates. Remove the valves from the cylinder head and place in a rack or label the parts in order for reassembly in their original locations.

1 Rocker pedestal nut 2 Valve cone (valve keeper) 3 Valve spring retainer 4 Valve spring 5 Plate washer 6 Valve Guide 7 Cylinder head 8 Expansion plugs 10 Intake valve seat 11 Intake valve 12 Exhaust valve 13 Exhaust valve seat 16 Rocker arm support stud 17 Strap 18 Rocker arm 19 Rocker arm 20 Rocker arm bushing 21 12M cylinder head bolt, injector side 22 12M cylinder head bolt, manifold side 23 14M cylinder head center bolt 24 Formed spacer washer (manifold side clamp) 25 Formed spacer washer (intermediate clamp) 26 Formed spacer washer (front and rear, end spacer) 27 End spacer 28 Oil pipe 29 Hollow bolt and sealing washers 30 Injector side of cylinder head 31 Plug, glow plug hole (or glow plug if equipped)

EXPANSION PLUGS Removal 1. Remove expansion plugs if leaking or damaged. NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried out.

Repair 1. Apply sealant (Loctite 290) to the outer diameter of the expansion plugs.

Cylinder Head End spacer Repair End spacer

89.92 - 90 mm

a - Expansion plugs

Basic Engine

107

R 750 VALVE GUIDES

1. Inspect the valve guides for cracks or chips. 2. Inspect the valve guide bores for seizure marks, carbon deposits or scoring. 3. Inspect the valve guide height. 4. Remove the valve stem seals. 5. Insert a new valve into guide. 6. Measure the valve stem clearance as follows: a. Attach a dial indicator to cylinder head. Position it against the valve stem and close to the valve guide. b. While holding the valve head off of the seat by about 2 mm move valve stem back and forth in directions shown. Compare stem clearance with specifications. Valve guidestem diameter - See chapter “Valves” Exhaust

7.921 - 7.939 mm

Intake

7.94 - 7.96 mm

Valve guide clearance - production Exhaust

(0.061 - 0.094 ) mm

Intake

(0.04 - 0.075) mm

c. Measure the valve guide inner diameter with a valve guide bore gauge. If measured value of stem clearance is not within specifications, replace the valve guide. Valve guide inner diameter Exhaust

8 - 8.015 mm

Intake Valve guide height Exhaust

54.75 - 55.25 mm

Intake

108

Basic Engine

R 750 Replacement CAUTION: Aluminum cylinder heads can be distorted or melted when heated improperly or unevenly.

a

A torch will improperly and unevenly heat an aluminum cylinder head. Do not use a torch to heat an aluminum cylinder head. To heat an aluminum cylinder head during valve seat or valve guide replacement, use an oven appropriately designed and constructed for the purpose. 1. Remove the valve stem seals. 2. Heat the cylinder head in an oven to 85 degrees C (185 degrees F). 3. Using a suitable drift, drive out the old guide from the underside of the cylinder head. 4. With the cylinder head temperature at 85 degrees C (185 degrees F), press the new guide in to obtain measurement as shown. a - Guide height measurement (above cylinder head upper surface) (EXHAUST/INTAKE)

a

1.5 - 2 mm

IMPORTANT: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.

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R 750 VALVE SEATS

1. Inspect the valve seats for cracks, excessive wear, and looseness in counterbore. 2. Measure exhaust and intake valve seats. Refer to valve seat specifications. 3. If measured values are not as specified, recondition the valve seat. If the valve seats cannot be repaired, it will be necessary to replace the cylinder head. Refer to Repair ‑ Valve Seat Reconditioning. Measurements a - Valve recession b - Counterbore inner diameter

Valve recession (service limit) (a) Exhaust Intake

0.3 mm

Counterbore inner diameter (b) Exhaust

38.964 - 38.988 mm

Intake

41.962 - 41.985 mm

Counterbore inner height (b1) Exhaust Intake

10 - 10.01 mm

a

a

b1 b

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R 750 INTAKE

d

f

e 45°

g

45°

exhaust

d

f

e 30°

Measurements 60°

d - Seat outer diameter

g

e - Seat height f - Seat width g - Seat angle

Seat outer diameter (d)

Exhaust

39.050 - 39.066 mm

Intake

42.070 - 42.086 mm

Seat height (e) Exhaust / Intake

7.85 - 7.95 / 7.73 ‑ 7.83 mm

Valve Seat Reconditioning

NOTE: Several different types of equipment are available for reconditioning valve seats. Equipment manufacturer’s recommendations should be followed carefully to attain proper results. IMPORTANT: Regardless of type of equipment, it is essential that valve guide bores be free of carbon or dirt to achieve proper centering of pilot in valve guide, ensuring concentricity when reconditioning valve seats. Recondition pitted or worn valve seats to the specified angles.

Seat width (f) R750 EU4 Exhaust Intake

1.6 ‑ 1.8 mm

R750 EU5 Exhaust Intake

1.6 ‑ 1.8 mm 2 - 2.2 mm

If during seats valve reconditioning excessively lowers valve recess or if the seat widht is wider than above specified measures, replace valve seat insert. During replacement operation, special care should be taken not to damage seat insert counterbore. Install seat valve inserts after heating cylinder head in an oven at 150°C or cooling them down at -170°C in liquid nytrogen athmosphere. Seat installation into head bore must be free, no requiring pressure for installation if above conditions are maintained.

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R 750 Valves

1. I nspect valves for damage, warpage, or both. Replace if necessary. 2. Measure the valve. If measured values are not as specified, repair the valve. Refer to Valve Refacing. Replace the valve if it cannot be repaired.

INTAKE (mm)

EXHAUST (mm)

A - Stem diameter (production, new)

7.94 - 7.96

7.921 - 7.939

F - Face width (production, new)

3.57 - 3.85

2.640 - 2.992

D - Margin thickness (Production, new)

1.82

1.73

1.30

Service limit E - Face angle (production, new)

29 degrees 30 minutes

44 degrees 30 minutes

B - Head diameter (production, new)

40.8 - 41

37.9 - 38.1

A

F

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R 750 Valve Refacing

Pitted valves can be refaced to proper angle on a valve grinder, that ensuring the correct relation between the cylinder head seat and the valve mating surface. Replace valves with excessive wear on stems or valves that are warped excessively. When an excessively‑-warped valve head is refaced, a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface. Knife edges lead to breakage or burning. NOTE: Various equipment is available for refacing valves. Manufacturer’s recommendations should be carefully followed to attain proper results. After refacing, measure the valves and replace if out of specifications. 1. Recondition the valve face to the proper angle if the valve face is pitted or worn. NOTE: When refacing do not thin the valve margin thickness less than 1.30 mm. After reconditioning, measure the valve margin. If the valve margin is less than the specified amount, replace the valve.

Assembly NOTE: Valve stem seals are used on intake and exhaust valves. 1. Lubricate valve guides and valve stems with engine oil. 2. Install each valve in the port from which it was removed or for which it has been fitted. 3. I nstall the valve guide seal onto the valve stem and push down until seated against the guide.

a

b

a - Valve stem seal b - Seal installed on guide 4. Install the plate washer, the valve spring, and the retainer on valve stem. 5. Compress the valve spring using valve spring compressor. NOTE: Lubricant may be used to hold valve locks in place while releasing compressor tool 6. Coat the valve stem locks with lubricant to hold in place. 7. Install the valve stem locks. a - Plate washer b - Valve spring c - Retainer d - Valve locks

a

b

c

d

8. Slowly release the valve spring compressor, ensuring that the valve locks seat properly in the valve stem groove.

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R 750 Valve Springs

1. Inspect the valve springs for discoloration due to excessive heat. 2. Inspect the valve spring valve locks, the retainers, and the washer for wear, distortion, or cracks. 3. Measure the free standing height of each spring. Replace the spring if measured value is other than specified. 4. Measure the spring inclination (distortion). If the measured value exceeds the specified limit, the valve spring must be replaced. a - Free standing height b - Spring inclination Free standing height Exhaust - Intake 48 mm Spring Inclination Exhaust - Intake

Service limit 2 mm

Valve open a - Applied pressure b - Height Applied pressure 294 N ± 6% Height 38.5 mm

Valve closed a - Applied pressure b - Height Applied pressure 635 N ± 4% Height 28.2 mm

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R 750 Rocker ARM removal 1. Remove the rocker arm covers. IMPORTANT: Mark or store the components during removal for reassembly in their original location. 2. Remove the rocker arm assemblies and valve push rods. Place the components in a numbered rack according to their position in the engine or mark the parts in order for reassembly to the original location.

Cleaning 1. Wash the components in cleaning solvent. 2. Put on safety glasses and dry the components with compressed air.

Inspection 1. Inspect components for excessive wear, cracks or damage. NOTE: The push rods are hollow and serve as oil galleries to lubricate each individual rocker arm assembly. 2. Visually inspect each pushrod for wear and deposits. Ensure the valve pushrod oil passage is not restricted. 3. Roll each valve pushrod on a flat surface and inspect the shaft for bends. 4. Replace all damaged parts. 5. Using a micrometer, measure the outside diameter of rocker arm support journals. Replace the rocker arm support if the journal outside diameter is less than specified. Outside diameter

a - Rocker arm support journal outside diameter

24.97‑25.00 mm

6. Using an inside micrometer, measure inside diameter of the rocker arm bushing. Inside diameter (Production)

25.020 ‑ 25.041 mm

Assembly clearance

0.020 - 0.071 mm

Wear limit

0.2 mm

a - Rocker arm bushing inside diameter

7. Replace the rocker arm assembly if wear limit is greater than specified.

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R 750 Assembly IMPORTANT: Before assembling the rocker arms assembly drain all of the residual oil in the valve lifter out of the drain hole in the valve lifter, by compressing the valve lifter, using the Valve Lifter Tool (Refer to Valve lifter section). Lubricate with engine oil the rocker arm bushings and rocker arm support journals. Install the rocker arms on the rocker arm support journals. Position as shown. Install the strap around the rocker arm assembly. Ensure that the strap is not spread open or the valve cover will not fit. Lubricate the outer surfaces and ends of the valve pushrods. Lubricate the valve lifter contact surfaces. Install the valve pushrods in their original locations. Ensure that the valve pushrods seat in the lifter sockets. Lubricate the rocker arm and rocker arm contact surfaces. Lubricate the threads of the rocker arm support studs. Install the rocker arm assembly onto the rocker arm support studs. Simultaneously align the valve pushrods with the rocker arm sockets. Install both rocker arm support nuts on the rocker arm support. Torque the rocker arm support nuts evenly. Rocker arm support nut

a - Rocker arm b - Rocker arm support c - Strap

29 Nm

x - rocker arm support nut y - Rocker arm support

d

IMPORTANT: Valve lash adjustment, or valve clearance, is hydraulically controlled and automatically set when the rocker arm support flanged nuts are properly torqued.

a - Rocker arm assembly b - Pushrod c - Rocker arm socket d -Valve pushrod seat in the lifter socket

Repeat the steps for the rocker arm assembly on each cylinder. No valve lash adjustment is required.

y

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x

R 750 Valve Lifters CAUTION: Camshafts and valve lifters develop matched wear patterns during engine operation. Mismatching worn camshafts and valve lifters or using worn components with new components can cause rapid and excessive wear resulting in engine component failure. Always use new camshafts and valve lifters whenever any of the components are replaced. The hydraulic roller valve lifters are held in position and prevented from rotation by special retainers. There is one retainer for each cylinder head. Care should be exercised when installing the retainers to ensure that the flat portions of the lifters are properly positioned in the retainers.

Removal 1. Remove the valve covers. IMPORTANT: Place rocker arm assemblies, pushrods and valve lifters in a rack for reassembly in their original locations. 2. Remove the rocker arm assemblies and the valve pushrods. Keep parts in matched sets. IMPORTANT: Lifters must be reassembled in the exact same position on the camshaft lobes so that the roller will operate in the same direction on the same lobe, if reused. 3. Make matching marks on all retainers and valve lifters showing the location and orientation in the bores. 4. Lift the retainer piece away from around the top of the valve lifters. Do not disturb the valve lifters at this time. 5. Insert the Valve Lifter Tool firmly into the valve lifter. Press downward on the internal spring until the top of the tool is lower than the stop. Turn the tool 90° and remove the valve lifter. 6. Remove the remaining valve lifters while keeping them in order for reassembly.

a - Drain hole b - Valve Lifter Tool

Cleaning 1. Except for the valve lifters, clean the parts with cleaning solvent. 2. Put on safety glasses and dry parts with compressed air. 3. While holding upright wipe the valve lifters with a clean, oil saturated, lint free cloth. Store lifters in the upright position.

Inspection

a - Push rod b - Retainer c - Valve lifter d - Roller

1. Inspect the valve push rod seat A. If the valve push rod seat is scuffed or worn, inspect the valve push rod. Check that valve push rod seat surfaces show no signs of dents, scoring and/or damage. 2. Inspect the outer valve lifter body wall. If wall is scuffed or worn, inspect engine block valve lifter bore. 3. Inspect the roller of the valve lifter. If the roller is scuffed or worn, inspect camshaft lobe. 4. Measure the outer diameter B of the valve lifter. If the measured value is less than specified, replace the valve lifter. Outer diameter

22.195 ‑ 22.212 mm

5. Inspect all parts carefully. If any parts are damaged or worn, the entire valve lifter assembly must be replaced.

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R 750 Installation CAUTION: Camshafts and valve lifters develop matched wear patterns during engine operation. Mismatching worn camshafts and valve lifters or using worn components with new components can cause rapid and excessive wear resulting in engine component failure.

a

Always use new camshafts and valve lifters whenever any of the components are replaced.

b

IMPORTANT: Before installation, coat the entire valve lifter with engine oil. If installing a new camshaft and valve lifters, engine oil has to be poured over valve lifters and camshaft lobes. IMPORTANT: Before assembling the valve lifters drain all of the residual oil in the valve lifter out of the drain hole in the valve lifter, by compressing the valve lifter, using the Valve Lifter Tool (Refer to Valve lifter section). Drain all of the residual oil in the valve lifter out of the drain hole in the valve lifter, by compressing the valve lifter, using the Valve Lifter Tool. Before installing the valve lifters, coat the entire valve lifter with engine oil. Install the valve lifters in the bores in order of removal, using the Valve Lifter Tool. Align the matching marks made prior to disassembly. Ensure the valve lifter drain hole is pointing towards the crankshaft.

c a - retainer b - square top or flat portion c - lifter

Install the retainers around the square top of the lifters to prevent them from rotating. Lubricate and install the valve push rods. Ensure the valve push rods seat in the valve lifter sockets.

NEW HYDRAULIC TAPPET VM PN 40432003F INSTALLED SINCE NOVEMBER 2009 IN PLACE OF VM CODE 40432001F. THE LASTEST TAPPET VM PN 40432003F SUPERSEDES THE PREVIOUS ONE. BOTH TAPPEST ARE INTERCHANGEABLES

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b

R 750 Valve Push Rods Removal 1. Remove the valve covers. IMPORTANT: Organize rocker arm assemblies and valve push rods in a rack for reassembly in their original locations. 2. Remove the rocker arm assemblies. 3. Lift the valve push rods from their seat in the valve lifter. a - Valve push rod b -‑ Valve lifter seat (not visible here)

Cleaning 1. Clean the rocker arm assemblies and push rods. 2. Clean the valve push rod oil passages. 3. Put on safety glasses and dry the components with compressed air.

Inspection 1. Inspect all contact surfaces for excessive wear or scoring. 2. Ensure that the valve push rod oil passage is not restricted. 3. Roll the valve push rods on a flat surface and inspect them for bends. 4. Replace all damaged parts.

Installation IMPORTANT: Before assembling the valve push rods drain all of the residual oil in the valve lifter out of the drain hole in the valve lifter, by compressing the valve lifter, using the Valve Lifter Tool (Refer to Valve lifter section). 1. Lubricate the outer surfaces and ends of valve push rods. 2. Install the valve push rods in their original locations. Ensure that the push rods seat in the valve lifter seat. 3. Install the rocker arms.

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R 750 fractured Connecting Rod

Disassembly

removal IMPORTANT: Each connecting rod assembly must be reassembled in the same original location. Mark or identify each connecting rod assembly to ensure placement in the original cylinder number location during reassembly. Retain the rod cap and bearings with the connecting rod and piston assembly. Do not mix the components. Remove the connecting rod bearings. Keep the bearings, with the original connecting rod and connecting rod cap, together as a matched set.

1. Clamp the connecting rod in a soft‑-jawed vise. 2. Use the Piston Ring Expander Tool to remove the first and second compression rings and the oil control ring with spring. 3. Remove the snap rings retaining the piston pin. Push the piston pin out of the connecting rod and piston. 4. Note the orientation of the piston combustion chamber recess in relation to the casting node, paint mark on con rod shaft, and the connecting rod number.

IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and piston cooling jet. Ensure no components are damaged during connecting rod removal. While protecting the crankshaft journal, cylinder bore, and piston cooling jets from damage, push the piston and connecting rod out of the cylinder. IMPORTANT: The mating surfaces of the connecting rods and the connecting rod bearing caps form an individual fit and as a result must not be interchanged or damaged under any circumstances. To avoid damage, do not lay connecting rods or connecting rod bearing caps on their mating surfaces.

x

FRACTURED CONNECTING RODS

x - piston cooling jet

a - Combustion chamber recess orientation b - Connecting rod number c - Casting Node d - Paint mark (for weight classification) e - matching marks on the connecting rod cap and connecting rod shaft

a

FRACTURE

d d b

c

e

120

b

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c

R 750 Inspection (fractured Connecting Rod) IMPORTANT: Measurements should be taken when components are at room temperature. Coloured paint marks on the connecting rods shaft identify the weight classification. Ensure all connecting rods have the same color paint mark. Replace connecting rods that are not the same weight classification and do not have the same color paint mark. If only one connecting is replaced, replace however all connecting rods. Check for twisted or bent connecting rods. Peform Magnaflux inspection of all rods and caps if any doubts exixst. Torque temporarirly the bolts at 88 Nm (Refer to Connecting Rod Assembly for the correct tightening procedure and torque value) Parallelism deviation between piston pin end and bearing end

0.15 mm

x - Lenght

162.975 - 163.025 mm

x

Use an inside dial indicator to measure the connecting rod crankshaft journal bore inside diameter, out of round and taper. a - Connecting rod crankshaft journal bore Inner diameter (without bearings)

57.563 ‑ 57.582 mm

Maximum allowable wear 0.02 mm or taper IMPORTANT: Refer to Crankshaft Section to determine the Connecting Rod Crankshaft Journal Outer Diameter and Connecting Rod Bearing Clearance. Inspect for damage to the bearing cap and bolt threads. Measure connecting rod bushing inner diameter and piston pin outer diameter. Replace the connecting rod bushing if clearance exceeds specification. a - Rod bushing inner diameter b - Piston pin outer diameter IMPORTANT: In service when replacing the rod bushing it must be bored once that is installed into its rod. Install the bushing by aligning the lubrication oil hole with the rod hole. Bushing inner diameter

30.035 - 30.050 mm

Piston pin outer diameter

29.992 - 29.996 mm

Piston pin bore

34 - 34.025 mm

Maximum allowable wear 0.01 mm or taper Mounting Clearance

0.039 - 0.058 mm

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R 750 Assembly (fractured Connecting Rod ) Lubricate with engine oil the inside of the connecting rod bushing, piston pin bore, and piston pin. Assemble the piston to the connecting rod with the combustion chamber recess, paint mark on con ros shaft, and the connecting rod number all oriented as noted during disassembly, or refer to the picture. Assemble the piston to the connecting rod with the combustion chamber recess orientated towards intake & exhaust side and the connecting rod number positioned as shown in the picture. Insert the piston pin and install the snap ring. Install the piston-connecting rod assembly into the cylinder block bore by taking care do not damage the liner surface and crankshaft journal.

x

IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and the piston cooling jet. Ensure no components are damaged during connecting rod installation.

x - piston cooling jet

Align the connecting rod with the crankshaft journal and tap on the piston top until the connecting rod bearing contacts the journal. Do not scratch or nick the crankshaft journal. Ensure that the matching marks on the connecting rod cap and the connecting rod shaft are the same and that the rod cap numbers point toward the camshaft/ injection side. .

FRACTURED CONNECTING RODS a - Combustion chamber recess orientation b - Connecting rod number c - Casting Node d - Paint mark (for weight classification) e - matching marks on the connecting rod cap and connecting rod shaft

a

FRACTURE

d d b

c

e

122

b

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c

R 750 IMPORTANT: New connecting rod screw threads and the screw head do not generally require lubrication. An anti‑friction product has been applied by the factory. Usually the bolts are replaced: if the screw threads are not stretched, and the top or bottom of the bolt head does not show damage, the connecting rod screws may be reused. When reusing a connecting rod screw, lubricate the threads and bottom of the screw head with engine oil. Lubricate the connecting rod screw threads and the underside of the screw head, unless the screws are being replaced with new screws that are pre‑lubricated. Apply engine oil to the crankshaft journal and connecting rod bearing surfaces. Install the connecting rod cap. Install and finger tighten the connecting rod screws and torque them as specified : Connecting rod screw - Fractured Connecting Rod First pass

10 Nm

Connecting rod screw - Fractured Connecting Rod Second pass

30 Nm

Final pass (Angle Torque)

+ 40

Verify that proper torque was achieved by testing the torque setting of each connecting rod screw to be at least as specified in the following table. Do not apply more than this specified amount during the validation test. Connecting rod screw validation test torque

88 Nm

Ensure that the connecting rod assembly and the crankshaft journal are not binding and that there is proper side‑to‑-side movement. IMPORTANT: Refer to Crankshaft Section to determine Connecting Rod Bearing Clearance between the bearings and crankshaft journal when the connecting rod is installed on crankshaft.. Install the remaining piston and connecting rod assemblies.

Connecting rod bolt specification - connecting rod broached

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R 750 BROACHED Connecting Rod removal IMPORTANT: Each connecting rod assembly must be reassembled in the same original location. Mark or identify each connecting rod assembly to ensure placement in the original cylinder number location during reassembly. Retain the rod cap and bearings with the connecting rod and piston assembly. Do not mix the components. Remove the connecting rod bearings. Keep the bearings, with the original connecting rod and connecting rod cap, together as a matched set.

Disassembly 1. Clamp the connecting rod in a soft‑-jawed vise. 2. Use the Piston Ring Expander Tool to remove the first and second compression rings and the oil control ring with spring. 3. Remove the snap rings retaining the piston pin. Push the piston pin out of the connecting rod and piston. 4. Note the orientation of the piston combustion chamber recess in relation to paint mark on con rod shaft, and the connecting rod number.

IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and piston cooling jet. Ensure no components are damaged during connecting rod removal. While protecting the crankshaft journal, cylinder bore, and piston cooling jets from damage, push the piston and connecting rod out of the cylinder. IMPORTANT: The mating surfaces of the connecting rods and the connecting rod bearing caps form an individual fit and as a result must not be interchanged or damaged under any circumstances. To avoid damage, do not lay connecting rods or connecting rod bearing caps on their mating surfaces.

x

x - piston cooling jet

a

BROACH

d

b

b

d a - Combustion chamber recess orientation b - Connecting rod number cd - Paint mark (for weight classification) e - matching marks on the connecting rod cap and connecting rod shaft

b

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R 750 Inspection (Connecting Rod - BROACHED) IMPORTANT: Measurements should be taken when components are at room temperature. Coloured paint marks on the connecting rods shaft identify the weight classification. Ensure all connecting rods have the same color paint mark. Replace connecting rods that are not the same weight classification and do not have the same color paint mark. If only one connecting is replaced, replace however all connecting rods. Check for twisted or bent connecting rods. Peform Magnaflux inspection of all rods and caps if any doubts exixst. Torque temporarirly the bolts at 88 Nm (Refer to Connecting Rod Assembly for the correct tightening procedure and torque value) Parallelism deviation between piston pin end and bearing end

0.15 mm

x - Lenght

162.975 - 163.025 mm

x

Use an inside dial indicator to measure the connecting rod crankshaft journal bore inside diameter, out of round and taper. a - Connecting rod crankshaft journal bore Inner diameter (without bearings)

57.563 ‑ 57.582 mm

Maximum allowable wear 0.02 mm or taper IMPORTANT: Refer to Crankshaft Section to determine the Connecting Rod Crankshaft Journal Outer Diameter and Connecting Rod Bearing Clearance. Inspect for damage to the bearing cap and bolt threads. Measure connecting rod bushing inner diameter and piston pin outer diameter. Replace the connecting rod bushing if clearance exceeds specification. a - Rod bushing inner diameter b - Piston pin outer diameter IMPORTANT: In service when replacing the rod bushing it must be bored once that is installed into its rod. Install the bushing by aligning the lubrication oil hole with the rod hole. Bushing inner diameter

30.035 - 30.050 mm

Piston pin outer diameter

29.992 - 29.996 mm

Piston pin bore

34 - 34.025 mm

Maximum allowable wear 0.01 mm or taper Mounting Clearance

0.039 - 0.058 mm

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R 750 Assembly (Connecting Rod - BROACHED) Lubricate with engine oil the inside of the connecting rod bushing, piston pin bore, and piston pin. Assemble the piston to the connecting rod with the combustion chamber recess, paint mark on con ros shaft, and the connecting rod number all oriented as noted during disassembly, or refer to the picture. Assemble the piston to the connecting rod with the combustion chamber recess orientated towards intake & exhaust side and the connecting rod number positioned as shown in the picture. Insert the piston pin and install the snap ring. Install the piston-connecting rod assembly into the cylinder block bore by taking care do not damage the liner surface and crankshaft journal. IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and the piston cooling jet. Ensure no components are damaged during connecting rod installation. Align the connecting rod with the crankshaft journal and tap on the piston top until the connecting rod bearing contacts the journal. Do not scratch or nick the crankshaft journal. Ensure that the matching marks on the connecting rod cap and the connecting rod shaft are the same and that the rod cap numbers point toward the camshaft/ injection side. .

x

x - piston cooling jet

BROACHED CONNECTING RODS

a

BROACH

b d b

d

a - Combustion chamber recess orientation b - Connecting rod number cd - Paint mark (for weight classification) e - matching marks on the connecting rod cap and connecting rod shaft

126

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R 750 IMPORTANT: New connecting rod screw threads and the screw head do not generally require lubrication. An anti‑friction product has been applied by the factory. Usually the bolts are replaced: if the screw threads are not stretched, and the top or bottom of the bolt head does not show damage, the connecting rod screws may be reused. When reusing a connecting rod screw, lubricate the threads and bottom of the screw head with engine oil. Lubricate the connecting rod screw threads and the underside of the screw head, unless the screws are being replaced with new screws that are pre‑lubricated. Apply engine oil to the crankshaft journal and connecting rod bearing surfaces. Install the connecting rod cap. Install and finger tighten the connecting rod screws and torque them as specified : Connecting rod screw - Broached Connecting Rod First pass

30 Nm

Final pass (Angle Torque)

+ 60°

Verify that proper torque was achieved by testing the torque setting of each connecting rod screw to be at least as specified in the following table. Do not apply more than this specified amount during the validation test. Connecting rod screw validation test torque

88 Nm

Ensure that the connecting rod assembly and the crankshaft journal are not binding and that there is proper side‑to‑-side movement. IMPORTANT: Refer to Crankshaft Section to determine Connecting Rod Bearing Clearance between the bearings and crankshaft journal when the connecting rod is installed on crankshaft.. Install the remaining piston and connecting rod assemblies.

Connecting rod bolt specification - connecting rod broached

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R 750 piston Disassembly 1. Clamp the connecting rod in a soft‑jawed vise. 2. Use the Piston Ring Expander Tool to remove the first and second compression rings and the oil control ring with spring. 3. Remove the snap rings retaining the piston pin. Push the piston pin out of the connecting rod and piston. 4. Note the orientation of the piston combustion chamber recess in relation to the paint mark, the casting node (only for fractured connnecting rods), and the connecting rod number. (Refer to Connecting Rods Section)

CLEANING IMPORTANT: Do not wire brush on any part of a piston. 1. Wash the components in cleaning solvent. 2. Clean varnish from piston skirts and pins with a suitable cleaning solvent. 3. Clean the ring grooves. 4. Clean the piston oil lubrication holes and slots. 5. Put on safety glasses and dry the components with compressed air.

Inspection Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts or eroded areas at top of piston. Replace pistons that are damaged or show signs of excessive wear. NOTE: Do not mistake tapered or different ring design characteristics for unusual wear patterns. The first (upper) compression ring is trapezoidal (tapered) in design. That is, it has a taper on both upper and lower surfaces. Correspondingly, the first compression ring groove is tapered on top and bottom. The second (scraper) compression ring and the oil control ring are more typical in design.

a - First compression ring ‑ trapezoidal (tapered) b - First compression ring groove ‑ (tapered) c - Outer edge of first compression ring

b

c a

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R 750 Measure the piston outer diameter 17 mm from the bottom and 90 degrees to the piston pin . Replace the piston if measurement is less than specified. a - Outer diameter measurement point Outer diameter

93.930 - 93.950 mm

Wear limit

0.10 mm

Inspect the piston ring grooves for nicks or burrs that might cause the rings to bind. Except on the upper piston ring groove, insert the edge of the rings into respective piston ring groove and roll the ring entirely around the groove to make sure that ring does not bind. If resistance or binding occurs at any point, determine the cause. a. If binding is caused by a distorted ring, recheck with another ring. IMPORTANT: When using a fine cut file, do not remove excess material. Verify with a feeler gauge and compare to specifications. b. If binding is caused by ring groove, remove the material causing the binding by dressing the ring groove with a fine cut file. Measure the thickness of the rings. Replace piston rings as a set if out of specification.

17 mm

First compression ring

First compression (tapered ‑ outer edge)

2.568 ‑2.597 mm

Second compression

1.970 - 1.995 mm

Oil control

2.97 ‑ 2.99 mm

2.568 ‑2.597 mm

Piston Ring Thickness (Production)

First compression ring

1.5 mm

Second compression ring

Second compression ring

2° + or ‑ 30 minutes

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R 750 Measure the piston ring groove width. Piston Ring Groove Width (Production) First compression (tapered ‑ outer edge)

3 mm (nominal)

Second compression

2.06 ‑ 2.08 mm

Oil control

3.03 ‑ 3.05 mm

Using a feeler gauge, measure the clearance between the serviceable, or new, second compression and oil control piston rings and ring groove at several points around the piston. Replace the piston if the measured values exceed the specification. Piston Ring Groove Clearance First compression

Not applicable (tapered)

Second compression

0.065 - 0.11 mm

Oil control

0.04 - 0.08 mm

Check the piston ring end gap: a. Position the selected ring in the cylinder bore.

2 - Not applicable ‑ first compression ring and groove tapered 3 - Second compression ring and groove 4 - Oil control ring and groove

NOTE: The ring must be level (at right angles to the bore surface) for measurement. Push the ring 6 mm into the bore with the crown of the piston. b. Measure the gap between the ends of the ring with a feeler gauge as shown. Piston Ring End Gap (Production) First compression

0.30 - 0.42 mm

Second compression

0.65 - 0.85 mm

Oil control

0.30 - 0.60 mm

Piston Ring End Gap First compression

0.5 mm maximum

Second compression

0.9 mm maximum

Oil control

0.7 mm maximum

c. If the gap between the ends of the piston ring is less than specified, remove the ring and try to fit another. Check the cylinder bore if the specification cannot be met with new rings. Refer to Cylinder Liners. d. Fit each ring to the cylinder in which it is going to be installed.

130

Basic Engine

R 750 assembly 1. Lubricate the inside of the connecting rod bushing, piston pin bore, and piston pin. 2. Assemble the piston to the connecting rod (Refer to connecting Rod Section). 3. Insert the piston pin and install the snap ring. 4. Clamp the connecting rod in a soft‑jawed vise

First compression ring ‑ trapezoidal (tapered)

a

IMPORTANT: Always install rings with ring markings (“CTOP”, “PIP” or a dot) facing the top of piston. a - ring markings 5. Install the oil control ring spring in lower piston groove. 6. Using the Piston Ring Expander Tool, install the oil control ring. 7. By hand, squeeze the ring into the groove to seat the spring and check for binding. 8.Using the tool, install the second compression ring in the center piston groove. The inner taper is toward the bottom of the piston. 9. By hand, squeeze the ring into the groove and check for binding. 10. Using the tool, install the first compression ring in upper piston groove. 11. By hand, squeeze the ring into the groove and check for binding.

Second compression ring

a

Oil control ring

a

Basic Engine

131

R 750 Installation 1. Before installing pistons into cylinders, ring gaps must be positioned as show in the picture: a. First compression ring (trapezoidal) gap, 20° to the right of combustion chamber recess. b. Second compression ring gap, centered on the combustion chamber recess. c. Oil control ring gap, 20° to the left of combustion chamber recess. a - First compression ring (trapezoidal) gap b - Second compression ring gap c - Oil control ring gap

2. Lubricate the cylinder bores and piston rings. 3. Each piston and connecting rod assembly must be installed in the cylinder from which it was removed.

IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and the piston cooling jet. Ensure no components are damaged during connecting rod installation. 4. Turn the crankshaft to position the crank pin away 7. Align the connecting rod with the crankshaft jourfrom the cylinder so the connecting rod will not damage nal and tap on the piston top until the connecting rod it during installation. bearing contacts the journal. Do not scratch or nick the 5. Using a ring compressor, install the piston by tapping crankshaft journal. on the piston‑top with a suitable device. 8.Install the connecting rod cap. 6. Insert the connecting rod bearings into the connec9. Install and torque the connecting rod screws. (Refer ting rod and matching connecting rod cap. Lubricate the to Connecting Rod Section) bearings and crankshaft journal with engine oil.

x - Combustion chamber recess y - Camshaft/Injection side

x

x

y

132

Basic Engine

R 750 Oil Pan & Oil Pickup Removal Drain the oil out of the engine. Refer to the Maintenance section. Remove the oil pan screws. Cut through oil pan sealant on pan rails using a suitable tool. Ensure do not bend the pan rails. Remove the oil pan. a - Sealant cutting tool b - Hammer c - Oil pan

a b

c

Oil Pickup Removal 1. Remove the oil pick‑up tube and strainer mounting screws. 2. Remove the oil pickup tube and strainer and spacers. a - Oil pickup tube b - Oil pickup tube screw c - Oil strainer d - Spacers

b1

a

d

b

3. Remove the old oil pickup tube O‑ring.

Installation 1. Replace the oil pickup tube O‑ring. 2. Lubricate the oil pickup tube O‑ring. 3. Install the oil pick‑up tube and strainer on the engine block. 4. Install the oil pick‑up tube and strainer screws. Torque the screws. oil pick‑up tube and strainer screws

(b) 12.7 Nm (b1) 32.4 Nm

1. Wipe off all excess oil and foreign matter from sealing surface on crankcase and oil pan. Thoroughly de‑grease all sealing surfaces prior to application of sealant.

c

b1

a

b

CAUTION Excessive amounts of sealant could loosen and become lodged on the oil pickup strainer resulting in a restricted oil flow. Do not apply excessive amounts of sealant. 2. Apply a continuous bead of sealant (silicon type Dow Corning 7091) around the oil pan flange on the inside of the bolt holes as shown. 3. Install the oil pan. 4. Install oil pan screws finger tight. Torque the oil pan screws evenly, in a diagonal pattern. Oil pan screw

12.7 Nm

b

a

a - Oil pan flange b - Continuous bead of sealant

Basic Engine

133

R 750 Oil Pressure Relief Valve

The oil pressure relief valve (oil pressure regulator valve) is installed vertically in the underside of the crankcase.

Removal 1. Remove the oil pan. 2. Clean old gasket material from the area around the relief valve. 3. If removing only the relief valve and spring, or springs: proceed to Disassembly. Observe all precautions and perform all steps except step 1. 4. If removing the complete pressure relief valve assembly:

a - Example of suitable tool b - Valve assembly c - Slots

a. Unscrew the oil pressure relief valve assembly from the crankcase using a suitable tool. The tool should engage the 2 slots opposite each other on the edge of the valve assembly. NOTE: Locking compound is used during installation of the oil pressure relief valve assembly. Area around the assembly may need to be heated to aid in removal. b. Remove the pressure relief valve assembly from the crankcase. c. Proceed to Disassembly.

Disassembly 1. Lock the pressure relief valve assembly in a soft‑jawed vise, if the complete assembly was removed. CAUTION The oil pressure relief valve cap and high pressure spring are retained by a snap‑ring. If released suddenly the spring could propel the valve cap with enough force to cause injury. Use caution when removing or installing the snap‑ring. Wear safety glasses. 2. Push the cap in against the high pressure spring and hold. Remove snap‑ring. 3. Release spring pressure slowly. a - Cap b - Snap‑ring c - Valve body

134

a

Basic Engine

b

R 750 4. Remove cap, springs and relief valve from bore of the valve body. NOTE: Some oil pressure relief valves have only one spring.

a - Cap b - Spring (inner ‑ if dual spring equipped) c - Spring (outer ‑ if dual spring equipped) d - Relief valve

Cleaning 1. Clean gasket sealing material from cylinder block and pan flanges. 2. Wash all parts in cleaning solvent. 3. Put on safety glasses and dry parts with compressed air.

Inspection 1. Replace the complete oil pressure valve assembly if the spring is broken. 2. Replace the complete valve assembly if the valve is badly worn or sticking in the bore. 3. The valve can be lapped into it the seat using a grinding paste, if necessary to restore pressure. 4. Ensure that the valve slides freely in the valve seat and valve body when coated with oil.

Assembly 1. Coat the inside of the oil pressure relief valve seat and body bore with engine oil. Liberally coat the remaining components. 2. Assemble the valve, springs, and cap. Install parts into valve seat and body. 3. Push the cap in against the high pressure spring and hold. 4. Install the snap‑ring.

a - Relief valve b - Spring (inner ‑ if dual spring equipped) c - Spring (outer ‑ if dual spring equipped) d - Cap e - Snap‑ring f - Valve seat and body

Installation 1. If installing only the oil pressure relief valve and spring, or springs: refer to Assembly. Observe all precautions and perform all steps with the valve body still in the crankcase. 2. If installing the complete oil pressure relief valve assembly: a. Apply sealant Loctite 510 to the threads when replacing the complete oil pressure relief valve assembly. Screw the complete assembly into the crankcase. b. Using a suitable tool, torque the oil pressure relief valve assembly into the crankcase. Oil pressure relief valve assembly

53.9 Nm

a - Oil pressure relief valve assembly b - Threads

Basic Engine

135

R 750 engine block crankcase

a

In case of engine overhaul or oil pan removal verify the installation and related caulking of plugs that close the balance shaft assembly lubricating oil gallery, on engine whit balance shaft assembly installed.

a - plugs

inspection On some engine versions is possible the balance shaft assembly is not installed. The balance shaft assembly lube oil gallery on the block are close by plugs.

Figura 1 Photo 1

a - Plugs In case of engine overhaul verify if the plugs (A) are caulked (see photo 2-3) In case of photo 1 the plug “B” comes out of block or is not correctly installed. The plug is NOT properly seated. The plug must be correctly installed and caulked. (see photo 2-3) B - plug comes out of crankcase

IMPORTANT: carry out always the caulking on all plugs: install the plug at the same level of the block surface as shown in the photo 2-3 and carry out the caulking by 180°.

Figura 2 Photo 2

Figura 3 Photo 3

136

Engine Block

b

R 750 engine block Liner removal Remove the liners by using the special tool

a

Remove engine components as needed, including pistons. Remove the piston cooling jets (oil spray nozzles). Remove the plate from Cylinder Liner Puller Tool. a - Cylinder Liner Puller Tool b - Plate IMPORTANT: To avoid mismatching cylinder liners and pistons upon reassembly, mark the liners in a suitable fashion as to the cylinder number and orientation in the cylinder block. Install the Cylinder Liner Puller Tool into the cylinder liner and attach the plate to the tool at bottom of the cylinder liner.

b

Screw the nut of the tool and remove the cylinder liners. Note the O‑rings on the cylinder liner lower part.

c

specifications Remove old sealant from the cylinder liners. Clean the cylinder liners, especially at areas where shown, and in the areas where the O‑rings fit. c - Areas for special cleanliness Wash the liners in cleaning solvent. Put on safety glasses and dry the components with compressed air. Inspect the cylinder liners for abnormal wear or cracks. Inspect the cylinder liners for a ridge at the top of the ring travel. Remove the ridge if the cylinder liners are within specification. Measure the cylinder liners for taper and out of round using a dial indicator or inside micrometer. If wear exceeds specification replace the cylinder liners. NOTE: Carefully move the gauge up and down in the cylinder liner bore to determine taper. Measure the taper at three different vertical positions and at opposite sides of the cylinder liner bore. Turn the gauge to different points around the cylinder liner wall to determine the out of round condition. Maximum measurement depth is 108 mm down from the top edge of the cylinder liner. Cylinder Liner Production diameter - inner

93.995 ‑ 94.015 mm

Wear limit

0.10 mm

Production out of round or taper

0.008 mm

Maximum out of round or taper

0.10 mm

Engine Block

137

R 750 Installation

a - Cylinder liner recess b - Cylinder liner c - Cylinder block d - Cylinder head mounting surface

Cylinder liners on all engines are required to protrude, or rise above, the surface of the cylinder block. CAUTION :Cylinder liner protrusion can only be correctly measured with the cylinder liners fully seated in the cylinder block. Incorrect measurements will result in engine performance problems or severe engine damage. Ensure the cylinder liners are fully seated in the cylinder block before measuring cylinder liner protrusion. NOTE: The cylinder liners will rotate freely in the bore when the cylinder block and cylinder liner are completely clean and ready for measuring cylinder liner protrusion. a. Unless being replaced, install the cylinder liners in the same cylinder block bore without O‑rings as marked or noted upon disassembly. b. Using a precision depth gauge measure and record the amount of cylinder liner recess (the depth below the cylinder head mounting surface of the cylinder block) of each liner. 1. Use the dial indicator and Support Block tool (liner gauge bar) (Refer to Special Tools Section) to measure the liner protrusion above the cylinder block. 2. Place Support Block with the dial indicator feeler gauge on the cylinder block. 3. Set the dial indicator to zero (0). 4. Move the dial indicator to the liner on the liner neck. Record the measurement. 5. Measure the liner protrusion of all liners. 6. Verify the amount of liner protrusion for each liner as specified: Cylinder liner protrusion

a - Support Block tool b - dial indicator

a

b

- 0.01 ÷ + 0.07 mm

x

If the amount is incorrect, replace the liner and install another one. If the amount is correct to procede with the installation of all liners as follows: 7. Install two coloured O‑ rings (same colour) in the liner grooves lower part and another O‑ ring (different colour than previous 2 O-rings) in liner groove lower part. (see picture). IMPORTANT: The first two O-rings have a different thickness and colour than the second one. Do not mix O-rings one another. 8. Lubricate with lubricant lower centering collars in cylinder block (those areas where lower liner O‑ rings seal against the bore). IMPORTANT: Do not lubricate upper bore area where sealant (LOCTITE 986) will be applied later.(see next step 9). 9. Select and apply the specified sealant (LOCTITE 986) to the liner surfaces, as shown in the picture.

y

x - two coloured O‑ rings in the liner grooves lower part (same colour) y - O‑ ring in liner groove lower part. (different colour than other 2 o-rings with same colour)

LOCTITE 986

138

Engine Block

R 750 10. Install the cylinder liners in the cylinder block, being careful not to damage the O‑ rings. 11. Once the liners are installed, hold the liners securely in position with the bolts and formed spacer‑washers. Temporarily torque the bolts and allow the sealant to get dry. a - Cylinder liner b - Suitable bolt c - Formed spacer washer IMPORTANT: If the cylinder heads are not installed within 1 hour, the cylinder liners must remain clamped by the spacer washers and bolts for roughly 8 hours, so that the sealant can properly cure. After 8 hours the spacer washers and bolts can be removed and the cylinder heads can be installed. 12. After the sealant is dry, verify the cylinder liner protrusion as stated before. 13. If the cylinder liner protrusion is correct, continue the engine assembling.

Engine Block

139

R 750 camshaft Testing ‑ Measuring Lobe Lift 1. Remove the rocker arm assemblies. 2. Secure the dial indicator to the cylinder head so the dial indicator plunger rests inside the push rod cup. 3. Turn the crankshaft so that the camshaft lobe is at the bottom of its travel. 4. Set the dial indicator to “0” (zero). 5. Turn the crankshaft 2 (two) complete revolutions while reading the dial indicator. 6. Measure all lobes of camshaft in the same manner. IMPORTANT: Camshaft replacement will be necessary if lobe dimensions are less than 0.05 mm of the values specified. Camshaft - Lobe lift Exhaust

7.303 mm

Intake

6.850 mm

Wear Limit

0.05 mm

CAMSHAFT lobe diameter 1. Measure the total camshaft height with a micrometer. Subtract the lobe diameter. The difference is lobe lift. If the lobe lift is less than specified, the camshaft must be replaced. Camshaft - Lobe diameter Exhaust

38.550 ‑ 38.650 mm

Intake

39.450 ‑ 39.550 mm

Wear Limit

0.05 mm

a - Total camshaft height b - Lobe diameter c - Lobe lift

CAMSHAFT JOURNAL DIAMETER 1. Use a micrometer to measure each camshaft journal diameter in two directions (“X‑X”) and (“Y‑Y”). If the measured value is less than specified, the camshaft must be replaced. NOTE: Camshaft bearings are available in 0.250 mm undersized. Clerance between camshaft journal and camshaft bearings, refert to “Camshaft Bearings” section. Camshaft

Journal diameter

Front

53.495 ‑ 53.510 mm

Center

53.450 ‑ 53.470 mm

Rear

53.480 ‑ 53.500 mm

Wear limit

0.200 mm

140

Engine Block

R 750 CLEARANCE BETWEEN THRUST PLATE AND CAMSHAFT 1. Measure clearance between thrust plate and camshaft. Camshaft Thrust plate and camshaft clearance

0.030‑0.095 mm

IMPORTANT: Camshaft gear is a press fit on shaft. If removal is needed, upon reassembly gear must be heated in an oven to 180‑200 degrees °C (360‑390 degrees °F) for 10 minutes and pressed on the shaft. After installing the proper thrust plate and positioning the key, press the gear until it is tight against the shoulder. 2. If the measured value exceeds specification, remove and inspect the thrust plate thickness at four opposite points. Replace the plate if assembly clearance is less than specified at any point. Camshaft thrust plate thickness (S)

3.95 ‑ 4.05 mm

s - Camshaft thrust plate thickness a,b,c,d - Thickness dimension at four opposite points e - Camshaft thrust plate f - camshaft gear

e

f

Engine Block

141

R 750 Removal Turn crankshaft to cylinder number 1 TDC of its compression stroke so that the timing marks on camshaft gear and idler gear are aligned as shown. IMPORTANT: Place rocker arm assemblies, valve push rods and lifters in a rack for reassembly in their original locations. Remove the rocker arm assemblies and valve push rods. Remove the valve roller lifters. Remove the cylinder heads. Remove the oil level dipstick. Remove camshaft thrust plate mounting screws and lock washers. Carefully withdraw the camshaft. Take care not to damage the camshaft bearings.

timing reference marks

a - Camshaft thrust plate mounting screw b - Camshaft thrust plate c - camshaft gear

c

c

b

a a Installation Lubricate the camshaft lobes with engine oil Lubricate the camshaft bearings. Install the camshaft. Be careful not to damage the bearings. Align the timing marks on camshaft gear and idler gear as shown previously. Install the thrust plate mounting screws using the lockwashers. Torque the screws. Camshaft thrust plate mounting screw

142

27.5 Nm

Engine Block

R 750 Camshaft bearings Inspection 1. Remove the camshaft. 2. Inspect the camshaft bearings. Replace the bearings if they are worn or damaged. 3. Measure the inner diameter of the camshaft bearings and compare to the camshaft journal dimensions. Calculate the bearing clearance. IMPORTANT: In service when replacing the front camshaft bushing it must be bored once that is installed into its cranckcase seat. Install the front bushing by aligning the lubrication oil hole in the block with the bushing hole. Refer to the picture to identify the inclination angle.

specifications Camshaft Front Bushing Bushing inner diameter (Bushing bored into the block)

53.59 - 53.62 mm

Clearance (bushing - journal)

0.08 - 0.125

Camshaft Rear and Center Bearing Bearing inner diameter (bearings installed in the block)

53.550 - 53.600 mm

Clearance (Center Bearing)

0.08 - 0.15

Clearance (Rear Bearing)

0.05 - 0.12

First oversized Bushing

0.25 mm

20° sede albero camme - camshaft seat

sede ingranaggio rinvio - idler gear seat

sede albero motore - crankshaft seat

sede pompa olio - oil pump seat

Engine Block

143

R 750 front journal Camshaft bushing Install a new bearing on bearing puller tool. Align the oil passage in the engine block with the hole of the new bearing. NOTE: To aid installation retain bearing halves on tool with a rubber band or similar. Assemble the Front Main Bearing and Camshaft Bearing Puller into front main bearing. a - Bearing puller tool b - Front main bearing (new bushing) Apply Loctite 601 on the bearing outer surface. Using two wrenches, hold the puller screw and then, turn the nut until the old bearing has been pulled out from proper seat. The Front Main Bearing and Camshaft Bearing Tool will install the bearing to the correct depth. IMPORTANT: While removing/install a new bearing (Crankshaft Front Main Bearing or Camshaft Bearing) ensure that the oil hole in the bearing is positioned correctly. The oil hole in the bearing must be aligned with the oil passage in the engine block for proper lubrication.

a - Oil passage (in crankcase) b - Bearing hole c - Front Main Bearing and Camshaft Bearing Puller Tool d - Bearing halves (on tool) e - Bearing bore

144

Engine Block

a

b

a

R 750 Piston Cooling Jets (Oil Spray Nozzles)

a

b

Oil spray from the piston cooling jet nozzles cools and lubricates the piston and other engine components. Inadequate or improper oil spray could result in engine damage. Ensure the oil spray nozzles are clean and the piston cooling jet assemblies are correctly installed to allow proper oil spray distribution. Remove the piston cooling jet assembly from near the cylinder bore. Remove and discard the O‑ring seal on the piston cooling jet.

d

a - Cooling jet assembly b - Nozzle c - Plate d - Bolt Clean the passages of the piston cooling jet and cylinder block. Put on safety glasses. Blow out any debris from cleaning, using compressed air. Ensure the check valve ball moves freely against the spring in the bore.

c b

x - Spring y - Check valve ball 2. Check for a cracked, bent or damaged tube or nozzle.

a

d

x

y

Install a new O‑ring in the piston cooling jet groove. Lubricate the piston cooling jet O‑ring. Insert the piston cooling jet assembly into the cylinder block. Ensure that the piston cooling jet assembly is correctly seated. Position the tube and nozzle as shown. Apply sealant to the piston cooling jet assembly screw threads. Install and torque the piston cooling jet assembly screw. Piston cooling jet assembly screw

12.7 Nm

Engine Block

145

R 750 crankshaft removal 1. Remove the main bearing locating screws and special locating screws that hold the main bearing carriers in cylinder block and supply lubricating engine oil to main bearings carriers and front / rear main bearings.

c

a - Locating screw ‑ standard b - Special locating screw (for oil supply hose to turbocharger) c - Oil supply pipe ‑ rocker arms

b

a

a

2. Install the Crankshaft Installer Tool over the timing gear to protect front main bearing. d - Crankshaft Installer Tool e - Crankshaft gear IMPORTANT: Before removing the crankshaft from the block, number or mark the bearing carriers according to the journal upon which they are fitted. Also make matching marks on both bearing carrier halves for correct reassembly.

e

IMPORTANT: When removing the crankshaft do not damage the piston cooling jet. Ensure to remove the oil piston cooling jet. (Refer to Oil Piston cooling Jets Section)

d

x - matching marks on both bearing carrier halves y - matching marks on all main bearing carriers (between carrier and block) z - number all main center bearing carrier according to the journal upon which they are fitted

z

3. Withdraw the crankshaft so that the main bearing carries can be disassembled. Disassemble all main bearing carriers. Take crankshaft off from the cylinder block. w - main bearing carriers removed proper block bore

y

w

146

Engine Block

x

R 750 Inspection 1. Inspect crankshaft for deep grooves, scratches, pitted surfaces or uneven wear. 2. Inspect crankshaft rear oil seal surface for scoring or damage. 3. Inspect crankshaft oil passages for restrictions. 4. Inspect the crankshaft threaded bolt holes for damage. 5. Inspect the crankshaft balancer keyway for damage. 6. After a seizure, overheating or grinding, crankshaft must be Magnafluxed to verify no surface cracks are present. After grinding perform “SURSULF” treatment (hardness HV 587 with load of 500 gr. corresponding to HRc 53). After treatment “SURSULF” perform lapping o n all surfaces with roughness Ra 0.18 / 0.22. IMPORTANT: It is forbidden the crankshaft straightening after SURSULF treatment. No material may be removed, either by hand or machine grinding, from thrust faces of crankshaft. Replace crankshaft if machined surfaces on front and rear ends or threaded areas of crankshaft ends are out-of-round, worn or damaged. 7. Measure the journals of the crankshaft to determine if replacement or grinding is necessary.

specifications Lenght (4 cylinders)

595.1 mm

Lenght (6 cylinders)

819.1 mm

Crankshaft Front Main Bearing Journal Outer diameter

62.985 - 63.005 mm

First Oversized Bearing

0.25 mm

Center Main Bearing Crankshaft Journal Outer diameter

63.005 - 63.02 mm

First Oversized Bearing

0.25 mm

Rear Main Bearing Crankshaft Journal Outer diameter

79.985 - 80 mm

First Oversized Bearing

0.25 mm

Crankshaft Connecting Rod Journal Outer diameter

53.940 - 53.955 mm

First Oversized Bearing

0.25 mm

Wear limit

0.10 mm

Front Main Bearing Clearance (between crankshaft Front Main Bearing Journal Outer diameter and crankshaft Front Main Bearing inner diameter)

0.023 - 0.083 mm

Center Main Bearing Clearance (between Center Main Bearing Crankshaft Journal Outer diameter and main bearings carrier inner diameter)

0.008 - 0.051 mm

Rear Main Bearing Clerance (between Rear Main Bearing Crankshaft Journal Outer diameter and Rear Main Bearing carrier inner diameter)

0.045 - 0.085 mm

Connecting Rod Bearing Clerance (between Crankshaft Connecting Rod Journal Outer diameter and connecting ros bearings inner diameter)

0.012 ‑ 0.066 mm

Engine Block

147

20172140F_1

R 750

148

Engine Block

20172136G_1

R 750

Engine Block

149

R 750 installation Lubricate with grease the main bearing bores in the cylinder block. Install the matching main bearing carrier halves on crankshaft journals in their original locations (marked during disassembly) or by referencing the factory paint marks on the side. Ensure that all carriers were positioned so that the front of the carrier halve is toward the crankshaft gear after installing them on the journal. Lubricate with MOLYguard LMP 180 grease the bearing carrier underside bolts and thread and torque them. Bearing carrier bolt

a - Brush dipped in lubricant b - Main bearing bore

44.1 Nm

a- Reference paint marks made by factory or operator during disassembly b-‑ Reference that identifies the front of the carrier, it must be pointed toward the crankshaft gear. c- crankshaft gear

c

Install the Crankshaft Installer Tool over the timing gear to protect the front main bearing. Position the engine cylinder block horizontal with the oil pan flange facing up. Carefully insert the crankshaft with the main bearing carriers attached into the cylinder block. a - Crankshaft assembly b - Main bearing carrier entering cylinder block

150

Engine Block

R 750 Rotate the bearing carriers to align with marks made during disassembly. If no marks are present, position the bearing carriers with the round hole through the casting pointing toward the oil pan flange. x - matching marks on both bearing carrier halves y - matching marks on all main bearing carriers (between carrier and block) z - Round holes through the castings

z

x

y

Install new sealing washers on all main bearing locating screws and special locating screws. To avoid damaging the threads,hand thread the main bearing locating screws and special locating screws into the bearing carriers. Torque all main bearing locating screws and special locating screws. a - Locating screw ‑ standard b - Special locating screw (for oil supply hose to turbocharger) Locating screw

53.9 Nm

b

Engine Block

a

a

151

R 750 Crankshaft front main bearing Install a new bearing on bearing puller tool. Align the oil passage in the engine block with the hole of the new bearing. NOTE: To aid installation retain bearing halves on tool with a rubber band or similar. Assemble the Front Main Bearing and Camshaft Bearing Puller into front main bearing. a - Bearing puller tool b - Front main bearing Apply Loctite 601 on the bearing outer surface. Using two wrenches, hold the puller screw and then, turn the nut until the old bearing has been pulled out from proper seat. The Front Main Bearing and Camshaft Bearing Tool will install the bearing to the correct depth. IMPORTANT: While removing/install a new bearing (Crankshaft Front Main Bearing or Camshaft Bearing) ensure that the oil hole in the bearing is positioned correctly. The oil hole in the bearing must be aligned with the oil passage in the engine block for proper lubrication.

a - Oil passage b - Bearing hole c - Front Main Bearing and Camshaft Bearing Puller Tool d - Bearing halves (on tool) e - Bearing bore

152

Engine Block

a

b

a

R 750 INJECTION SIDE INJECTION FUEL SYSTEM DIAGRAM

al veicolo

10a

. . 3. 4. 5. 6. 7. . 9. 0. . . 3. 4. 5. 6. 7. . 9. 0. . . 3. 4.

Serbatoio combustibile Filtro combustibile Blocchetto di rifiuto nafta Pompe iniezione alta pressione Valvola di regolazione pressione combustibile Valvola regolazione pressione nel rail Accumulatore di pressione (Rail) Sensore pressione rail Iniettori Filtro Aria - 10a. Debimetro (solo per motori EURO 5) Turbocompressore Intercooler Valvola aspirazione a farfalla Valvola EGR Scambiatore di calore EGR Collettore EGR Collettore aspirazione/ sensore pressione aria comburente Sensore di posizione albero motore/sensore giri Sensore da fase albero camme Sensore temperatura liquido di raffreddamento Sensore pressione e temperatura olio motore Candelette Pedale acceleratore Centralina motore

1. Tank 2. Fuel Filter Assembly 3. Fuel refuses collecting block 4. High Pressure Pump 5. Fuel metering Valve 6. Rail Pressure Regulator Valve 7. Rail 8. Rail Pressure Sensor 9. Injectors 10. Air Filter 10a. Air Mass Flow meter - only for EURO 5 engine models 11. Compressor 12. Intercooler 13. Electronic Throttle Body 14. EGR Pneumatic Valve 15. EGR Cooler 16. EGR Distributor 17. Intake Manifold Pressure + Temperature Sensor 18. Crankshaft Position / Engine Speed Sensor 19. Camshaft Position Sensor 20. Coolant Temperature Sensor 21. Oil temp & Pressure sensor 22. Glow Plugs 23. Pedal Assembly 24. Engine Control Unit

Injection Side

153

R 750 electrical sensors location

Engine Coolant temperature

154

Intake - air temperature and pressure sensor

Injection Side

R 750

Camshaft / Phase sensor

Fuel pressure regulator valve

Injection Side

155

R 750

Crankshaft position sensor / engine RPM sensor

156

Injection Side

R 750

Pressure sensor - Rail

Lube Engine oil Temperature and Pressure sensor

Injection Side

157

R 750 low pressure system requirements

C B

A

A

Inlet fuel filter - 0.4 bar

B

Outlet fuel filter/Inlet low pressure pump

B

max vacuum pressure

Difference between A - B

(max. bar)

C

fuel pump return

C

≤ 0.6 bar

158

Injection Side

R 750 high pressure pump removal Release the clamp and disconnect the fuel delivery rubber hose from the pump. Loosen and remove the fuel return hose hollow bolt and proper washers from the pump. Loosen and remove the fuel delivery pipe nut from high pressure pump to rail. Loosen and remove the 3 fixing flange screws. Take the pump off. Replace the gasket install on the studs.

b

a - fuel delivery rubber hose clamp

d

b - fuel return rubber hose hollow bolt and proper washers c - fuel delivery pipe from high pressure pump to rail.

a

d - fixing flange nut

d

c

Loosen the flange nut and use a normal gear extractor to remove the injection pump gear. Remove the collar out without damaging the body flange of the pump. At the spare parts the pump will supply as assembly: pump and collar. e - collar

e

Injection Side

159

R 750 Installation Install the collar with bevelled side towards outside. Press the collar till it goes in contact with body flange pump. a - bevel

a Install the gear on the pump shaft. IMPORTANT: The spline is not installed on the pump shaft keyway. b - keyway Install the nut and torque it. High pressure pump gear nut

86.4 Nm

b

160

Injection Side

R 750 Install a new gasket on the studs. c - gasket Install the high pressure pump on studs, thread the flange nuts and torque them. d - flange nut High pressure pump flange nut

27.5 Nm

NOTE: The pump must not be timed.

c Install with proper clamp the fuel return rubber hose to the pump.

x

Install the fuel delivery hose hollow bolt with proper washers to the body pump and torque it. x - fuel delivery hose hollow bolt

y

y - fuel return hose hollow bolt fuel delivery hose hollow bolt

27.5 Nm

fuel return hose hollow bolt

WARNING: When the pump is removed a specific procedure must be performed to install correctly high pressure fuel delivery pipes. Before installing the high pressure pipe from pump to rail and high pressure pipes from rail to injectors a specific procedure must be observed. (Refer to High Pressure fuel components Tightening Procedure)

d

NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes. (REFER TO HIGH PRESSURE FUEL COMPONENTS TIGHTENING PROCEDURE)

Injection Side

161

R 750 injector Removal IMPORTANT: Whenever injectors are removed for service, they must be retained in order. At the time of installation, they must be installed in the same locations as when removed, because each injector has a proper IMA code.

a

c

Loosen the injector fixing screw and remove the clamp. Loosen the high pressure fuel pipe nut. IMPORTANT: When loosing high pressure pipe nut on injector retain injector feed connector with a wrench 13 mm.

b

Push the fuel return hose clamp to remove it. Take the injector off by hand. a - injector fixing screw and the clamp b - fuel return hose clamp c - high pressure fuel pipe nut d - IMA code e - injector feed connector

b e

IMPORTANT: R750EURO 4 IMA code is composed by number 6 digit R750EURO 5 IMA code is composed by number 7 digit

d

162

Injection Side

R 750 Installation Verify the cleaning into cylinder head bore where the injector is located.

d

Install a new O-ring in proper groove in the injector and apply Molykote P 1500 paste as shown in the photo. Verify that the washer is installed at the end of the injector. Install the injector into the cylinder head. Verify the presence of the plaque on rocker arm cover.

f

Install the injector clamp and fixing screw with spherical washer, to be installed as shown in the photos. a - injector clamp b - injector washer c - injector fixing screw and proper spherical washer

c

a

d - plaque on rocker arm cover e - injector O-ring with Molikote P 1500 paste f - cylinder head bore where the injector is located. g - IMA code Finger tighten completely the injector fixing screws and torque them. injector fixing screw

21 - 25 Nm

c

a

WARNING: When the injector is removed a specific procedure must be performed to install correctly high pressure fuel delivery pipes.

d

Before installing the injector high pressure fuel pipes from rail to injectors a specific procedure must be observed. (Refer to High Pressure fuel components Tightening Procedure) NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes. (REFER TO HIGH PRESSURE FUEL COMPONENTS TIGHTENING PROCEDURE) IMPORTANT: Whenever one or all injectors are replaced, new IMA code must be re-written inside ECU by diagnostic tool.

e

b

g

Injection Side

163

R 750 rail Removal Remove any component wich hinders the rail removal. Remove high pressure pipes from the rail: from rail to injector and from high pressure pump to rail.

a

Remove the bolts fixing to rail bracket.

c

Remove the rail. a - high pressure pipes (from rail to injectors) b - high pressure pipes (from rail to high pressure pump) c - rail fixing bolt to rail bracket

b

Installation WARNING: When the rail is removed a specific procedure must be performed to install correctly high pressure fuel delivery pipes. Before installing the high pressure pipe from pump to rail and high pressure pipes from rail to injectors a specific procedure must be observed. (Refer to High Pressure fuel components Tightening Procedure)

NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes. (REFER TO HIGH PRESSURE FUEL COMPONENTS TIGHTENING PROCEDURE)

164

Injection Side

c

R 750 - Draft R 750 HIGH PRESSURE fuel COMPONENTS TIGHTENING PROCEDURE NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes. If this procedure is observed, a correct alignment of high fuel pressure pipes is carried out so that the fuel leakage in high pressure fuel system is avoided. IMPORTANT: Whenever any high pressure fuel delivery pipe (pipe from pump to rail and pipes from rail to injectors) is loose and/or removed, it must be replaced in order to avoid fuel leakage in the high pressure fuel system.

1 - Verify that the injectors are properly tight. (Refer to Injector Section). 2 - Verify that the high pressure pump is properly tight. (Refer to High pressure Pump Section). 3 - Even if the following screws are tight, therefore loosen them: •

the screws fixing the rail to the bracket

•

the screws fixing the rail bracket to crankcase.

4 - Finger tighten completely and simultaneously every high pressure pipes nuts. 5 - Install the clamp on the high pressure pipe from pump to rail and finger tighten proper screw. 6 - Torque the high pressure pipe nut no. 3 (for engine with 4 cylinders) no. 4 (for engine with 6 cylinders) at RAIL SIDE 19 ± 2 Nm 7 - Torque the high pressure pipe remaining nuts at RAIL SIDE (no. 1,2,4,5 for engine with 4 cylinders and 1,2,3,5,6,7 for engine with 6 cylinder.) 19 ± 2 Nm 8 - Torque the high pressure pipe nuts at INJECTOR SIDE (no.1,2,3,4 for engine with 4 cylinders and 1,2,3,4,5,6 for engine with 6 cylinder.) 27 ± 2 Nm 9 - Torque the high pressure pipe nut at HIGH PRESSURE PUMP 20.5 ± 2 .5 Nm 10 - Torque the screw of the clamp fixing the high pressure pipe from pump to rail to rail bracket 14.7 ± 2 Nm 11 - Torque the screws fixing the rail to the bracket and the screws fixing the rail bracket to crankcase 33 ± 2 Nm

b

a

e

b

a

c

e d

e

a - high pressure pipe nuts at RAIL SIDE (no. 3 for engine with 4 cylinders) (no.4 for engine with 6 cylinder) b - high pressure pipe nuts at INJECTION SIDE c - high pressure pipe nut at HIGH PRESSURE PUMP d - screw of the clamp fixing the high pressure pipe from pump to rail to rail bracket e - screws fixing the rail to the bracket and the screws fixing the rail bracket to crankcase

Injection Side

165

R 750 oil filter HOUSING Removal To remove the oil filter cartridge, refer to Maintenance Section. Loosen the bolt fixing the oil filter assembly (oil filter cartridge and oil filter housing) to oil heat exchanger. Remove the oil filter assembly. Loosen the special bolt fixing the oil heat exchanger to crankcase. Loosen the clamp fixing the rubber hoses to oil heat exchanger and remove it.

a

a - bolt fixing the oil filter assembly (oil filter cartridge and oil filter housing) to oil heat exchanger. b - special bolt fixing the oil heat exchanger to crankcase.

b

installation Replace the old O-ring into the groove of oil heat exchanger and install a new one. Grease the O-ring with Molykote 111.

b

a

Install the oil heat exchanger and torque the special bolt fixing the oil heat exchanger to crankcase. “b” special bolt fixing the oil heat exchanger to crankcase.

60 Nm

Replace the old O-ring into the groove of oil filter assembly and install a new one. Grease the O-ring with Molykote 111.

d

c

Replace the O-ring into the groove bolt fixing the oil filter assembly and grease it with Molykote 111. Finger tighten and torque it. “a” bolt fixing the oil filter assembly

e

39.2 Nm

c - O-ring into the groove of oil heat exchanger

d

d - O-ring into the groove of oil filter assembly e - O-ring into the groove bolt fixing the oil filter assembly to oil heat exchanger.

166

c

Injection Side

b

a

R 750 oil delivery pipe to rocker arm Removal Loosen and remove the hollow bolts (injection and exhaust side) and proper washers. Loosen also the clamp fixing the pipe to cylinder head end spacer). a - hollow bolts (injection side) b - hollow bolt (exhaust side) c - clamp fixing pipe to cylinder head spacer

Installation Install the hollow bolts with new washers. Lubricate with engine oil the hollow bolts thread.

a

Install the clamp and tighten securely it. hollow fixing bolt (cylinder head side)

14 Nm

hollow fixing bolt (exhaust side)

23.5 Nm

c

c

b

Injection Side

167

R 750 rocker arm cover Removal Remove any component that hinders the rocker arm cover removal.

a

Loosen and remove the fixing screws. Remove the gasket. a - rocker arm fixing screw

Installation Install a new gasket if necessary. Install the cover and torque the fixing screws in a cross pattern (see picture) rocker arm fixing screws

11.8 Nm

coolant manifold Removal

Remove any component that hinder the coolant manifold removal. Remove the fixing screws and take the manifold off.

Rocker arms cover - tightening procedure

Replace the old gasket. x - coolant manifold fixing screw

x

Installation Inspect the sealing surfaces for deep nicks and scratches. Inspect the castings for cracks or corrosion that might prevent a proper seal. Replace or repair components as needed. IMPORTANT: The end cover and the coolant manifold gasket flanges must align for proper sealing on the cylinder heads. Align the flanges using a straight edge as shown. Align the coolant manifold end cover and the coolant manifold using a straight edge device and then, torque the coolant manifold end cover screws evenly in a diagonal pattern. Insert a new gasket between Coolant manifold and Coolant manifold end cover, by applying Loctite 510 on both surfaces. coolant manifold screws

11.8 Nm

coolant manifold end cover screws

10.8 Nm

a - Coolant manifold end cover b - Gasket c - Coolant manifold d - Typical straight edge device e - Coolant manifold end cover screw and washer

168

Injection Side

R 750 thermostatic valve Removal

x

Remove the no. 4 thermostat cover screws. Remove the cover and take the thermostat off. x - thermostat cover screws

installation Install the cover and torque the fixing screws. thermostat cover screws

10.8 Nm

y

Injection Side

169

R 750 vacuum pump removal If needed remove the alternator from the engine. Disconnect oil feed pipe and oil return pipe from vacuum pump.

c

Loosen the vacuum pump fixing screws.

Installation Ensure that the O-ring is properly seated.

a

Replace it if needed. Install the vacuum pump on the alternator. Torque the vacuum pump fixing screws to alternator. x - oil feed pipe to vacuum pump y - oil return pipe from vacuum pump a - vacuum pump b - O-ring c - vacuum pump fixing screw Refer to section “Alternator” to identify the torque value of vacuum pump oil supply hollow bolt

y

a c

b

170

Injection Side

x

R 750 ENGINE ELECTRICAL Alternator Removal

a

•

Remove Poly-V belt.

•

Disconnect wiring electrical connections from the alternator.

•

Detach from the vacuum pump any oil feeding and draining hose

•

Loosen and remove the alternator fixing bolt.

•

a - Alternator

•

b - Vacuum pump

•

c - alternator fixing bolt

•

d1 - Vacuum pump oil feeding

•

d2 - Vacuum pump oil draining hose

c

Installation

b

Position the alternator on the bracket. Thread the bolts in the alternator and torque the nuts. Alternator fixing bolt

45.1 Nm

Install vacuum pump oil feeding hollow bolt with proper washers and draining hoses . vacuum pump oil feeding hollow bolt (on vacuum pump)

24.5 Nm

vacuum pump oil feeding hollow bolt (on crankcase)

27.5 Nm

d1 c

d2

Alternator pulley Removal The alternator pulley could be idle type: it can be identified if the front cover is present or the special tool 68420022F installs on the pulley. Remove the cover and install the special tool 68420022F and dissamble the pulley.

installation Thread the pulley on the alternator shaft. Tighten the pulley. Alternator idle pulley

80 ± 5 Nm

IMPORTANT: Install alternator fan with the arrow rinted on it as shown in the photo.

Engine Electrical

171

R 750 testing

W TERMINALE W - corrente in uscita

D+

TERMINALE D+ - per carica / lampada carica batteria

schema per controllo alternatore

WL: Lampada carica alternatore da 2 a 4 watts, 12 V IS: Interuttore accensione

172

Engine Electrical

corrente in uscita

R 750

Constant Voltage

Ampere

RPM Alternator

13.5 V

0 amp

1000 rpm

23 amp

1500 rpm

105 amp

6000 rpm

Volt Costanti

Ampere

giri/min Alternatore

13.5 V

0 amp

1000 giri/min

23 amp

1500 giri/min

105 amp

6000 giri/min

alternatore giri/min.

Rapporto puleggia albero motore / puleggia alternatore 2.63 crankshaft pulley / alternator pulley ratio 2.63

Engine Electrical

173

R 750 voltage regulator removal •

Remove the alternator from the engine.

•

Remove the vacuum pump if needed and loosen the voltage regulator fixing screws.

•

a - vacuum pump

•

b - voltage regulator fixing screws

•

c - voltage regulator

c a

b

c

Alternator Bracket Removal

a

•

Unscrew the alternator bracket bolts.

•

Remove the bracket

a - alternator fixing bracket bolts Assembling •

Position the bracket on the cranckcase

•

Thread the bolts and torque them. Alternator bracket bolt

68.6 Nm

Starter Removal •

Unscrew the starter fixing bolts.

•

Remove the starter

a - starter fixing bolts

a Assembling •

Position the starter on the flywheel housing

•

Thread the bolts and torque them. Starter fixing bolt

174

83.4 Nm

Engine Electrical

R 750 ENGINE CONTROL

DIAGNOSTIC TROUBLE CODES “euro 4”

NOTE: In VM Motori internet web site Customer Reserved Area “EXTRANET”, section “Diagnostic Tool & Troubleshooting Common Rail Engines R750 MR700-500” are available: •

the lastest Diagnostic Tool Software Release for Common Rail Engine Models

•

Industrial and Marine Common Rail engine troubleshooting symptoms charts

ENGLISH

ITALIANO

DTC

Crankshaft/Camshaft Position Sensor Offset Error

Errore di Posizione Sensore Albero a Camme/Albero Motore

P0016

BPA Boost Pressure Actuator Solenoid Circuit Malfunction

Malfunzionamento Circuito Solenoide Attuatore di Controllo Pressione di Sovralimentazione BPA

P0046

BPA Boost Pressure Actuator Solenoid Circuit Malfunction

Malfunzionamento Circuito Solenoide Attuatore di Controllo Pressione di Sovralimentazione BPA

P0047

BPA Boost Pressure Actuator Solenoid Circuit Malfunction

Malfunzionamento Circuito Solenoide Attuatore di Controllo Pressione di Sovralimentazione BPA

P0048

Air Temperature Signal Duty Cycle Error

Errore Duty Cycle Segnale Temperatura Aria

P0070

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0087

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0088

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0089

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0090

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0091

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

Errore Pressione Rail durante Controllo Pressione Rail da Regolatore di Pressione

P0092

Raw Air Mass Signal Plausability Error

Errore di Plausibilità Segnale Portata Aria

P0100

Raw Air Mass Signal Plausability Error

Errore di Plausibilità Segnale Portata Aria

P0101

Battery Voltage Signal Range Check Error

Errore Intervallo di Controllo Segnale Tensione Batteria

P0103

Air Mass Signal Range Check Error of Reference Errore Segnale Portata Aria di Riferimento Signal

P0104

Intake Air Temperature Sensor Error

P0110

Errore Sensore Temperatura Aria in Aspirazione

Intake Air Temperature Sensor Warning

Allarme Sensore Temperatura Aria in Aspirazione

P0113

Engine Coolant Sensor Error

Errore Sensore Acqua Motore

P0115

Engine Coolant Temperature Warning

Allarme Temperatura acqua Motore

P0118

Accelerator Pedal Position Sensor 1 Error

Errore Posizione Pedale Acceleratore - Sensore 1

P0120

Fuel Temperature Sensor Error

Errore Sensore Temperatura Gasolio

P0180

Fuel Rail Pressure Signal Error

Errore Segnale Pressione Rail

P0190

Fuel Rail Pressure Sensor Offset Monitoring Error

Errore Controllo Scostamento Segnale Pressione Rail

P0191

Oil Temperature Sensor Signal Error

Errore Segnale da Sensore Temperatura Olio Motore

P0195

Engine Oil Temperature Warning

Allarme Temperatura Olio Motore

P0198

Engine Control

175

R 750 Cylinder 1 - Injector Circuit Malfunction Warning

Cilindro 1 - Allarme di Malfunzionamento Circuito Iniettore

P0201

Cylinder 2 - Injector Circuit Malfunction Warning

Cilindro 2 - Allarme di Malfunzionamento Circuito Iniettore

P0202

Cylinder 3 - Injector Circuit Malfunction Warning

Cilindro 3 - Allarme di Malfunzionamento Circuito Iniettore

P0203

Cylinder 4 - Injector Circuit Malfunction Warning

Cilindro 4 - Allarme di Malfunzionamento Circuito Iniettore

P0204

Cylinder 5 - Injector Circuit Malfunction Warning

Cilindro 5 - Allarme di Malfunzionamento Circuito Iniettore

P0205

Cylinder 6 - Injector Circuit Malfunction Warning

Cilindro 6 - Allarme di Malfunzionamento Circuito Iniettore

P0206

Accelerator Pedal Position Sensor 2 Error

Errore Posizione Pedale Acceleratore - Sensore 2

P0220

Accelerator Pedal Position Sensors Synchroniza- Errore di Sincronizzazione Sensori di Posizione tion Error Pedale Acceleratore

P0221

Turbo/Super Charger Overboost Condition

Condizioni di Alta Pressione di Sovralimentazione

P0234

Boost Pressure Sensor Error

Errore Sensore Pressione di Sovralimentazione

P0235

Boost Pressure Warning

Allarme Pressione di Sovralimentazione

P0238

Metering Unit Solenoid PWM Control Circuit Malfunction

Malfunzionamento Circuito di Controllo PWM Solenoide Regolatore di Pressione

P0252

Metering Unit Solenoid PWM Control Circuit Malfunction

Malfunzionamento Circuito di Controllo PWM Solenoide Regolatore di Pressione

P0253

Metering Unit Solenoid PWM Control Circuit Malfunction

Malfunzionamento Circuito di Controllo PWM Solenoide Regolatore di Pressione

P0254

PCV Pressure Control Valve Analogic/Digital Channel Error

Errore Canale Analogico/Digitale di Controllo Valvola Regolazione Portata Combustibile PCV

P0256

PCV Pressure Control Valve PWM Circuit Malfunction

Malfunzionamento Circuito PWM di Controllo Valvola Regolazione Portata Combustibile PCV

P0257

PCV Pressure Control Valve PWM Circuit Malfunction

Malfunzionamento Circuito PWM di Controllo Valvola Regolazione Portata Combustibile PCV

P0258

PCV Pressure Control Valve PWM Circuit Malfunction

Malfunzionamento Circuito PWM di Controllo Valvola Regolazione Portata Combustibile PCV

P0259

Cylinder 1 - Injector Circuit Malfunction Specific Error

Cilindro 1 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0262

Cylinder 2 - Injector Circuit Malfunction Specific Error

Cilindro 2 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0265

Cylinder 3 - Injector Circuit Malfunction Specific Error

Cilindro 3 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0268

Cylinder 4 - Injector Circuit Malfunction Specific Error

Cilindro 4 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0271

Cylinder 5 - Injector Circuit Malfunction Specific Error

Cilindro 5 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0274

Cylinder 6 - Injector Circuit Malfunction Specific Error

Cilindro 6 - Errore Specifico di Malfunzionamento Circuito Iniettore

P0277

Turbo/Super Charger Underboost Condition

Condizioni di Bassa Pressione di Sovralimentazione

P0299

Crankshaft Position Sensor Error

Errore Sensore di Giri Albero Motore

P0335

Engine Overspeed Warning

Allarme Fuorigiri Motore

P0338

Camshaft Position Sensor Error

Errore Sensore di Fase Albero a Camme

P0340

GCU-R Glow Control Unit - Standard Voltage System Relay Circuit Malfunction

GCU Unità di Controllo Candelette Malfunzionamento Relè

P0380

Glow Lamp Indicator Malfunction

Malfunzionamento Spia Candelette

P0381

176

Engine Control

R 750 EGR Exhaust Gas Recirculation Flow Insufficient Detected

Portata Insufficiente del Ricircolo dei Gas di Scarico EGR

P0401

EGR Exhaust Gas Recirculation Flow Excessive or Inlet Air Circuit Malfunction Detected

Portata Eccessiva del Ricircolo dei Gas di Scarico EGR o Malfunzionamento Impianto di Ingresso Aria

P0402

EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di ction Scarico EGR

P0404

Fan 1 Control Relay Malfunction

Malfunzionamento Circuito Relè Ventola 1

P0480

Fan 2 Control Relay Malfunction

Malfunzionamento Circuito Relè Ventola 2

P0481

Fan 3 Control Relay Malfunction

Malfunzionamento Circuito Relè Ventola 3

P0482

TVA Throttle Valve Actuator Monitoring Error Indicated by Digital Status Signal

Errore Attuatore Valvola Parzializzatrice Aspirazione TVA Indicato da Segnale Digitale di Stato

P0487

TVA Throttle Valve Actuator Circuit Malfunction

Malfunzionamento Circuito Attuatore Valvola Parzializzatrice Aspirazione TVA

P0488

EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di ction Scarico EGR

P0489

EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di ction Scarico EGR

P0490

Vehicle Speed Sensor Malfunction

Malfunzionamento Sensore di Velocità Veicolo

P0500

Brake Signal Error

Errore Segnale Freno

P0504

Incorrect Immobilizer Key

Chiave Immobilizer non Corretta

P0513

Engine Oil Pressure Sensor/Switch Signal Error

Errore Segnale da Sensore Pressione Olio Motore

P0520

Engine Oil Pressure Lamp Malfunction

Malfunzionamento Spia Pressione Olio Motore

P0521

Critical Engine Oil Pressure Warning

Allarme Pressione Olio Motore Critica

P0522

Low Engine Oil Pressure Warning

Allarme Pressione Olio Motore Bassa

P0524

Battery Voltage Error

Errore Tensione Batteria

P0560

Cruise Control Multi-Function Input “A”/”B” Correlation Error (Invalid Switch Combination Detected)

Malfunzionamento Circuito di Controllo Cruise Control (Controllo Dati di Input non Valido)

P0585

Add-on heater Circuit Malfunction

Malfunzionamento Circuito Riscaldatore Ausiliario

P0597

ECU Internal Communication Error - SPI

ECU Errore di Comunicazione Interna - SPI

P0600

ECU Internal EEPROM Memory Error

ECU Errore Interno Memoria EEPROM

P0601

TPU Time Processing Unit Monitoring Error

Errore di Verifica Tempo di Attivazione Processore TPU

P0606

ECU Internal Watchdog/Controller Error

Errore Interno Controllore/Processore ECU

P0607

Energizing Time Calibration Error

Errore Calibrazione Tempo di Apertura Iniettore

P0611

Starter Relay Circuit Malfunction

Malfunzionamento Circuito Relè Comando Motorino di Avviamento

P0615

Starter Relay Circuit Malfunction (Low Side Power Stage)

Malfunzionamento Circuito Relè Comando Motorino di Avviamento (Low Side Power Stage)

P0616

Starter Relay Circuit Malfunction (high Side Power Stage)

Malfunzionamento Circuito Relè Comando Motorino di Avviamento (high Side Power Stage)

P0617

Sensor Supply Voltage 1 Check Error

Errore Verifica Tensione di Alimentazione Sensori 1

P0641

Air Conditioning Relay Circuit Malfunction

Malfunzionamento Circuito Relè Aria Condizionata

P0645

MIL Lamp Circuit Malfunction

Malfunzionamento Circuito Spia MIL

P0650

Sensor Supply Voltage 2 Check Error

Errore Verifica Tensione di Alimentazione Sensori 2

P0651

GCU Glow Control Unit - Glow Plug GSK Diagnosis Transmission Error

GCU Unità di Controllo Candelette - Errore Trasmissione Diagnosi GSK

P0670

Engine Control

177

R 750 Glow Plug Circuit Malfunction Cylinder 1

Malfunzionamento Circuito Candeletta Cilindro 1

P0671

Glow Plug Circuit Malfunction Cylinder 2

Malfunzionamento Circuito Candeletta Cilindro 2

P0672

Glow Plug Circuit Malfunction Cylinder 3

Malfunzionamento Circuito Candeletta Cilindro 3

P0673

Glow Plug Circuit Malfunction Cylinder 4

Malfunzionamento Circuito Candeletta Cilindro 4

P0674

Glow Plug Circuit Malfunction Cylinder 5

Malfunzionamento Circuito Candeletta Cilindro 5

P0675

Glow Plug Circuit Malfunction Cylinder 6

Malfunzionamento Circuito Candeletta Cilindro 6

P0676

Main Relay Control Error

Errore Controllo Main Relè

P0685

Fan 1 Control Relay Malfunction

Malfunzionamento Circuito Relè Ventola 1

P0691

Fan 1 Control Relay Malfunction

Malfunzionamento Circuito Relè Ventola 1

P0692

Sensor Supply Voltage 3 Check Error

Errore Verifica Tensione di Alimentazione Sensori 3

P0697

Transmission Controller Unit TCU Generic Error

Errore Generico Centralina Cambio TCU

P0700

Main Clutch Signal Error

Errore Segnale Frizione

P0704

Transmission Controller Unit TCU Torque Converted Clutch out of Tolerance

Centralina Cambio TCU Valore di Coppia da Convertitore Fuori Tolleranza

P0740

Reverse Gear Switch Error

Errore Commutatore Inversione di Marcia Cambio

P0812

Transmission Controller Unit TCU Neutral Lamp Error

Centralina Cambio TCU Malfunzionamento Spia Cambio in Neutro

P1000

Transmission Controller Unit TCU Internal Error

Errore Interno Centralina Cambio TCU

P1601

E.C.U. Analogic/Digital Converter Error

Errore Convertitore Analogico/Digitale E.C.U.

P1602

Engine Coolant Sensor Malfunction

Malfunzionamento Sensore Acqua Motore

P1603

T15 Terminal Signal Plausibility Error

Errore di Plausibilità Segnale Terminale T15

P1605

T50 Terminal Signal Plausibility Error

Errore di Plausibilità Segnale Terminale T50

P1606

ECU Processor Recovery Locked

ECU Ripristino Processore Bloccato

P1612

ECU Internal Supply Voltage Error

ECU Errore Tensione di Alimentazione Interna

P1613

ECU Internal Supply Voltage Error

ECU Errore Tensione di Alimentazione Interna

P1614

Plausibility Error on Base Map for Torque to Quantity Conversion

Errore di Plausibilità nella Mappa di Conversione Coppia/Introduzioni

P1615

ECU - Fuel Injector Control Module A Performance Error

ECU - Errore Prestazione Modulo A di Controllo Iniezioni

P1616

ECU - Fuel Injector Control Module B Performan- ECU - Errore Prestazione Modulo B di Controllo ce Error Iniezioni

P1617

ECU Overrun Monitoring Error

ECU Errore Contollo Limiti Tempo di Attivazione Iniettori

P1619

ECU Redundant Engine Speed Monitoring Error

ECU Errore Controllo di Ridondanza Segnale Giri Motore

P161A

ECU Processor Recovery Suppressed

ECU Ripristino Processore Abolito

P161B

ECU Redundant Shut Off Test Error during Initialization

ECU Errore Test di Ridondanza Disattivazione Iniettori durante Inizializzazione

P1620

ECU Internal Communication Error Between Function Computer and Monitoring Module

Errore Interno di Comunicazione tra Processore e Modulo di Controllo

P1627

Dataset Variant Coding Plausibility Error

Errore di Plausibilità della Codifica Variante Dataset

P1628

System Lamp Circuit Malfunction

Malfunzionamento Circuito Spia di Sistema

P1650

Transmission Controller Unit TCU Gear Incorrect Ratio

Errore Interno Centralina Cambio TCU Rapporto Marcia Errato

P1701

Transmission Controller Unit TCU Solenoid Circuit Error

Centralina Cambio TCU Errore Circuito Solenoidi

P1702

Transmission Controller Unit TCU Engine/Turbine Speed Sensor Error

Centralina Cambio TCU Errore Sensore Velocità Turbina

P1703

178

Engine Control

R 750 Transmission Controller Unit TCU Solenoid Switch Valve Latched

Centralina Cambio TCU Valvola Commutatrice Bloccata

P1704

Transmission Controller Unit TCU Relay Error

Centralina Cambio TCU Errore Relay

P1801

Transmission Controller Unit TCU Pressure Switch Check Error

Centralina Cambio TCU Errore nella Verifica Commutatore di Pressione

P1802

Transmission Controller Unit TCU Pressure Switch Test Failed

Centralina Cambio TCU Test Funzionamento Commutatore di Pressione Fallito

P1803

DPF Particulate Filter - Filter Dismounted or Defective

DPF Filtro Particolato - Filtro Smontato o Difettoso

P2002

Fuel Filter Heating Relay Circuit Malfunction

Malfunzionamento Circuito Relè Riscaldatore Filtro Gasolio

P2030

Exhaust Gas Temperature Sensor Error - Bank 1 - Position 1

Errore Sensore di Temperatura Gas di Scarico - Bancata 1 - Posizione 1

P2031

Exhaust Gas Temperature Sensor Error - Bank 1 - Position 2

Errore Sensore di Temperatura Gas di Scarico - Bank 1 - Posizione 2

P2033

Exhaust Gas Temperature Sensor Plausibility Check Error - Position 1

Errore nella Verifica di Plausibilità Sensore di Temperatura Gas di Scarico - Posizione 1

P2080

Exhaust Gas Temperature Sensor Plausibility Check Error - Position 2

Errore nella Verifica di Plausibilità Sensore di Temperatura Gas di Scarico - Posizione 2

P2084

TVA Throttle Valve Actuator Circuit Malfunction

Malfunzionamento Circuito Attuatore Valvola Parzializzatrice Aspirazione TVA

P2141

TVA Throttle Valve Actuator Circuit Malfunction

Malfunzionamento Circuito Attuatore Valvola Parzializzatrice Aspirazione TVA

P2142

Injector Bank 1 Circuit Malfunction Warning

Allarme di Malfunzionamento Circuito Iniettori Bancata 1

P2147

Injector Bank 1 Circuit Malfunction Specific Error

Errore Specifico di Malfunzionamento Circuito Iniettori Bancata 1

P2148

Injector Bank 2 Circuit Malfunction Warning

Allarme di Malfunzionamento Circuito Iniettori Bancata 2

P2150

Injector Bank 2 Circuit Malfunction Specific Error

Errore Specifico di Malfunzionamento Circuito Iniettori Bancata 2

P2151

Barometric Pressure Sensor Error

Errore Sensore Pressione Atmosferica

P2226

Water in Fuel Sensor Circuit Malfunction

Malfunzionamento Circuito Sensore Acqua nel Gasolio

P2266

Water in Fuel Sensor Circuit Malfunction

Malfunzionamento Circuito Sensore Acqua nel Gasolio

P2267

Water in Fuel Detection

Rilevamento Acqua nel Gasolio

P2269

PRV Rail Pressure Relief Valve Error

Errore Valvola di Limitazione Pressione Massima Rail PRV

P2293

PRV Rail Pressure Relief Valve Error

Errore Valvola di Limitazione Pressione Massima Rail PRV

P2294

Accelerator Pedal Position/Brake not plausible

Posizione Acceleratore/Freno non plausibile

P2299

EGR Cooler By-pass Valve Actuator Malfunction

Malfunzionamento Attuatore By-pass Radiatore EGR

P2425

EGR Cooler By-pass Valve Actuator Malfunction

Malfunzionamento Attuatore By-pass Radiatore EGR

P2426

EGR Cooler By-pass Valve Actuator Malfunction

Malfunzionamento Attuatore By-pass Radiatore EGR

P2427

Exhaust Gas Temperature Sensor Error - Bank 1 - Position 1

Errore Sensore di Temperatura Gas di Scarico - Bancata 1 - Posizione 1

P2428

DPF Particulate Filter - Engine Protection Active

DPF Filtro Particolato - Protezione Motore Attiva

P242F

DPF Particulate Filter - Differential Pressure Sensor Defective

DPF Filtro Particolato - Sensore Pressione Differenziale Difettoso

P2452

Engine Control

179

R 750 DPF Particulate Filter - Differential Pressure not Plausible

DPF Filtro Particolato - Pressione Differenziale non Plausibile

P2453

DPF Particulate Filter - Low System Efficiency

DPF Filtro Particolato - Efficienza Sistema Bassa

P2458

PTO Enable Switch Circuit Malfunction

Malfunzionamento Commutatore PTO

P251C

Water Level in Fuel Actuator Malfunction

Malfunzionamento Attuatore Livello di Acqua nel Gasolio

P3200

CAN Messages Error from Communication Manager

Errore Messaggi CAN da Gestore Comunicazioni CAN

U0001

CAN A Controller Error

Errore Controllo Linea CAN A

U0028

CAN B Controller Error

Errore Controllo Linea CAN B

U0037

CAN C Controller Error

Errore Controllo Linea CAN C

U0046

CAN Message Timeout Error from Transmission Controller Unit TCU

Errore Messaggio CAN da Centralina Cambio TCU

U0101

CCVS CAN Error on Cruise Control

CCVS Errore Messaggio CAN da Cruise Control

U0104

RXEEC2 CAN Message Timeout Error

RXEEC2 Errore Messaggio CAN

U0107

PTO CAN Message Timeout Error

PTO Errore Messaggio CAN

U0117

TSC1-VE Speed Override Vehicle Dynamic Control Module VC Error Message

TSC1-VE Errore Messaggio da Controllo Veicolo VC

U0122

EBC1 CAN Message Timeout Error

EBC1 Errore Messaggio CAN

U0129

TSC1-PE Torque/Speed Override Control Module TSC1-PE Errore Messaggio da Controllo Esterno PTO Error Message di Coppia/Velocità PTO

U0140

Lost Communication with Vehicle Immobilizer Control Module

Comunicazione con Centralina Immobilizer Interrotta

U0167

Invalid Data Received from Transmission Controller Unit TCU

Dati Ricevuti da Centralina Cambio TCU non Coerenti

U0402

RXEEC2 CAN Message Out of Range

RXEEC2 Messaggio CAN oltre i limiti

U0408

Invalid Data Received from Vehicle Immobilizer Control Module (EEPROM Error)

Dati Ricevuti da Centralina Immobilizer non Coerenti (Errore EEPROM)

U0426

EEC2 Message or Accelerator Pedal not Present

EEC2 Errore Messaggio CAN o Pedale Acceleratore non presente

U1001

Accelerator Pedal Signal Above Threshold Value

Segnale Pedale Acceleratore Eccede Limite Superiore

U1002

180

Engine Control

R 750 DIAGNOSTIC TROUBLE CODES “euro 5” NOTE: In VM Motori internet web site Customer Reserved Area “EXTRANET”, section “Diagnostic Tool & Troubleshooting Common Rail Engines R750 MR700-500” are available: •

the lastest Diagnostic Tool Software Release for Common Rail Engine Models

•

Industrial and Marine Common Rail engine troubleshooting symptoms charts

DTC

SPN

Description

FMI FMI Max Min

FMI Sig

FMI Npl

FMI Max

16

228

Crankshaft/ Camshaft Position Sensor Offset Error

1

FF

FF

FF

offset between camshaft and crankshaft

87

157

Error Fuel Low Rail Pressure

1

FF

FF

FF

maximum positive deviation of rail pressure exceeded

87

157

Error Fuel Low Rail Pressure

5

FF

FF

FF

maximum positive deviation of rail pressure exceeded concerning set flow of fuel

87

157

Error Fuel Low Rail Pressure

9

FF

FF

FF

minimum rail pressure exceeded

88

157

Error Fuel High Rail Pressure

1

FF

FF

FF

maximum negative rail pressure deviation with metering unit on lower limit is exceeded

88

157

Error Fuel High Rail Pressure

5

FF

FF

FF

maximum rail pressure exceeded

89

157

Fuel Rail Pressure Monitoring Error for Active Pressure Control by Metering Unit Governor

5

FF

FF

FF

setpoint of metering unit in overrun mode not plausible

96

172

Air mass temperatu- 1 re signal error

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

100

132

Raw Air Mass Signal Error

9

A

B

FF

Signal range check high error

Signal ran- signal ge check cutoff low error or short circuit to either battery or ground

101

132

Raw Air Mass Signal Plausability Error

1

2

FF

FF

airmass ratio is higher than threshold high

airmass ratio is lower than threshold low

Engine Control

FMI Min

FMI Sig

FMI Npl

181

R 750 102

132

 Error path exceeding the maximum drift limit in low-idle mode

5

6

FF

FF

If the upper limit is exceeded when the correction value calculation is released

If values fall below the lower when the correction value calculation is released

102

132

 Error path exceeding the maximum drift limit in the load range

9

A

FF

FF

If the upper limit is exceeded when the correction value calculation is released

If values fall below the lower when the correction value calculation is released

103

132

Battery Voltage Signal Range Check Error

1

2

FF

FF

Voltage above upper Limit

Voltage below lower Limit

110

105

Intake Air Temperature Sensor Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

113

105

Intake Air Tempera- 1 ture Sensor Warning

FF

FF

FF

air temperature above upper Limit

115

110

Engine Coolant Sensor Error

1

2

3

4

Voltage abo- Voltage ve upper limit below lower limit

118

110

Engine Coolant Temperature Warning

1

FF

FF

FF

Coolant temperature above upper limit

120

91

Accelerator Pedal Position Sensor 1 Error

1

2

FF

4

Voltage abo- Voltage ve upper limit above upper limit

168

174

Fuel over temp

1

FF

FF

FF

Over temp

180

174

Fuel Temperature Sensor Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

190

164

Fuel Rail Pressure Signal Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

195

175

Oil Temperature Sensor Signal Error

1

2

3

4

Voltage abo- Voltage ve upper limit below lower limit

198

175

Engine Oil Tempera- 1 ture Warning

FF

FF

FF

Oil Temperature above upper limit

201

651

Cylinder 1 - Injector Circuit Malfunction Warning

FF

FF

3

FF

Open load

202

652

Cylinder 2 - Injector Circuit Malfunction Warning

FF

FF

3

FF

Open load

182

Engine Control

Can Msg. value defect

plausibility defect between OTS and CTS

Unplausible voltage

signal error for CAN

Plausibility error between OTS and CTS

R 750 203

653

Cylinder 3 - Injector Circuit Malfunction Warning

FF

FF

3

FF

Open load

204

654

Cylinder 4 - Injector Circuit Malfunction Warning

FF

FF

3

FF

Open load

216

629

ECU Overrun Monitoring Error

1

FF

FF

FF

Energising time exceeds limit of overrun monitoring (ECU Overrun monitoring error)

216

629

ECU Redundant 5 Engine Speed Monitoring Error

FF

FF

FF

Plausibility error in engine speed check (ECU Redundant engine speed monitoring error)

220

91

Accelerator Pedal Position Sensor 2 Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit above upper limit

221

91

Accelerator Pedal Position Sensors Synchronization Error

FF

FF

FF

4

234

641

Turbo/Super Charger Overboost Condition

FF

2

FF

FF

235

102

Boost Pressure Sensor Error

1

2

3

4

Voltage abo- Voltage ve upper limit below lower limit

238

102

Boost Pressure Warning

1

FF

FF

FF

Boost pressure above upper limit

252

1347 Metering Unit Solenoid PWM Control Circuit Malfunction

FF

FF

3

4

253

1347 Metering Unit Solenoid PWM Control Circuit Malfunction

FF

2

FF

FF

254

1347 Metering Unit Solenoid PWM Control Circuit Malfunction

1

FF

FF

FF

deviation between APP1 and APP2 voltage too high negative governor deviation below limit CAN signal defect

Not plausible with atmospheric pressure sensor

open load of metering unit output

excess temperature of metering unit powerstage

short circuit to ground of metering unit output short circuit to battery of metering unit output

Engine Control

183

R 750 262

651

Cylinder 1 - Injector Circuit Malfunction Specific Error

1

2

3

4

short circuit on Low Side to battery

general short circuit

263

651

Energizing Time Calibration Error

1

2

FF

FF

above upper limit of energizing time

below lower limit of energizing time

265

652

Cylinder 2 - Injector Circuit Malfunction Specific Error

1

2

3

4

short circuit on Low Side to battery

general short circuit

266

652

Energizing Time Calibration Error

1

2

FF

FF

above upper limit of energizing time

below lower limit of energizing time

268

653

Cylinder 3 - Injector Circuit Malfunction Specific Error

1

2

3

4

short circuit on Low Side to battery

general short circuit

269

653

Energizing Time Calibration Error

1

2

FF

FF

above upper limit of energizing time

below lower limit of energizing time

271

654

Cylinder 4 - Injector Circuit Malfunction Specific Error

1

2

3

4

short circuit on Low Side to battery

general short circuit

272

654

Energizing Time Calibration Error

1

2

FF

FF

above upper limit of energizing time

below lower limit of energizing time

299

641

Turbo/Super Charger Underboost Condition

1

FF

FF

FF

positive governor deviation above limit

335

190

Crankshaft Position Sensor Error

1

2

FF

FF

no crankshaft wrong signal crankshaft signal

338

190

Engine Overspeed Warning

1

FF

FF

FF

engine speed above upper limit

340

723

Camshaft Position Sensor Error

1

2

FF

FF

no camshaft signal

wrong camshaft signal

380

676

GCU-R Glow Control Unit - Standard Voltage System Relay Circuit Malfunction

1

2

3

4

Short Circuit to Battery

Short Circuit to Ground

No Load

Excess Temperature

381

675

Glow Lamp Indicator Malfunction

1

2

3

4

Short Circuit to Battery

Short Circuit to Ground

No Load

Excess Temperature

401

27

EGR Exhaust Gas FF Recirculation Flow Insufficient Detected

2

FF

FF

184

Labour Time Guide

negative governor deviation below limit

short not-classifcircuit Low yable error Side to High Side

short not-classifcircuit Low yable error Side to High Side

short not-classifcircuit Low yable error Side to High Side

short not-classifcircuit Low yable error Side to High Side

R 750 402

27

EGR Exhaust Gas Recirculation Flow Excessive or Inlet Air Circuit Malfunction Detected

1

FF

FF

FF

Positive governor deviation above limit

403

27

EGR Exhaust Gas Recirculation Actuator Malfunction

FF

FF

3

4

405

27

EGR Exhaust Gas FF Recirculation Flow Insufficient Detected During DPF Regeneration

2

FF

FF

negative governor deviation below limit

489

27

EGR Exhaust Gas Recirculation Actuator Malfunction

FF

2

FF

FF

Short Circuit to Ground

490

27

EGR Exhaust Gas Recirculation Actuator Malfunction

1

FF

FF

FF

Short Circuit to Battery

500

84

Vehicle Speed Sensor Malfunction

1

FF

3

4

520

100

Engine Oil Pressure Sensor/Switch Signal Error

1

2

3

521

835

Engine Oil Pressure Lamp Malfunction

1

2

522

100

Critical Engine Oil Pressure Warning

1

524

100

Low Engine Oil Pressure Warning

1

544

173

560

No Load

Excess Temperature

exceeding of the maximum vehicle speed

HW signal for vehicle speed not valid

vehicle speed not plausible with injection mass and engine speed

FF

Voltage abo- Voltage ve upper limit below lower limit

Voltage signal absent

3

4

short circuit to battery

No Load

excess temperature

FF

FF

FF

Oil Pressure below lower limit

FF

FF

FF

Oil Pressure below lower limit

DPF Particulate 5 Filter - Exhaust Gas Temperature Sensor Error

6

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

168

Battery Voltage Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit above upper limit

571

597

Brake Signal Error

FF

FF

3

4

brake signal is defective

brake signal not plausible

585

527

Cruise Control FF Multi-Function Input “A”/”B” Correlation Error (Invalid Switch Combination Detected)

FF

FF

4

short circuit to ground

Labour Time Guide

Eeprom error

185

R 750 600

629

ECU Internal Communication Error - SPI

600

627

601

FF

FF

FF

ECU Internal Com- FF munication Error Between Function Computer and Monitoring Module

FF

FF

4

Set, if SPI-communication failed

629

ECU Processor Recovery Locked

FF

FF

FF

4

A recovery has occurred

602

629

ECU Processor Recovery Suppressed

FF

FF

FF

4

a recovery has occurred

606

625

Plausibility Error on Base Map for Torque to Quantity Conversion

FF

FF

FF

4

Not plausible fault

606

629

TPU Time Processing Unit Monitoring Error

FF

FF

FF

8

Deviation between TPU and system time

607

629

ECU Internal Watchdog/Controller Error

FF

FF

FF

8

Set, if errorcounter of Watchdog or controller are not plausible or the system must shut down (ECU Internal Watchdog error)

615

677

T50 Terminal Signal Plausibility Error

1

FF

FF

FF

Terminal 50 always Pressed

616

677

Starter Relay Circuit 1 Malfunction (Low Side Power Stage)

2

3

4

Short Circuit to Battery

617

677

Starter Relay Circuit FF Malfunction (high Side Power Stage)

2

FF

FF

641

1079 Sensor Supply Voltage 1 Check Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

645

1351 Air Conditioning Relay Circuit Malfunction

1

2

3

4

Short Circuit to Battery

650

1213 MIL Lamp Circuit Malfunction

1

2

3

4

Short Circuit to Battery

186

1

communication error of CJ940 (ECU Internal Communication Malfunction)

Short Circuit to Ground

No load

Overheated

Short Circuit to Ground

No load

Excess Temperature

Short Circuit to Ground

No load

Unplausble

Short Circuit to Ground

Labour Time Guide

R 750 651

1079 Sensor Supply Voltage 2 Check Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

685

1485 Main Relay Control Error

1

2

FF

FF

main relay does not open in time

697

1079 Sensor Supply Voltage 3 Check Error

1

2

FF

FF

Voltage abo- Voltage ve upper limit below lower limit

1620

629

ECU Redundant Shut Off Test Error during Initialization

FF

2

3

4

1628

628

Dataset Variant Coding Plausibility Error

FF

FF

3

4

2002

131

DPF Particulate Filter - Filter Dismounted or Defective

FF

A

FF

FF

Corrected maximum differential pressure is lower than the threshold

2102

634

TVA Throttle Valve Actuator Circuit Malfunction

FF

2

FF

FF

Short Circuit to Ground

2103

634

TVA Throttle Valve Actuator Circuit Malfunction

1

FF

FF

FF

Short Circuit to Battery

2146

657

Injector Bank 1 Circuit Malfunction Specific Error

1

2

FF

4

general short circuit

short circuit on Low Side to ground

not-classifyable error

2149

658

Injector Bank 2 Circuit Malfunction Specific Error

1

2

FF

4

general short circuit

short circuit on Low Side to ground

not-classifyable error

2226

108

Barometric Pressure 1 Sensor Error

2

FF

4

Voltage abo- Voltage ve upper limit above upper limit

2264

97

Water Level in Fuel 1 Actuator Malfunction

2

3

4

Short Circuit to Battery

2269

97

Water in Fuel Detec- 1 tion

FF

FF

FF

Water in fuel detected

2293

157

PRV Rail Pressure Relief Valve Error

2

3

FF

PRV was recognised as OPEN

1

main relay opens too early

Watch dog switch off path defect ECU Internal Shut-off Path Watchdog

Voltage monitoring upper limit shut off path defect ECU Internal Shut-off Path High Voltage

Voltage monitoring lower limit shut off path defect ECU Internal Shut-off Path Low Voltage

Signal fault

Not plausible fault

Not plausiple with boost pressure sensor

Short Circuit to Ground

No Load

pressure shock requested

PRV did not open after pressure shock

Labour Time Guide

Excess Temperature

187

R 750 2452

131

DPF Particulate Filter - Differential Pressure Sensor Defective

1

2

FF

FF

2453

81

DPF Particulate Filter - Differential Pressure not Plausible

FF

FF

FF

1C

2454

81

Soot mass over limit 1

FF

FF

FF

2533

677

T15 Terminal Signal Plausibility Error

FF

FF

3

FF

2687

859

Fuel Filter Heating Relay Circuit Malfunction

1

2

3

4

Short Circuit to Battery

242F

131

DPF Particulate Filter - Engine Protection Active

1

FF

FF

FF

Differential pressure above limit

242F

81

DPF Particulate Filter - Engine Protection Active

5

FF

FF

FF

Soot mass greater than the threshold

251C

979

PTO Enable Switch Circuit Malfunction

1

2

FF

4

short circuit to battery

short circuit to ground

252F

98

Critical Oil Mass Check Error

1

2

FF

FF

Max Error path for critical engine oil mass

Min Error path for critical engine oil mass

60B

629

Analog digital converter error

1

2

3

4

Voltage abo- Voltage ve upper limit below lower limit

60C

627

ECU Internal Supply 1 Voltage Error

FF

FF

FF

ECU internal supply voltage above upper limit

60C

627

ECU Internal Supply FF Voltage Error

6

FF

FF

61F

634

TVA Throttle Valve Actuator Circuit Malfunction

FF

FF

7

8

62B

629

ECU - Fuel Injector Control Module A Performance Error

1

2

3

4

CY33X internal reset / clockloss / undervoltage

62B

629

ECU - Fuel Injector Control Module B Performance Error

5

6

7

8

CY33X CY33X internal parity internal error program flow error

188

Voltage abo- Voltage ve upper limit below lower limit hose line defective or signal not plausible Over limit No Terminal 15 signals detected Short Circuit to Ground

No Load

Excess Temperature

Multiple State Switch not Plausible

Check signal error

Time out conversion

No Load

Excess Temperature

ECU internal supply voltage below lower limit

Labour Time Guide

CY33X is CY33X is unlocked / in TestmoCY33X init de error

CY33X check of inv. YSEL during ON failed

CY33X SPI communication error /checksum/ readback CY33X ON timeout for at least 1 cylinder

R 750 62F

628

ECU Internal EEPROM Memory Error

FF

2

3

4

C001

639

CAN Messages Error from Communication Manager

FF

FF

3

FF

C028

639

CAN A Controller Error

1

FF

FF

FF

Bus off in CAN A

C037

639

CAN B Controller Error

1

FF

FF

FF

Bus off in CAN B

C046

639

CAN C Controller Error

1

FF

FF

FF

Bus off in CAN C

C101

898

TSC1-TE CAN Mes- 15 sage Timeout Error from Transmission Controller Unit TCU

FF

17

FF

timeout for TSC1-TE, when active

C107

91

RXEEC2 CAN Message Timeout Error

FF

FF

3

FF

C122

898

TSC1-VE Speed Override Vehicle Dynamic Control Module VC Error Message

1

FF

3

FF

timeout for TSC1-VE, when active

C140

898

TSC1-PE Torque/ 1 Speed Override Control Module PTO Error Message

2

FF

FF

timeout for TSC1-PE, when active

C408

91

RXEEC2 CAN Message Out of Range

FF

FF

FF

Out of range data in CAN message RxEEC2

1

error during last read operation

error during last write operation

default value used

Timeout in CAN send messages

timeout for TSC1TE, when inactive Timeout of CAN message EEC2 timeout for TSC1VE, when inactive timeout for TSC1PE, when inactive

Labour Time Guide

189

R 750

190

Labour Time Guide

R 750

Labour Time Guide

191

R 750 labour time guide KEY TO DEFINITIONS

R/R = removal and re-installation

INTERPRETING THE CODE OF THE OPERATION Cod. 3Z - EAA / 4 The first code group identifies the operation performed (ex: 3Z = replacement) The second group separated by a dash, identifies the component (ex: EAA = camshaft) The number after the slash, identifies the quantity of components involved in the operation, this number can be omitted if there are no other similar components on the engine. This type of code is used when there are no other similar components or multiple components on the engine. 3Z - EAA 3Z = Replacement EAA= Camshaft This type of code is used when there are other similar components or multiple components on the engine. 10Z - OAA / 6 10Z = Test OAA = Injector /6 = no.6 injectors

OPERATION Time 0.125 = 7.30 minutes 0.25 = 15 minutes 0.50 = 30 minutes 0.75 = 45 minutes 1 = 1 hour

COMPONENTs groups A - SYSTEM (ENGINE - CRANKCASE - LINER) b - SYSTEM (CRANKSHAFT - MAIN REAR CARRIER ) c - SYSTEM (piston - connecting rods ) D - SYSTEM (CYLINDER HEAD - ROCKER ARM ) e - SYSTEM (camshaft - hydraulic tappet - push rods) g - SYSTEM (lubrication) H - SYSTEM (cooling) j - SYSTEM (BELT - PULLEY - TENSIONER) k - SYSTEM (intake and exhaust, DPF FILTER) M - SYSTEM (flywheel housing - oil pan - timing cover) o - SYSTEM (FUEL) p - SYSTEM (injection pump ) q - SYSTEM (crankshaft main bearings ) s - SYSTEM (electrical)

192

Labour Time Guide

R 750 ECU diagnosis Operazione

Ore

ECU diagnosis + download engine collect data (log file)

1

ECU calibration - updating

0.50

Engine idle RPM - RPM modification

0.50

IMA injector code writing

0.50

EGR-TVA Test

0.50

DPF filter Regeneration

1

Compression cylinder Test

0.50

Dash Board light/lamps Test

0.50

Injector test

0.50

Engine serial number writing

0.50

Electrical measurement through break out box

1

Labour Time Guide

193

R 750 A - SYSTEM (ENGINE - CRANKCASE - LINER)

Operation

SYSTEM

14Z - AAA

ENGINE REMOVAL AND REINSTALLATION (ENGINE INSTALLED ON THE VEHICLE)

3Z - AAA

SHORT BLOCK REPLACEMENT

4 6

11 11.50

7Z - AAA

MAJOR ENGINE OVERHAUL Steam clean and completely dismantle; clean all parts; flush all oil and water passages and replace plugs; check crankshaft for size and wear and inspect all parts. Check the liner wear and if necessary replace them. Replace, or renew where necessary, camshaft and auxiliary drive bushes, main and big end bearings and thrust washers. Inspect and replace timing gears, as necessary. Replace water pump, oil pump. Overhaul turbochargeR Clean head and disassemble completely; inspect all parts and magnaflux head (Magnaflux crack detector); and Hydraulic test with special tool (pressure the cylinder head at ~ 2 bar ( 29 psi) dip it in a hot water +50-60°C (+122-140°F) for two minutes and check for air bubble.) Check longitudinal and horizontal warpage on head surface; replace valve guides or ream as needed. Grind valves and seats; replace valves and/or seats, as required. Check springs, keepers and retainers and replace as required. Lap valves and reassemble. Final test bench.

4 6

25 32.50

8Z - AAA

Partial engine overhaul Steam clean parts and partial dismantle (cylinder heads and pistons). Clean the disassembled parts, replace plug (only if worn), check liners dimension and wear. Hone cylinder liners and replace the compression rings. Check or replace, valves, guide valves and seats grind. Inspect and replace timing gears, as necessary. Inspect and renew, as required water pump, oil pump and turbocharger. Engine reassembly and test bech.

4 6

10 12

2I - AAA

Oil consumption rectification Remove cylinder head, lube oil pan and oil pump. Remove all pistons and connecting rods. Deglaze all cylinder bores. Clean and check pistons for wear, renewing as necessary and replace all piston rings. Check condition of oil pump and renew if necessary. Reassemble all parts using new gaskets.

4 6

10.25 15.50

1N - AAA

ENGINE FLYWHEEL SIDE - OIL LEAKAGE R&R flywheel and flywheel housing Rear crankshaft seal - replacement Rear main carrier o-ring - replacement Camshaft o-ring Flywheel o-ring

194

Labour Time Guide

No. Cyl.

Hours 4

1.50

R 750 Operation

SYSTEM

No. Cyl.

Hours

3Z - ABA

Cylinder Block - Replacement Steam clean complete engine, dismantle, clean and inspect all component parts. Reassemble engine complete into new bare block with same or new pistons, using new rings main and big end bearings and thrust washers, gaskets and seals, and torque to specifications. Run engine and check for leaks.

4 6

11 16.50

3Z - AIA/1

LINER - REPLACEMENT (ONE)

4

6.75

3Z - AIA/1

LINER - REPLACEMENT (ONE)

6

9.25

3Z - AIA/4

LINER - REPLACEMENT (ALL)

4

7.75

3Z - AIA/6

LINER - REPLACEMENT (ALL)

6

10.25

b - SYSTEM (CRANKSHAFT - MAIN REAR & CeNTER CARRIER - flywheel - timing gears)

Operation

SYSTEM

No. Cyl.

Hours

3Z - BAA

CRANKSHAFT - Replacement – rear crankshaft seal & o-ring, camshaft o-ring, flywheel o-ring replacement. – R&R flywheel housing. – R&R oil pan and strainer. – R&R oil pump. – R&R vibration damper. – R&R thrust washers, replace if necessary. – R&R timing gear cover. – R&R head. – R&R main center bearing carriers. – R&R pistons and connecting rods.

4 6

13 15

3Z - BIA

Replace main rear bearing carrier R&R Flywheel and flywheel housing

3Z - BHA

CENTER MAIN BEARING CARRIERS R&R oil pan and strainer

3Z - BLA

CRANKSHAFT FRONT HUB

0.75

3Z - BFA

FLYWHEEL (WITH FLYWHEEL GEAR)

0.50

3Z - BFE

FLYWHEEL GEAR

0.75

3Z - BAF

CRANKSHAFT FRONT GEAR

1.75

3Z - EAC 3Z - BAF 3Z - LCA 3Z - PAC

TIMING GEARS EAC (CAMSHAFT GEAR) BAF (CRANKSHAFT FRONT GEAR) LCA (IDLER GEAR) PAC (INJECTION DRIVE GEAR)

2.50

Labour Time Guide

1.25

4 6

12.50 14.50

195

R 750 c - SYSTEM (piston - connecting rods )

Operation

SYSTEM

No. Cyl.

Hours

3Z - CAA/1

Piston and Connecting Rod (one)

4

6.50

3Z - CAA/1

Piston and Connecting Rod (one)

6

9

3Z - CAA/4

Piston and Connecting Rod (all)

4

7.50

3Z - CAA/6

Piston and Connecting Rod (all)

6

10

3Z - CAD

PISTON RINGS (ALL PISTONS)

4

7.75

6

10.25

D - SYSTEM (CYLINDER HEAD - ROCKER ARMS )

Operation

SYSTEM

No. Cyl.

Hours

8Z - DAA

Top overhaul (cylinder heads and/or gaskets) Remove cylinder head(s) and gasket(s). Remove all traces of jointing compound and old gasket. Check cylinder head(s) and reseat valves. Fit new gasket and replace head(s) if necessary, Check injector atomisers and service as necessary. Torque head. Engine bench test

4 6

8.50 10.50

3Z - DAA

Cylinder Head AND GASKET ReplaceMENT (all cyl.heads) R&R and renew rocker arm assembly R&R intake manifold R&R exhaust manifold R&R water manifold from heads R&R rocker arm lubricating pipe Installation new gaskets

4 6

4.50 6

10Z - DFA

rocker arm assembly - check (ALL) Clean and disassemble rocker arm assembly. Inspect all parts and renew or replace as necessary. Reassemble head assembly.

4 6

1.25 1.50

3Z - DGG 3Z - DGF

INTAKE & EXHAUST VALVE GUIDES - REPLACEMENT (ALL) Includes: R&R cylinder head

4 6

7.50 9

3Z - DGH/1 3Z - DGI/1

VALVE SPRING - REPLACEMENT (ONE)

1

3Z - DGH/4/6 3Z - DGI/4/6

VALVE SPRING - REPLACEMENT (ALL)

2

e - SYSTEM (camshaft - hydraulic tappet - push rods)

Operation

SYSTEM

No. Cyl.

Hours

3Z - EAA

CAMSHAFT - REPLACEMENT

4 6

6.50 8.50

3Z - ECA

PUSH RODS

3Z - EBB

HYDRAULIC TAPPET

3Z - EFA

VALVE COVER

196

Labour Time Guide

1.75 4 6

5 6.50 1.50

R 750 g - SYSTEM (lubrication)

Operation

SYSTEM

No. Cyl.

Hours

3Z - GEA

OIL HEAT EXCHANGER (MODINE)

0.50

3Z - GAA

OIL PUMP

1.25

3Z - GGA

oil pressure relief valve

1

3Z - GAQ

rocker arm oil feed pipe

0.50

3Z - GBA

OIL FILTER

0.25

H - SYSTEM (cooling)

Operation

SYSTEM

No. Cyl.

Hours

3Z - HAA

COOLANT PUMP

0.50

3Z - HAL

COOLANT PUMP PULLEY

0.25

3Z - HDA

THERMOSTATIC VALVE

0.25

3Z - HHA

RADIATOR

1

j - SYSTEM (BELT - PULLEY - TENSIONER)

Operation

SYSTEM

3Z - JBA

COOLANT PUMP BELT AUTOMATIC BELT TENSIONER

No. Cyl.

Hours 0.25

k - SYSTEM (intake and exhaust, DPF FILTER)

Operation

SYSTEM

No. Cyl.

Hours

3Z - KAA

INTAKE MANIFOLD

0.75

3Z - KDA

TURBOCHARGER

0.50

3Z - KBA

EXHAUST MANIFOLD

0.75

3Z - KCH

EGR COOLER

0.75

3Z - KCA

EGR VALVE & INTAKE THROTTLE VALVE ASS.BY

0.25

5E - KGB

DPF FILTER (cleaning by compressed air and replacement DPF filter clamps

0.90

M - SYSTEM (flywheel housing - oil pan - timing cover)

Operation

SYSTEM

3Z - MAA

FLYWHEEL HOUSING Rear crankshaft seal - replacement Ream main carrier o-ring - replacement Camshaft o-ring Flywheel o-ring

1.50

3Z - MCA

TIMING COVER R&R alternator belt R&R crankshaft front hub cleaning of silicon from timing cover

1

3Z - MCE

TIMING COVER - FRONT OIL SEAL

0.75

3Z - MBA

OIL PAN

0.75

Labour Time Guide

No. Cyl.

Hours

197

R 750 o - SYSTEM (FUEL)

Operation

SYSTEM

No. Cyl.

Hours

3Z - OAA/1

INJECTOR (ONE)

3Z - OAA

INJECTOR (ALL)

10Z - OAA

FUEL RETURN QUANTITY FROM INJECTOR - TEST

0.25

12Z - OEL

AIR BLEEDING FROM INJECTION SYSTEM

0.25

3Z - OEC

FUEL FILTER

0.25

3Z - OHB

FUEL PRESSURE ACCUMULATOR (RAIL)

0.50

0.50 4 6

1 1.25

p - SYSTEM (injection pump )

Operation

SYSTEM

No. Cyl.

Hours

3Z - PAC

fuel pump drive gear

0.75

3Z - PAA

INJECTION PUMP - REPLACEMENT

0.75

3Z - PCA

FUEL PRESSURE CONTROL VALVE (MPROP)

0.25

q - SYSTEM (crankshaft main bearings AND CONNNECTING ROD BEARINGS )

Operation

SYSTEM

No. Cyl.

Hours

3Z - QAA

CRANKSHAFT FRONT MAIN BEARING

4 6

13.50 15.50

3Z - QBB

CONNECTING ROD BEARINGS (ALL CON-RODS) R&R oil pan and strainer Cleaning of silicon from oil pan Engine test for oil leakage

4 6

2 3

3Z - QAD

CRANKSHAFT REAR MAIN BEARING (REAR MAIN BEARING CARRIER) Replace also: • Rear crankshaft seal - replacement • Rear main carrier o-ring - replacement • Camshaft o-ring • Flywheel o-ring

198

Labour Time Guide

1.75

R 750 s - SySTEM (electrical)

Operation

SYSTEM

No. Cyl.

Hours

3Z - SEA

ALTERNATOR

0.50

3Z - SEF

ALTERNATOR VOLTAGE REGULATOR

0.50

3Z - SGA

STARTER MOTOR

0.25

3Z - SGD

STARTER MOTOR - SOLENOID

0.50

3Z - SAA

ENGINE WIRING HARNESS

1

Labour Time Guide

199

R 750

200

Labour Time Guide

electrical system

Electrical Schematic Diagrams - “A” SIDE - Engine

r754 EURO4 - euro 5

201

Electrical System

r756 EURO4 - EURO5

202

Electrical System

engine Wiring harness

r754 euro 4

203

Electrical System

r754 euro5

204

Electrical System

r756 euro4

205

Electrical System

r756 euro5

206

Electrical System

installation electric diagram - “k” side - vehicle

r754 - r756 euro4 - R756IE3

Disegno nr. 16662041F_Ed 1 - 03/2007

207

15

50

Drawing no. 16662041F_Ed 1 - 03/2007

Electrical System

r750 euro4 - R750IE3 Disegno nr. 16662041F_Ed 2 - 11/2008 Drawing no. 16662041F_Ed 2 - 11/2008

208

Electrical System

R750IE3

Disegno nr. 16662056F_Ed1_04_2010 Drawing no. 16662056F_Ed1_04_2010

209

Electrical System

r754 - r756 euro5 ed.2 Disegno nr. 16662051F_Ed_2

50

15

Drawing no. 16662051F_Ed_2

210

Electrical System

r754 - r756 euro5 ed.3 Disegno nr. 16662051F_Ed_3 Drawing no. 16662051F_Ed_3

211

Electrical System

212

Electrical System

Halvorsen Section 3. Transmission

ALLISON TRANSMISSION Division of General Motors Corp. OPERATOR’S MANUAL (OM3063EN) 1000/2000/2400 Series Allison On-highway Transmissions SERVICE MANUAL (SM319EN) 1000, 2000, 2000mh, 2400 Series On-highway Transmissions TRANSMISSION TROUBLESHOOTING MANUAL (TS319EN) 1000 And 2000 Product Families Electronic Controls MECHANIC’S TIPS (MT3190EN) 1000 and 2000 Product Family Transmission STONE BENNETT CORP. DESCRIPTION AND INSTALLATION BULLETINS Transmission Shift Controls PARTS LIST MANUAL SNS-01 Bennett Shift System

TRANSMISSION

5-3 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

OM3063EN_200306.pdf

8/19/04

8:57:52 AM

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Operator’s Manual 1000/2000/2400 Series Allison On-Highway Transmissions OM3063EN

OM3063EN

Operator’s Manual

Allison On-Highway 1000 SeriesTM 2000 SeriesTM 2400 SeriesTM

June 2003

Division of General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com

Printed in the USA

Copyright © 2003 General Motors Corp.

NOTES

2

TABLE OF CONTENTS INTRODUCTION KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7 A BRIEF DESCRIPTION OF THE ALLISON 1000/2000/2400 SERIES TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PLANETARY GEARS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . 11 COOLER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SHIFT SELECTORS DESCRIPTION OF AVAILABLE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION OF THE SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITH P (PARK) POSITIONS . . . . . . . . . . . . . . . . . . . RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITIONS . . . . . . . . . . . . . . . . RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 17 20 24 28 32

DRIVING TIPS MAXIMUM VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENT MAJOR PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURNING ON/OFF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY/SECONDARY SHIFT SCHEDULES . . . . . . . . . . . . . . . . . . . . KICKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SPEED INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RANGE INHIBIT(ED) LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK TRANS OR MALFUNCTION INDICATOR LIGHT . . . . . . . . . . . . SHIFT INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . RANGE PRESELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFUSE PACKER STEP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . TWO-SPEED AXLE (Some 1000/2000/2400 Series Applications) . . . . . . . . . . DRIVING ON SNOW OR ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

36 36 36 37 37 38 38 38 38 39 41 41 43 43 43 43 44 44 45

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARK PAWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING/LEAVING VEHICLE WITH ENGINE RUNNING . . . . . . . . . . . . TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SURGING NATURAL GAS ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . .

45 46 47 49 49

POWER TAKEOFF POWER TAKEOFF (PTO) SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 50 CONVERTER-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . 50 SPLIT-SHAFT POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . . . . 53

CARE AND MAINTENANCE PERIODIC INSPECTIONS AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL . . . . . . . . . . . TRANSMISSION FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FLUID AND FILTER CHANGE INTERVALS . . . . . . . . . . TRANSMISSION FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . . . COOLER FLUSHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE . . . . . . . . . VENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 56 56 60 60 62 64 65 66 68

DIAGNOSTICS DIAGNOSTIC CODES AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

CUSTOMER SERVICE OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . .

4

70 72 73 76

TRADEMARK USAGE The following trademarks are the property of the companies indicated: • 1000 Series™ is a trademark of the General Motors Corporation. • 2000 Series™ is a trademark of the General Motors Corporation. • 2400 Series™ is a trademark of the General Motors Corporation. • DEXRON® is a registered trademark of the General Motors Corporation. • TranSynd™ is a trademark of Castrol Ltd.

5

WARNINGS, CAUTIONS, NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems (including appropriate warnings, cautions, and notes). Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair is important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission (or the vehicle manufacturer) and described in this handbook are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. Three types of headings are used in this manual to attract your attention. These warnings and cautions advise of specific methods or actions that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. WARNING: A warning is used when an operating procedure, practice, etc., if not correctly followed, could result in personal injury or loss of life.

CAUTION: A caution is used when an operating procedure, practice, etc., if not strictly observed, could result in damage to or destruction of equipment.

NOTE: A note is used when an operating procedure, practice, etc., is essential to highlight.

6

INTRODUCTION

KEEPING THAT ALLISON ADVANTAGE

STOP R YIELD

R SPEED ZONE

HILL V01724

Allison 1000/2000/2400 Series provide many advantages for the driver who must “stop and go” or change speeds frequently. Driving is easier, safer, and more efficient. The 1000/2000/2400 Series transmissions are rugged and designed to provide long, trouble-free service. This handbook will help you gain maximum benefits from your ALLISON-equipped vehicle.

7

8

Figure 1. 1000/2000/2400 Series Transmission—Left-Front View

OIL VENT (BREATHER) TURBINE SPEED SENSOR ENGINE SPEED SENSOR

PARKING BRAKE MOUNTING PROVISION

OUTPUT SPEED SENSOR

NSBU SWITCH SELECTOR SHAFT SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL) AVAILABLE OIL FILL TUBE LOCATION CONTROL MAIN OIL FILTER

1000 / 2000 / 2400 SERIES TRANSMISSION — LEFT-FRONT VIEW

V06692.00.00

9

Figure 2. 1000/2000/2400 Series Transmission—Right-Rear View

ENGINE SPEED SENSOR TURBINE SPEED SENSOR

OIL VENT (BREATHER) OUTPUT SPEED SENSOR

MOUNTING PAD (SAE #3 HOUSING ONLY) COOLER PORTS AVAILABLE OIL FILL TUBE LOCATION SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL)

OPTIONAL TACHOGRAPH PROVISION MAIN ELECTRICAL CONNECTOR

1000 / 2000 / 2400 SERIES TRANSMISSION — RIGHT-REAR VIEW

V06693

A BRIEF DESCRIPTION OF THE ALLISON 1000/2000/2400 SERIES TRANSMISSIONS The 1000/2000/2400 Series transmissions are fully automatic, torque-converter driven, electronically controlled transmissions best suited for light-medium duty, on-highway applications. Each transmission series contains features which have been designed for specific vocational needs. • 1000 Series™—These models are best suited for light duty on-highway applications. The 1000 Series™ transmissions have park pawls. • 2000 Series™ and 2400 Series™—These models are best suited for single-axle medium duty on-highway applications. The 2400 Series™ transmissions have park pawls; the 2000 Series™ transmissions do not have park pawls. The park pawl exists but cannot be engaged in some vehicle configurations using 1000 Series™ and 2400 Series™ transmissions (e.g., some rear engine vehicles with air brakes). For these configurations, the P (Park) position is not used. A provision to mount a Power Takeoff (PTO) is available on all models. The PTO drive gear is optional. All models have up to five forward ranges and one reverse. All clutches are hydraulically-actuated, spring-released, and have automatic compensation for wear. Gearing is helical type, arranged in planetary sets. Electronic controls provide automatic gear selection in each drive range and automatic engagement of the torque converter (lockup) clutch.

ELECTRONIC CONTROL SYSTEM The 1000/2000/2400 Series control system consists of five major components connected by customer-furnished wiring harnesses. These components are: • Transmission Control Module (TCM) • Engine throttle position sensor or direct electronic communication of throttle information • Engine, turbine, and output speed sensors • NSBU switch • Control valve module The control valve module contains solenoids and a pressure switch module to position and monitor control valve operation. The pressure switch module also contains a thermistor to monitor sump fluid temperature. The throttle position sensor (or engine-to-transmission communication link), speed sensors, pressure switch module, and NSBU switch transmit information to the TCM. The TCM processes this information and then sends signals to actuate specific solenoids located on the control valve module in the transmission. These solenoids control 10

both oncoming and offgoing clutch pressures to provide closed-loop shift control by matching rpm during a shift to a previously established desired profile that is programmed into the TCM. The 1000/2000/2400 Series electronic control system has the “adaptive shifting” feature. Adaptive shifting helps optimize shift quality by monitoring critical characteristics of clutch engagement and making on-going adjustments to improve subsequent shifts. The transmission shift calibration is based on several different types of shifts, e.g., full throttle, part throttle, closed throttle—upshifts, downshifts, etc. Each shift is associated with specific speed and throttle position parameters. In order to optimize each type of shift for normal driving, shift controls must experience operation and shifting in a wide variety of operating conditions. A “drive in” period under varied driving conditions is required before the Adaptive Controls can be expected to optimize each and every shift. In general, shift quality will begin to converge to their “adapted” level after five typical shifts of a particular shift type.

TORQUE CONVERTER The torque converter consists of three elements—pump, turbine, and stator. The pump is the input element and is driven directly by the engine. The turbine is the output element and is hydraulically driven by the pump. The stator is the reaction (torque multiplying) element. When the pump turns faster than the turbine, the torque converter is multiplying torque. When the turbine approaches the speed of the pump, the stator starts to rotate with the pump and turbine. When this occurs, torque multiplication stops and the torque converter functions as a fluid coupling. All 1000/2000/2400 Series torque converters contain a torque converter (lockup) clutch. When engaged, this clutch causes the torque converter pump and turbine to be locked together, thus enabling them to rotate in unison at engine speed. This condition, commonly referred to as “torque converter clutch operation,” thus provides direct drive through the transmission. This type of operation maximizes engine braking and enhances fuel economy. The torque converter (lockup) clutch is regulated by the shift controls to engage automatically. The torque converter clutch releases at lower speeds or when the TCM detects conditions requiring it to be released. The torque converter clutch contains a damping mechanism which reduces the transmittal of engine-induced torsional vibrations into and beyond the transmission.

PLANETARY GEARS AND CLUTCHES A series of three helical planetary gear sets and shafts provides the mechanical gear ratios and direction of travel for the vehicle. The planetary gear sets are controlled by five multiplate clutches that work in pairs to produce up to five 11

forward speeds and one reverse speed. The clutches are applied and released hydraulically in response to electronic signals from the TCM to the appropriate solenoids.

COOLER CIRCUIT The transmission fluid is cooled by a remote-mounted oil cooler. The bottom of the transmission torque converter housing provides for the direct mounting of a control main filter and includes two ports to facilitate the attachment of the oil cooler lines.

12

Figure 3. 1000 Series™ Transmission Cross Section

13 CONTROL MAIN FILTER

TORQUE CONVERTER ASSEMBLY

OUTPUT YOKE

MAIN SHAFT

MAIN HOUSING MODULE • MAIN HOUSING • C3 CLUTCH • C4 CLUTCH • C5 CLUTCH

REAR COVER MODULE • REAR COVER • OUTPUT SPEED SENSOR • OUTPUT SHAFT • P3 PLANETARY • PARK PAWL P2 PLANETARY P1 PLANETARY SHALLOW OIL PAN (OPTIONAL) CONTROL VALVE MODULE SUCTION FILTER ROTATING CLUTCH MODULE • TONE WHEEL OR OPTIONAL PTO DRIVE GEAR • C2 CLUTCH • C1 CLUTCH • TURBINE SHAFT V06630.00.02

CONVERTER HOUSING/FRONT SUPPORT MODULE • CONVERTER HOUSING • INPUT SPEED SENSOR • OIL PUMP TURBINE • FRONT SUPPORT SPEED SENSOR

Figure 4. 2000 Series™ Transmission Cross Section

14

Same as 1000 Series™ except as shown

COOLER MANIFOLD

CONVERTER HOUSING

TONE WHEEL V06631.00.02

REAR COVER MODULE • REAR COVER • C5 PISTON • P3 PLANETARY NO PARK PAWL

DEEP OIL PAN SUCTION FILTER

PTO DRIVE GEAR (OPTIONAL)

Figure 5. 2400 Series™ Transmission Cross Section

15

Same as 1000 Series™ except as shown

COOLER MANIFOLD

CONVERTER HOUSING

TONE WHEEL

DEEP OIL PAN SUCTION FILTER

PTO DRIVE GEAR (OPTIONAL)

V06632.00.02

REAR COVER MODULE • REAR COVER • C5 PISTON • P3 PLANETARY

V06633.00.02

REAR COVER MODULE • REAR COVER CONVERTER HOUSING

Figure 6. 1000 Series™ Transmission Cross Section With Optional Converter Housing and Rear Cover 16

SHIFT SELECTORS

DESCRIPTION OF AVAILABLE TYPES The 1000/2000/2400 Series transmissions use lever-type shift selectors. The shift positions on the shift selector can vary according to the shift selector installed.

OPERATION OF THE SHIFT SELECTOR The shift selector is used by the operator to select the following ranges. • Park (P) for transmissions with park pawls • Auto-Apply Parking Brake (PB) for vehicles with automatically engaged parking brakes • Reverse (R) • Neutral (N) • Drive (D)* • Fourth Range (4)** • Third Range (3)** • Second Range (2)** • First Range (1) * The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). ** In calibrations with five forward ranges, one of these selector positions will not be available. Ranges are selected by moving the lever to the desired selector position (P, PB, R, N, D, 4, 3, 2, or 1). Five speed transmission models have five forward ranges, first through fifth. Four speed models have four forward ranges, first through fourth. When a forward range has been selected, the transmission automatically upshifts through each range. As the vehicle slows, the transmission will downshift automatically through each range.

17

The following tables list the shift selector positions and corresponding ranges for all 1000/2000/2400 Series models. All 1000 Series™ and 2400 Series™ Transmissions With P (Park) Position Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive)** 4 (Fourth) 3 (Third) 1 (First)

Range Neutral* Reverse Neutral 1–5

Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive)**

Range Neutral* Reverse Neutral 1–5

Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive)**

1–4 1–3 1

4 (Fourth) 2 (Second) 1 (First)

1–4 1–2 1

3 (Third) 2 (Second) 1 (First)

Range Neutral* Reverse Neutral 1–5 (1–4)*** 1–3 1–2 1

* With Park Pawl engaged ** The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range) *** 1–4 in Trailering Mode or 4 Speed Calibration

All 1000 Series™ and 2400 Series™ Transmissions Without P (Park) Position Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5

Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5

4 (Fourth) 3 (Third) 1 (First)

4 (Fourth) 2 (Second) 1 (First)

1–4 1–3 1

1–4 1–2 1

Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5 (1–4)*** 3 (Third) 1–3 2 (Second) 1–2 1 (First) 1

** The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range) *** 1–4 in Trailering Mode or 4 Speed Calibration

18

All 2000 Series™ Transmissions With Auto-Apply Parking Brake Shift Selector Position PB (Auto-Apply Parking Brake) R (Reverse) N (Neutral) D (Drive)**

Shift Selector Range Position Neutral* PB (Auto-Apply Parking Brake) Reverse R (Reverse) Neutral N (Neutral) 1–5 D (Drive)**

Shift Selector Range Position Neutral* PB (Auto-Apply Parking Brake) Reverse R (Reverse) Neutral N (Neutral) 1–5 D (Drive)**

4 (Fourth) 3 (Third) 1 (First)

1–4 1–3 1

1–4 1–2 1

4 (Fourth) 2 (Second) 1 (First)

3 (Third) 2 (Second) 1 (First)

Range Neutral*

Reverse Neutral 1–5 (1–4)*** 1–3 1–2 1

* With Auto-Apply Parking Brake engaged ** The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). *** 1–4 in Trailering Mode or 4 Speed Calibration

All 2000 Series™ Transmissions Without Auto-Apply Parking Brake Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5

Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5

4 (Fourth) 3 (Third) 1 (First)

4 (Fourth) 2 (Second) 1 (First)

1–4 1–3 1

1–4 1–2 1

Shift Selector Position Range R (Reverse) Reverse N (Neutral) Neutral D (Drive)** 1–5 (1–4)*** 3 (Third) 1–3 2 (Second) 1–2 1 (First) 1

** The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). *** 1–4 in Trailering Mode or 4 Speed Calibration

There are several features of the 1000/2000/2400 Series transmissions that can inhibit transmission shifting. See the SHIFT INHIBITS paragraph of this manual. With an Allison-equipped vehicle, selecting the right moment to upshift or downshift during changing road and traffic conditions is not necessary. The Allison 1000/2000/2400 Series transmission does it for you. However, knowledge of the ranges and when to select them will make vehicle control and your job even easier. 19

RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITH P (PARK) POSITIONS ALL TRANSMISSIONS WITH P (PARK) POSITION WARNING: For vehicles containing 1000 Series™ and 2400 Series™ transmissions, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the park pawl by slowly releasing the service brake. • If a parking brake is present, apply the parking brake. Make sure the parking brake is properly engaged. • Apply the emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage. P

Use P (Park) for the following. • to turn on or turn off the engine • to check vehicle accessories • to operate the engine at idle for longer than five minutes • for stationary operation of the power takeoff (if your vehicle is equipped with a PTO) This position places the transmission in N (Neutral) and engages the park pawl. WARNING: R (Reverse) may not be obtained due to an active inhibitor. Always apply the service brakes when selecting R (Reverse) to prevent unexpected vehicle movement and because a service brake inhibit can be present. Always be sure that “R” is not flashing whenever R (Reverse) is selected. Check for active diagnostic codes if R (Reverse) is not attained.

20

ALL TRANSMISSIONS WITH P (PARK) POSITION WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from R (Reverse) to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in R (Reverse) for more than five minutes. Extended idling in R (Reverse) can cause transmission overheating and damage. Always select P (Park) whenever time at idle exceeds five minutes. R

R (Reverse) is used to back the vehicle. Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range. The reverse warning signal is activated when the shift selector is in this position. WARNING: To help avoid injury or property damage caused by unexpected vehicle movement, do not make shifts to or from N (Neutral) without manually or automatically applying an appropriate vehicle brake.

WARNING: DO NOT allow the vehicle to “coast” in N (Neutral). There is no engine braking in N (Neutral). You could lose control of the vehicle, causing property damage or personal injury. Coasting in neutral can cause severe transmission damage. N

This position places the transmission in N (Neutral). Used for starting the engine and stationary operation. WARNING: D (Drive) and other forward ranges can not be obtained due to an active inhibitor. The range selected can not be obtained, resulting in unexpected vehicle movement. To help avoid injury and/or property damage, always apply the service brakes when selecting D (Drive) or other forward ranges. Check for the RANGE INHIBIT(ED) light or the CHECK TRANS light.

21

ALL TRANSMISSIONS WITH P (PARK) POSITION WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from a forward range to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in D (Drive) or any forward range for more than five minutes. Extended idling in D (Drive) can cause transmission overheating and damage. Always select P (Park) whenever time at idle exceeds five minutes.

D*

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or R (Reverse) will not be attained unless the shift is made with the engine at idle. Use D (Drive) for normal driving. The transmission will initially attain first range when D (Drive) is selected. As vehicle speed increases, the transmission will upshift automatically through each available range up to 4 (FOURTH) or 5 (FIFTH). As the vehicle slows, the transmission will downshift automatically. * The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

22

ALL TRANSMISSIONS WITH P (PARK) POSITION WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected. However, during downhill operation, if engine governed speed is exceeded in the lower range, the transmission will upshift to the next higher range to prevent engine damage. This will reduce engine braking and could cause a loss of control. Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected. 4* 3*

3* 2*

1

Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on steep downgrades. * 3 for shift selectors with P,R,N,D,3,2,1 Actual ranges available depend on programming by vehicle manufacturer. Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking on steeper downgrades. * 3 for shift selectors with P,R,N,D,4,3,1 Actual ranges available depend on programming by vehicle manufacturer. Use 1 (FIRST) range for the following. • when pulling through mud and deep snow • when maneuvering in tight spaces • while driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect.

23

RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITIONS 1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITION WARNING: For vehicles containing 1000 Series™ and 2400 Series™ models without P (Park) positions, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Ensure that the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brake and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If the procedure is not followed, the vehicle may move suddenly and cause injury and/or property damage.

WARNING: R (Reverse) may not be obtained due to an active inhibitor. Always apply the service brakes when selecting R (Reverse) to prevent unexpected vehicle movement and because a service brake inhibit can be present. Always be sure that “R” is not flashing whenever R (Reverse) is selected. Check for active diagnostic codes if R (Reverse) is not attained.

WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from R (Reverse) to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in R (Reverse) for more than five minutes. Extended idling in R (Reverse) can cause transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds five minutes.

24

1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITION R R (Reverse) is used to back the vehicle. Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range. The reverse warning signal is activated when the shift selector is in this position. WARNING: To help avoid injury or property damage caused by unexpected vehicle movement, do not make shifts to or from N (Neutral) without manually or automatically applying an appropriate vehicle brake.

WARNING: DO NOT allow the vehicle to “coast” in N (Neutral). There is no engine braking in N (Neutral). You could lose control of the vehicle, causing property damage or personal injury. Coasting in neutral can cause severe transmission damage. N

Use N (Neutral) for the following. • to turn on or turn off the engine • to check vehicle accessories • to operate the engine at idle for longer than five minutes • for stationary operation of the power takeoff (if your vehicle is equipped with a PTO) WARNING: D (Drive) and other forward ranges can not be obtained due to an active inhibitor. The range selected can not be obtained, resulting in unexpected vehicle movement. To help avoid injury and/or property damage, always apply the service brakes when selecting D (Drive) or other forward ranges. Check for the RANGE INHIBIT(ED) light or the CHECK TRANS light.

25

1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITION WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from a forward range to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in D (Drive) or any forward range for more than five minutes. Extended idling in D (Drive) can cause transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds five minutes.

D*

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or R (Reverse) will not be attained unless the shift is made with the engine at idle. Use D (Drive) for normal driving. The transmission will initially attain first range when D (Drive) is selected. As vehicle speed increases, the transmission will upshift automatically through each available range up to 4 (FOURTH) or 5 (FIFTH). As the vehicle slows, the transmission will downshift automatically. * The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

26

1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK) POSITION WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected. However, during downhill operation, if engine governed speed is exceeded in the lower range, the transmission will upshift to the next higher range to prevent engine damage. This will reduce engine braking and could cause a loss of control. Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected. 4* 3*

3* 2*

1

Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on steep downgrades. * 3 for shift selectors with R,N,D,3,2,1 Actual ranges available depend on programming by vehicle manufacturer. Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking on steeper downgrades. * 3 for shift selectors with R,N,D,4,3,1 Actual ranges available depend on programming by vehicle manufacturer. Use 1 (FIRST) range for the following. • when pulling through mud and deep snow • when maneuvering in tight spaces • while driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect.

27

RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE 2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE WARNING: For vehicles containing 2000 Series™ transmissions without PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure the parking brake is porperly engaged. • Apply the emergency brake and make sure it is properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property dmage. PB

Use PB (Auto-Apply Parking Brake) for the following. • to turn on or turn off the engine • to check vehicle accessories • to operate the engine at idle for longer than five minutes • for stationary operation of the power takeoff (if your vehicle is equipped with a PTO) This position places the transmission in N (Neutral) and engages the parking brake. WARNING: R (Reverse) may not be obtained due to an active inhibitor. Always apply the service brakes when selecting R (Reverse) to prevent unexpected vehicle movement and because a service brake inhibit can be present. Always be sure that “R” is not flashing whenever R (Reverse) is selected. Check for active diagnostic codes if R (Reverse) is not attained.

28

2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from R (Reverse) to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in R (Reverse) for more than five minutes. Extended idling in R (Reverse) can cause transmission overheating and damage. Always select PB (Auto-Apply Parking Brake) whenever time at idle exceeds five minutes. R

R (Reverse) is used to back the vehicle. Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range. The reverse warning signal is activated when the shift selector is in this position. WARNING: To help avoid injury or property damage caused by unexpected vehicle movement, do not make shifts to or from N (Neutral) without manually or automatically applying an appropriate vehicle brake.

WARNING: DO NOT allow the vehicle to “coast” in N (Neutral). There is no engine braking in N (Neutral). You could lose control of the vehicle, causing property damage or personal injury. Coasting in neutral can cause severe transmission damage. N

This position places the transmission in N (Neutral). Used for starting the engine and stationary operation.

29

2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE WARNING: D (Drive) and other forward ranges can not be obtained due to an active inhibitor. The range selected can not be obtained, resulting in unexpected vehicle movement. To help avoid injury and/or property damage, always apply the service brakes when selecting D (Drive) or other forward ranges. Check for the RANGE INHIBIT(ED) light or the CHECK TRANS light.

WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from a forward range to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in D (Drive) or any forward range for more than five minutes. Extended idling in D (Drive) can cause transmission overheating and damage. Always select PB (Auto-Apply Parking Brake) whenever time at idle exceeds five minutes.

D*

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or R (Reverse) will not be attained unless the shift is made with the engine at idle. Use D (Drive) for normal driving. The transmission will initially attain first range when D (Drive) is selected. As vehicle speed increases, the transmission will upshift automatically through each available range up to 4 (FOURTH) or 5 (FIFTH). As the vehicle slows, the transmission will downshift automatically. * The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range).

30

2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected. However, during downhill operation, if engine governed speed is exceeded in the lower range, the transmission will upshift to the next higher range to prevent engine damage. This will reduce engine braking and could cause a loss of control. Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected. 4* 3*

3* 2*

1

Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on steep downgrades. * 3 for shift selectors with PB,R,N,D,3,2,1 Actual ranges available depend on programming by vehicle manufacturer. Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking on steeper downgrades. * 3 for shift selectors with PB,R,N,D,4,3,1 Actual ranges available depend on programming by vehicle manufacturer. Use 1 (FIRST) range for the following. • when pulling through mud and deep snow • when maneuvering in tight spaces • while driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect.

31

RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE 2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE WARNING: For vehicles containing 2000 Series™ transmissions without PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral), apply the parking brake, emergency brake, and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

WARNING: R (Reverse) may not be obtained due to an active inhibitor. Always apply the service brakes when selecting R (Reverse) to prevent unexpected vehicle movement and because a service brake inhibit can be present. Always be sure that “R” is not flashing whenever R (Reverse) is selected. Check for active diagnostic codes if R (Reverse) is not attained.

WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from R (Reverse) to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in R (Reverse) for more than five minutes. Extended idling in R (Reverse) can cause transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds five minutes.

32

2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE R R (Reverse) is used to back the vehicle. Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range. The reverse warning signal is activated when the shift selector is in this position. WARNING: To help avoid injury or property damage caused by unexpected vehicle movement, do not make shifts to or from N (Neutral) without manually or automatically applying an appropriate vehicle brake.

WARNING: DO NOT allow the vehicle to “coast” in N (Neutral). There is no engine braking in N (Neutral). You could lose control of the vehicle, causing property damage or personal injury. Coasting in neutral can cause severe transmission damage. N

Use N (Neutral) for the following. • to turn on or turn off the engine • to check vehicle accessories • to operate the engine at idle for longer than five minutes • for stationary operation of the power takeoff (if your vehicle is equipped with a PTO) WARNING: D (Drive) and other forward ranges can not be obtained due to an active inhibitor. The range selected can not be obtained, resulting in unexpected vehicle movement. To help avoid injury and/or property damage, always apply the service brakes when selecting D (Drive) or other forward ranges. Check for the RANGE INHIBIT(ED) light or the CHECK TRANS light.

33

2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not make shifts from a forward range to N (Neutral) without applying the service brakes, parking brake, or emergency brake. Selecting N (Neutral) does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed.

CAUTION: Do not idle in D (Drive) or any forward range for more than five minutes. Extended idling in D (Drive) can cause transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds five minutes.

D*

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or R (Reverse) will not be attained unless the shift is made with the engine at idle. Use D (Drive) for normal driving. The transmission will initially attain first range when D (Drive) is selected. As vehicle speed increases, the transmission will upshift automatically through each available range up to 4 (FOURTH) or 5 (FIFTH). As the vehicle slows, the transmission will downshift automatically. * The shift selector position representing this gear range may be labeled “5” (for the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the complete gear range). WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

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2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING BRAKE WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected. However, during downhill operation, if engine governed speed is exceeded in the lower range, the transmission will upshift to the next higher range to prevent engine damage. This will reduce engine braking and could cause a loss of control. Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected. 4*3*

3*2*

1

Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on steep downgrades. * 3 for shift selectors with R,N,D,3,2,1 Actual ranges available depend on programming by vehicle manufacturer. Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking on steeper downgrades. * 3 for shift selectors with R,N,D,4,3,1 Actual ranges available depend on programming by vehicle manufacturer. Use 1 (FIRST) range for the following. • when pulling through mud and deep snow • when maneuvering in tight spaces • while driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect.

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DRIVING TIPS

MAXIMUM VEHICLE LOADING WARNING: Operation with excessive loads can cause transmission damage and unexpected vehicle movement. To help avoid injury, property damage and/or transmission damage, do not exceed the following. • For 1000 Series™ and 2400 Series™ transmissions, do not exceed 11 800 kg (26,000 lb) GCW or the OEM vehicle rating, whichever is less. • For 2000 Series™ transmissions, do not exceed 13 600 kg (30,000 lb) GCW or the OEM rating, whichever is less.

PREVENT MAJOR PROBLEMS Minor problems can be kept from becoming major problems if you notify an Allison Transmission distributor or dealer when any of these conditions occur. • Shifting feels abnormal • Transmission leaks fluid • Unusual transmission-related sounds (changes in sound caused by normal engine thermostatic fan cycling, while climbing a long grade with a heavy load, have been mistaken for transmission-related sounds) • CHECK TRANS light or RANGE INHIBIT(ED) light comes on frequently

TURNING ON/OFF THE VEHICLE Before turning on or off the engine, the driver must verify that one of the following ranges has been selected and engaged. • P (Park) • PB (Auto-Apply Parking Brake) • N (Neutral) if P (Park) or PB (Auto-Apply Parking Brake) is not available The vehicle should not start unless these ranges have been selected. If the vehicle starts in any other range, seek service immediately.

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Transmission operation at cold ambient temperatures may require preheating or the use of a lower viscosity transmission fluid. See the FLUID RECOMMENDATIONS paragraph in this manual. Even when the engine is warm and capable of full-throttle output, the transmission should not be taken out of P (Park), PB (Auto-Apply Parking Brake), or N (Neutral) for at least thirty seconds to allow for buildup of transmission fluid pressure.

ACCELERATOR CONTROL WARNING: To avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to a forward range or R (Reverse) when the throttle is open. The vehicle will lurch forward or rearward and the transmission can be damaged. Avoid this condition by making shifts from N (Neutral) to a forward range or R (Reverse) only when the throttle is closed and service brakes are applied. The position of the accelerator pedal influences the timing at which automatic shifting occurs. When the pedal is fully depressed, upshifts will occur automatically at high engine speeds. A partially depressed position of the pedal will cause the upshifts to occur at lower engine speeds. An electronic throttle position signal tells the TCM how much the operator has depressed the pedal. Excessive throttle position may inhibit the directional shift.

PRIMARY/SECONDARY SHIFT SCHEDULES The points at which shifts occur depend upon predetermined speeds and other operating conditions. A transmission “shift calibration” includes several sets of shift points which may be used according to current or anticipated operating conditions. Some shift schedules may be inhibited as a result of operating conditions, such as engine or transmission fluid temperature. Shift schedules may be changed through selection of a remote (usually dash-mounted) switch—which is typically associated with a change in anticipated vehicle operation. The TCM includes the capacity for two separate and distinct shift calibrations (customer-selectable), one for use in “Primary Mode” of operation and one in “Secondary Mode.” • Primary—This shift schedule is typically used for all normal vehicle operations. • Secondary—This is an alternate shift schedule that the TCM uses upon request. Not all vehicles will be equipped with a secondary shift. The request can be interlocked with a vehicle component, or be operator-controlled via a dash-mounted switch. 37

Your vehicle may have a dash-mounted light that illuminates when the secondary mode is active.

KICKDOWN Some vehicles have a “kickdown” feature that allows the operator to choose between an “Economy” primary shift schedule and “Performance” secondary shift schedule. The throttle pedal will have a detent feel when full-throttle is achieved using “Economy” shift points. When the operator “steps through” this detent, the function is activated and “Performance” shift points are achieved.

OUTPUT SPEED INDICATOR Your vehicle may contain a light or other indicator that is activated when a preset output speed has been exceeded in the vehicle, transmission, or auxiliary equipment. The output speed may occur in either the forward or reverse direction. This indicator may be used to alert the operator that a specific overspeed condition has occurred or to indicate the attainment of a minimum or maximum operating speed.

RANGE INHIBIT(ED) LIGHT The red or amber RANGE INHIBIT(ED) warning light is located on or near the shift selector. The purpose of this indicator is to alert the operator that transmission operation is being inhibited and that range shifts being requested by the operator may not occur. When certain operating conditions are detected by the TCM, the controls will command the transmission to be locked in the range currently in use. If the torque converter clutch is applied when the condition is detected, the clutch will be disengaged concurrently with the activation of the RANGE INHIBIT(ED) light. Each time the engine is started, the RANGE INHIBIT(ED) light will illuminate, then turn off after two seconds. If the light does not illuminate during ignition, or if the light remains on after ignition, the transmission system should be checked immediately. For the conditions under which shift inhibits occur, see the SHIFT INHIBITS paragraph in this manual.

CHECK TRANS OR MALFUNCTION INDICATOR LIGHT The red or amber CHECK TRANS light or Malfunction Indicator Light (MIL) of some type is located on the dash panel. For vehicles which are compliant to industry On Board Diagnostics II (OBD II) requirements, an MIL Light will be present. For vehicles which are not compliant to industry OBD II requirements, a CHECK TRANS light will be present. 38

Each time the engine is started, the CHECK TRANS or MIL light will illuminate, then turn off after two seconds. If the light does not illuminate during ignition, or if the light remains on after ignition, the transmission system should be checked immediately. Illumination of the CHECK TRANS light at any time after start-up indicates that a problem has been detected. The TCM will register a diagnostic code and shifts may be restricted. Depending upon the severity of the problem, operation may continue in order to reach service assistance. The TCM may not respond to shift selector requests since upshifts and downshifts may be restricted and direction changes may not occur. Illumination of the MIL Light at any time after start-up may indicate a problem with the engine or transmission.

SHIFT INHIBITS The transmission control system will inhibit shifting to protect the transmission from some types of abusive operation, in response to diagnostic trouble codes, and to satisfy transmission feature/option requirements. These shift inhibits fall within the following types. • • • •

Above-idle neutral-to-range shifts Forward/reverse directional shifts Transmission problems Auxiliary equipment operation

Above-Idle Neutral-to-Range Shifts. WARNING: To avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to a forward range or R (Reverse) when the throttle is open. The vehicle will lurch forward or rearward and the transmission can be damaged. Avoid this condition by making shifts from N (Neutral) to a forward range or R (Reverse) only when the throttle is closed and service brakes are applied. Above-idle (greater than 900 rpm) shifts from N (Neutral) to R (Reverse) or N (Neutral) to a forward range are normally inhibited (except in emergency vehicles or some other type of specialized equipment). When these shifts are inhibited, the RANGE INHIBIT(ED) light will illuminate. See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for further information.

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Forward/Reverse Directional Shifts. WARNING: To avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to a forward range or R (Reverse) when the throttle is open. The vehicle will lurch forward or rearward and the transmission can be damaged. Avoid this condition by making shifts from N (Neutral) to a forward range or R (Reverse) only when the throttle is closed and service brakes are applied. Forward/reverse directional changes are typically not permitted if appreciable output shaft speed is detected. When these shifts are inhibited, the RANGE INHIBIT(ED) light will illuminate. See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for further information. Transmission Problems. Lights such as a RANGE INHIBIT(ED), CHECK TRANS, and a flashing PRNDL display will be illuminated when the transmission detects a problem. An illuminated RANGE INHIBIT(ED) light or a flashing PRNDL display indicates that the TCM has locked the transmission into a forward range or R (Reverse). Shifts from N (Neutral)-to-D (Drive), N (Neutral)-to-R (Reverse) and directional shifts will be inhibited. The locked range allows the vehicle to reach service assistance. The transmission will remain locked until the problem has been corrected. With the exception of diagnostic trouble code (DTC) U2105, the CHECK TRANS light will be illuminated when the TCM has registered a DTC. When a U2105 is registered, the CHECK TRANS light may not be illuminated in earlier models. Depending upon the severity of the problem, operation may continue to allow the vehicle to reach service assistance by locking the transmission in the range currently in use. The TCM may inhibit upshifts, downshifts and directional change shifts. See the DIAGNOSTIC CODES AND TOOLS paragraph in this manual for further information. An illuminated Malfunction Indicator Light (MIL) may indicate a problem with the transmission or engine. See the RANGE INHIBIT(ED) LIGHT and CHECK TRANS OR MALFUNCTION INDICATOR LIGHT paragraphs in this manual for further information. Auxiliary Equipment Operation. The TCM will prevent shifts from P (Park), PB (Auto-Apply Parking Brake), or N (Neutral)-to-range when auxiliary equipment is in operation (e.g., a wheelchair lift). For some vehicles such as buses, shifts from P (Park), PB (Auto-Apply Parking Brake), or N (Neutral)-to-range will be prevented unless the brake pedal is depressed. 40

USING THE ENGINE TO SLOW THE VEHICLE WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected. However, during downhill operation, if engine governed speed is exceeded in the lower range, the transmission will upshift to the next higher range to prevent engine damage. This will reduce engine braking and could cause a loss of control. Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected. To use the engine as a braking force, select the next lower range. If the vehicle is exceeding the maximum speed for this range, use the service brakes and/or other retarding devices to slow the vehicle. When a lower speed is reached, the TCM will automatically downshift the transmission. Engine braking provides good speed control for going down grades. When the vehicle is heavily loaded, or the grade is steep, it may be desirable to preselect a lower range before reaching the grade. If engine-governed speed is exceeded, the transmission will upshift automatically to the next range. CAUTION: Using the retarder or engine brake on wet or slippery roads may cause loss of traction on the drive wheels — your vehicle may slide out of control. To help avoid injury or property damage, turn the retarder or engine brake enable to OFF when driving on wet or slippery roads.

RANGE PRESELECTION Range preselection means selecting a lower range to match driving conditions you encounter or expect to encounter. Learning to take advantage of preselected shifts will give you better control on slick or icy roads and on downgrades.

41

Downshifting to a lower range increases engine braking. The selection of a lower range often prevents cycling between that range and the next higher range on a series of short up-and-down hills. NOTE: Preselecting during normal operation may result in reduced fuel economy.

Manual range downshifts will not occur until a calibration value of output speed is reached. When a range downshift is manually selected and the transmission output speed is above the calibration value, the transmission will stay in the range it was in even though a lower range was requested. Apply the vehicle service brakes or some retarding device to reduce the transmission output speed to the calibration value and then the shift to the lower range will occur. Two shift schedules are used with range preselection: hold upshift and preselect downshift. Hold Upshift. This shift schedule keeps the transmission from shifting above the selected range. This shift schedule permits upshifts to occur if an engine overspeed condition could result by the transmission remaining (by operator selection) in a range lower than its highest range. When the hold feature is activated, transmission upshift points occur at engine speeds which are higher than normal upshifts in order to “hold” the transmission from upshifting beyond the current range. WARNING: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to prevent exceeding engine governed speed in the held range.

Preselect Downshift. This shift schedule is used when the driver preselects a lower range. The operator may preselect any range below D (Drive) on the shift selector at any time. When a range has been “preselected” in this manner, shift points to and from ranges above the preselected range are higher than the normal shift points. The transmission will downshift when an engine overspeed condition will not result after the shift. Shifts below the preselected range are not affected.

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REVERSE Putting the transmission into R (Reverse) may activate vehicle back-up lights and/or reverse warning devices. To achieve REVERSE range in some European transit and tour buses, an instrument panel-mounted switch must be pressed simultaneously with the R (Reverse) shift selector button.

REFUSE PACKER STEP SWITCH When personnel are on the rear step of a refuse packer, the transmission will operate in FIRST and NEUTRAL only. • An operator request to upshift beyond FIRST or to shift to R (reverse) is ignored by the TCM. • If the transmission is in R (reverse), the TCM will cause the transmission to shift to NEUTRAL. • If the transmission is in a forward range higher than 1 (FIRST), the TCM will invoke “preselect downshifts” until FIRST is attained.

TWO-SPEED AXLE (Some 1000/2000/2400 Series Applications) The two-speed axle may be shifted while the vehicle is moving. However, the axle or vehicle manufacturer’s recommendations should be followed for shifting the axle. It is recommended that axle shifts be made with the transmission in the highest range, or vehicle stopped, to prevent a transmission shift from coinciding with an axle shift.

DRIVING ON SNOW OR ICE Here is where all of your ability as a professional driver comes into focus regardless of what transmission you have. If possible, reduce your speed and select a lower range before you lose traction. Select the range that will not exceed the speed you expect to maintain. Accelerate or decelerate very gradually to prevent losing traction. It is very important to slow gradually when a lower range is selected. It is important that you reach the lower range selected before attempting to accelerate. This will avoid an unexpected downshift during acceleration. NOTE: If ABS is activated, the lockup clutch is automatically disengaged.

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ROCKING OUT WARNING: To avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to a forward range or R (Reverse) when the throttle is open. The vehicle will lurch forward or rearward and the transmission can be damaged. Avoid this condition by making shifts from N (Neutral) to a forward range or R (Reverse) only when the throttle is closed and service brakes are applied.

CAUTION: If the wheels are stuck and not turning, do not apply full power for more than 30 seconds in either D (Drive) or R (Reverse). Full power for more than 30 seconds under these conditions will cause the transmission to overheat. If the transmission overheats, shift to N (Neutral) and operate the engine at 1200–1500 rpm until it cools (2–3 minutes). If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock it out. Shift to D (Drive) and apply steady, light throttle (never full throttle). When the vehicle has rocked forward as far as it will go, apply and hold the vehicle service brakes. Allow the engine to return to idle; then select R (Reverse). Release the brakes and apply a steady, light throttle and allow the vehicle to rock in R (Reverse) as far as it will go. Again, apply and hold the service brakes and allow the engine to return to idle. This procedure may be repeated in D (Drive) and R (Reverse) if each directional shift continues to move the vehicle a greater distance. Never make N (Neutral)-to-D (Drive) or directional shift changes when the engine rpm is above idle.

OPERATING TEMPERATURES To ensure proper operation of the transmission, adhere to the following minimum and maximum transmission operating temperatures. Sump, minimum continuous Sump, maximum intermittent To cooler, maximum intermittent

40°C (100°F) 121°C (250°F) 149°C (300°F)

Your transmission may have a converter-out transmission temperature gauge near the “to-cooler” port on the transmission converter housing.

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HIGH FLUID TEMPERATURE CAUTION: Always select P (Park), PB (Auto-Apply Parking Brake), or N (Neutral) whenever time at idle exceeds five minutes. Extended idling in any other ranges can cause transmission overheating and damage.

CAUTION: Sustained use of the parking brake with the engine running and the transmission in range can cause an overheating failure of the transmission. The vehicle can contain a buzzer or dash-mounted light to alert the operator when the ignition switch is “ON”, the parking brake is applied, and the transmission selector is in range.

CAUTION: The engine should never be operated for more than 30 seconds at full throttle with the transmission in range and the output stalled. Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and will cause severe overheat damage to the transmission. Your vehicle may have a dash indicator or other alarm that turns on when the transmission sump temperature or to-cooler temperature exceeds specified limits. If the transmission overheats during normal operations, do the following. • Check the fluid level in the transmission. See the CARE AND MAINTENANCE section of this manual. • Safely stop the vehicle and check the cooling system. If it appears to be functioning properly, run the engine at 1200–1500 rpm with the transmission in N (Neutral). This should reduce the transmission and engine temperatures to normal operating levels in 2 or 3 minutes. If temperatures do not decrease, reduce the engine rpm. • If high temperature in either the engine or transmission persists, stop the engine and have the overheating condition investigated by maintenance personnel.

PARKING BRAKE For shift selectors with a PB (Auto-Apply Parking Brake) position, selecting PB (Auto-Apply Parking Brake) places the transmission in NEUTRAL and automatically engages the parking brake. For shift selectors without a PB (Auto-Apply Parking Brake) position, the parking brake must be manually engaged. Your vehicle may have an indicator light that illuminates when the parking brake is applied. 45

CAUTION: Do not apply the transmission-mounted parking brake with the vehicle in motion. Transmission and/or driveline damage can result. In the event of a dynamic brake apply, recheck the torque of all brake mounting bolts to verify the integrity of the mount.

CAUTION: Sustained use of the parking brake with the engine running and the transmission in range can cause an overheating failure of the transmission. The vehicle can contain a buzzer or dash-mounted light to alert the operator when the ignition switch is “ON”, the parking brake is applied, and the transmission selector is in range.

PARK PAWL A park pawl is standard on 1000 Series™ and 2400 Series™ transmissions and is not available on 2000 Series™ transmissions. The park pawl effectively grounds the transmission output shaft, thereby preventing rotation of the driveline. Provided the vehicle is stationary, selecting P (Park) on the shift selector places the transmission in NEUTRAL and engages the park pawl. The park pawl exists but cannot be engaged in some vehicle configurations using 1000 Series™ and 2400 Series™ transmissions (e.g., some rear engine vehicles with air brakes). For these configurations, the P (Park) position is not used. WARNING: To help avoid injury and/or property damage caused by unexpected vehicle movement, do not attempt to engage P (Park) with the vehicle in motion (2 km/hr (1 mph) or higher). If you attempt to engage P (Park) with the vehicle in motion (2 km/hr (1 mph) or higher), the park pawl will ratchet, will not engage, and will not hold the vehicle. Repeated park pawl ratcheting can cause transmission damage.

WARNING: If the vehicle has four-wheel-drive and the transfer case is in Neutral, the vehicle can be free to roll even if the P (Park) position is selected. To avoid injury and/or property damage caused by unexpected movement of the vehicle, be certain that the transfer case is in “high” drive range, not Neutral, whenever the vehicle is parked.

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WARNING: If the vehicle is equipped with a two-speed axle or two-speed transfer case which is engaged in “low”, even very low vehicle speeds can produce appreciable transmission output shaft speed. Even the slightest vehicle motion can deter engagement of the park pawl in such cases. To help avoid injury and/or property damage caused by unexpected vehicle movement, be certain that the axle or transfer case is in “high” drive range whenever the vehicle is parked and the park pawl is engaged.

Torque Lock. If the vehicle is parked on an incline and P (Park) is properly engaged, the weight of the vehicle may generate an excessive amount of torque on the park pawl in the transmission. In this situation, it may be difficult to shift the transmission out of the P (Park) position. This condition is commonly called “torque lock.” To drive a vehicle with torque lock, do the following. 1. Push the vehicle uphill a small amount to release the pressure on the park pawl and permit the shift out of P (Park). 2. Shift the transmission out of P (Park) while applying the service brakes. 3. Release the parking brake.

PARKING/LEAVING VEHICLE WITH ENGINE RUNNING WARNING: For vehicles containing 1000 Series™ and 2400 Series™ transmissions, follow this procedure each time the operator’s staton will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the park pawl by slowly releasing the service brake. • If a parking brake is present, apply the parking brake. Make sure the parking brake is properly engaged. • Apply the emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

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WARNING: For vehicles containing 1000 Series™ and 2400 Series™ transmissions without P (Park) positions, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brakes and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

WARNING: For vehicles containing 2000 Series™ transmission with PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure the parking brake is properly engaged. • Apply the emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

WARNING: For vehicles containing 2000 Series™ transmission without PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral), apply the parking brake, emergency brake, and make sure they are properly engaged. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

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TOWING OR PUSHING CAUTION: Failure to lift the driving wheels off the road, disconnect the driveline, or remove the axle shafts before pushing or towing can cause serious transmission damage. The engine cannot be started by pushing or towing. Before pushing or towing a vehicle, lift the drive wheels off the road, disconnect the driveline, or remove the axle shafts from the drive wheels. When the axle shafts are removed, be sure to cover the wheel openings to prevent loss of lubricant and entry of dust and dirt. An auxiliary air supply will usually be required to release the vehicle brake system.

SURGING NATURAL GAS ENGINES NOTE: Engine surging or engine speed cycling may occur on natural gas powered equipment. This condition typically occurs when the transmission is being operated in a hold position with throttle applied and the engine speed above full load engine governed speed. Surging may also occur at closed and part throttle. This condition is an engine characteristic and NOT a transmission concern.

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POWER TAKEOFF

POWER TAKEOFF (PTO) SYSTEMS Three types of PTO systems may be used with the 1000/2000/2400 Series transmissions. • Transmission-Mounted Converter-Driven PTO—A transmission-mounted converter-driven PTO drive provides both an infinitely-variable PTO drive ratio and a protective hydraulic cushion against abrupt loading/unloading (during “converter mode” operation) and engine-driven PTO speed control (during “torque converter clutch mode” operation). • Split-Shaft PTO—A split-shaft PTO, a chassis-mounted component, is typically used in applications which require full engine power being available to either propel the vehicle or to power auxiliary equipment through the PTO drive—but not both simultaneously. In both cases, the transmission output shaft delivers power to the split-shaft transfer case. The split-shaft transfer case is then shifted to deliver this power to either the driveline or PTO drive. • Flywheel-Driven PTO—A flywheel-driven PTO, often called a “sandwich PTO,” mounts between the engine and transmission. The PTO is normally driven directly by the engine.

CONVERTER-DRIVEN POWER TAKEOFF (PTO) The following pertains to Transmission-Mounted Converter-Driven PTOs only. PTO Configuration. The PTO is mounted on the left and/or right side of the transmission housing. The PTO drivetrain consists of a large drive gear in the transmission, an idler gear arrangement, and a smaller driven gear in the PTO. The drive gear is integral to the transmission rotating clutch housing, which rotates at the same speed as the torque converter turbine. With this drive configuration, the PTO rotates in the same direction as the engine. Two types of transmission-mounted PTOs may be used with these transmission models. • A constant-drive PTO is used in applications which require full-time PTO operation. The PTO driven gear is in constant mesh with the drive gear and cannot be disengaged. • A clutch drive PTO is used in applications which require only part-time operation of the PTO. For clutch drive PTOs, the following applies: 1) the 50

engagement/disengagement provision is facilitated by a hydraulic clutch mechanism in the PTO assembly; 2) the PTO can be engaged or disengaged at any time (except at engine speeds that exceed drive speed limits imposed on the driven equipment). PTO Engagement — Sliding Gear PTOs. CAUTION: Do not use or install a sliding gear PTO where the sliding gear meshes directly with the PTO drive gear. The PTO drive gear can be damaged when the sliding gear slides into the PTO drive gear, producing metal particles that can cause transmission damage.

NOTE: “Manual shift PTOs”—units which are engaged/disengaged to the PTO drive gear in the transmission through use of a manual (“sliding gear”) mechanism—are not compatible with the design of these transmission models.

PTO Engagement — Manual Shift PTO. Manually shifted (Cable, Electrical, Air shifted) PTOs that engage internally inside the PTO can be used. WARNING: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured. DO NOT leave the vehicle with the engine running unless you have taken all of the following precautions: • Shift the transmission to N (Neutral) or P (Park) • Make sure that the engine is at low idle (500–800 rpm) • Apply the park brake or emergency brake and make sure it is properly engaged • Chock the wheels and take any other steps necessary to keep the vehicle from moving On automatic transmissions, the gears in the transmission turn when the transmission is in neutral, therefore, gears clashing will occur if the PTO is shifted into range or out of range at this time. With Converter Driven Gear: 1. Engine idle. With the operator seated in the driver’s seat and while activating the vehicle’s brake, shift transmission level into any of the drive positions. (This will stop transmission gear from turning.) 2. Shift PTO into or out of range. 3. If the PTO does not engage release the PTO to the disengage position, shift the transmission to neutral and repeat the above steps from step A.

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4. Shift the transmission into park or neutral. (This will start transmission gears turning.) If you hear a grinding or ratcheting sound turn PTO off and repeat these procedures from step A. PTO Engagement — Clutch Driven. The PTO will engage only when the PTO switch is on, the throttle position is low, and engine speed and output speed are within user-specified limits. Your vehicle may have a light on the dash that illuminates when the PTO is engaged. CAUTION: Do not exceed the engagement and operational speed limits imposed on the driven equipment during the operation of the PTO. Exceeding the speed limits produces high hydraulic pressure in the PTO that can damage the PTO components. Consult the vehicle manufacturer’s literature for these speed limits.

CAUTION: Some vehicles “creep” in range at low vehicle speeds while maintaining a specified engine speed for PTO operation (e.g., paint stripers and feedlot trucks). DO NOT use the vehicle brakes to control vehicle speed during PTO operation. Use ONLY throttle to control both engine and vehicle speed when the transmission is in reverse or a forward range. Applying BOTH brakes and throttle will cause the transmission to overheat. Extended operation at elevated temperatures will damage the transmission.

PTO Operation. The transmission operates in either converter mode or torque converter clutch mode. In converter mode, the torque converter (lockup) clutch is not engaged and the PTO is driven through the torque converter, producing a torque at the PTO drive gear that is always greater than the input torque. In torque converter clutch mode, the torque converter (lockup) clutch is engaged, the PTO drivetrain is driven at a speed proportional to the engine speed. The PTO drive is normally in continuous converter mode operation when the transmission is in P (Park), PB (Auto-Apply Parking Brake), and R (Reverse). Torque converter clutch operation in N (Neutral) is available for some applications. If the PTO is used with the transmission in D (Drive) or another forward range, transmission shifts (both converter/torque converter clutch mode shifts and shifts between gears) are based on the automatic shift sequence of the transmission shift controls. PTO drive gear speed will be affected each time a shift occurs. With the vehicle stopped and the engine at idle, PTO output speed is dependent upon the transmission gear selection. • If the transmission is in D (Drive) or R (Reverse), the PTO output speed is zero. 52

• If the transmission is in N (Neutral), P (Park), or PB (Auto-Apply Parking Brake), the PTO output will rotate slowly. In some vehicles, the transmission will shift into N (Neutral) regardless of the shift selector position under the following conditions. • the PTO is enabled • the transmission output speed is near zero • the throttle position is near zero To reselect a range, the operator must shift into N (Neutral), then shift to the desired range. CAUTION: Do not exceed the engagement and operational speed limits imposed on the driven equipment during the operation of the PTO. Exceeding the speed limits produces high hydraulic pressure in the PTO that can damage the PTO components. Consult the vehicle manufacturer’s literature for these speed limits.

CAUTION: When the PTO disengages due to overspeed, the PTO will automatically re-engage at a user-specified speed, which is typically relatively low. The resultant re-engagement shock could cause damage to a high-inertia PTO system.

PTO Overspeed Protection. All 1000/2000/2400 Series-equipped vehicles with PTO enable have engagement and operational speed limits programmed into the TCM to help protect PTO equipment. The PTO will deactivate when operational speeds (either engine or transmission output) are exceeded. When the PTO is disengaged due to overspeed, the PTO will be automatically re-engaged at a user specified speed, which is typically relatively low. After the speed has been reduced, the operator may manually engage the PTO by repeating the engagement process.

SPLIT-SHAFT POWER TAKEOFF (PTO) For many split-shaft PTOs, holding the transmission in direct drive at all engine speeds is desirable. In this manner, the automatic range shifts are eliminated, thereby eliminating rapid torque changes which would occur at the driven equipment during a shift in the transmission. Such a condition, for instance, could create an undesirable pressure surge (and directional control problem) at the nozzle-end of a fire hose.

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NOTE: Unlike most Allison on-highway transmission models, the 1000/2000/2400 Series transmission models do not have a controls provision which supports this type of split-shaft PTO application. The output of a split-shaft PTO driven by these models will, therefore, be subjected to transmission range shifts and will experience rapid speed and torque changes with each occurrence.

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CARE AND MAINTENANCE

PERIODIC INSPECTIONS AND CARE Transmission Inspection. CAUTION: Do not spray steam, water, or cleaning solution directly at the vent assembly (breather). Spraying steam, water, or cleaning solution at the vent assembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid. Seal all openings and the vent assembly (breather) before spraying steam, water, or cleaning solutions on the transmission. Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of these inspections. Inspect the transmission for:. • • • • • • • •

loose bolts — transmission and mounting components fluid leaks — repair immediately loose, dirty, or improperly adjusted throttle sensor or shift selector linkage damaged or loose hoses worn, frayed, or improperly routed electrical harnesses worn or frayed electrical connections worn or out-of-phase driveline U-joints and slip fittings clogged or dirty vent assembly

Vehicle Inspection. Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler.

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Welding. CAUTION: When welding on the vehicle: • DO NOT WELD on the vehicle without disconnecting all control system wiring harness connectors from the TCM. • DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads. • DO NOT WELD on any control components. • DO NOT CONNECT welding cables to any control components. • PROTECT CONTROL COMPONENTS FROM SPARKS AND HEAT DURING WELDING. A label describing on-vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place. A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on-vehicle welding label. Refer to SA2607.

IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools, lubricates, and transmits hydraulic power. Always maintain proper fluid level. If fluid level is too low, the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats. If the level is too high, the fluid aerates—causing the transmission to shift erratically and overheat. Fluid may be expelled through the vent assembly or dipstick tube when the fluid level is too high.

TRANSMISSION FLUID CHECK WARNING: For vehicles containing 1000 Series™ and 2400 Series™ transmissions, follow this procedure each time the operator’s staton will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the park pawl by slowly releasing the service brake. • If a parking brake is present, apply the parking brake. Make sure the parking brake is properly engaged. • Apply the emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

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WARNING: For vehicles containing 1000 Series™ and 2400 Series™ transmissions without P (Park) positions, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brakes and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

WARNING: For vehicles containing 2000 Series™ transmission with PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure the parking brake is properly engaged. • Apply the emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

WARNING: For vehicles containing 2000 Series™ transmission without PB (Auto-Apply Parking Brake) selector position, follow this procedure each time the operator’s station will be unoccupied with the engine running. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral), apply the parking brake, emergency brake, and make sure they are properly engaged. If this procedure is not followed, the vehicle can move unexpectedly and cause injury and/or property damage.

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Fluid Check Procedure. Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using the following procedure and report any abnormal fluid levels to your maintenance persons. Cold Check Procedure. The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. CAUTION: The fluid level rises as fluid temperature rises. DO NOT fill the transmission above the “COLD CHECK” band if the transmission fluid is below normal operating temperatures. During operation, an overfull transmission can become overheated, leading to transmission damage. Check the fluid level as follows: 1. Bring the vehicle to a complete stop on a level surface using the service brake. 2. Make sure the engine is at low idle rpm. 3. Put the transmission in P (Park), PB (Auto-Apply Parking Brake), or N (Neutral). 4. Apply any other parking brake, if present, and make sure it is properly engaged. 5. Chock the wheels and take any other steps necessary to keep the vehicle from moving. 6. Run the engine at 1000–1500 rpm for at least one minute to purge air from the system. Apply the service brakes and shift to D (Drive), then to N (Neutral), and then shift to R (Reverse) to fill the hydraulic system. Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly release the service brakes. 7. With the engine running, remove the dipstick from the tube and wipe the dipstick clean. 8. Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. 9. If the fluid level is within the “COLD CHECK” band (Figure entitled Typical Dipstick Markings), the transmission may be operated until the fluid is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band. 58

10. Perform a hot check at the first opportunity after the normal operating sump temperature of 71°C–93°C (160°F–200°F) is reached. Hot Check Procedure. CAUTION: When performing the Hot Check procedure, the fluid must be hot to ensure an accurate check and help prevent transmission damage. The fluid level rises as temperature increases. During operation, an overfull transmission can become overheated, leading to transmission damage. Operate the transmission in D (Drive) until normal operating temperature is reached: • sump temperature 71°C–93°C (160°F–200°F) • converter-out temperature 82°C–104°C (180°F–220°F) • If a transmission temperature gauge is not present, check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour.

HOT RUN BAND COLD CHECK BAND

V06713

Figure 7. Typical Dipstick Markings Check the fluid level as follows: 1. Bring the vehicle to a complete stop on a level surface using the service brake. 2. Make sure the engine is at low idle rpm. 3. Put the transmission in P (Park), PB (Auto-Apply Parking Brake), or N (Neutral).

59

4. Apply any other parking brake, if present, and make sure it is properly engaged. 5. Chock the wheels and take any other steps necessary to keep the vehicle from moving. 6. With the engine running, remove the dipstick from the tube and wipe the dipstick clean. 7. Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. NOTE: Safe operating level is within the “HOT RUN” band on the dipstick. See Figure entitled Typical Dipstick Markings. The width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal opeating sump temperature. 8. If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level to within the “HOT RUN” band. Consistency of Readings. Always check the fluid level at least twice using the procedure described above. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission vent assembly (breather) to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distributor or dealer.

KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay the dipstick in a clean place while filling the transmission. CAUTION: Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause the clutch plates and some seals to fail.

FLUID RECOMMENDATIONS Hydraulic fluids (oils) used in the transmission are important influences on transmission performance, reliability, and durability. Any fluids meeting DEXRON®-III specifications are acceptable for use in the 1000, 2000, and 2400 Series transmissions. TranSynd™ fluids fully meet the DEXRON®-III specifications.

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To ensure the fluid is qualified for use in Allison transmissions, check for a DEXRON®-III fluid license or approval numbers on the container, or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types. CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life. When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or geographical location must be taken into consideration. The table below lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) for a minimum of 20 minutes before attempting range operation. Transmission Fluid Operating Temperature Requirements

Viscosity Grade DEXRON®-III TranSynd™

Ambient Temperature Below Which Preheat is Required Celsius Fahrenheit –25° –13° –30° –22°

(Ref. SIL 13-TR-90)

Some shift ranges and the torque converter clutch mode may not be reached during cold weather operation. As the transmission reaches normal operating temperature, all shift ranges and the torque converter clutch mode will begin to function.

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TRANSMISSION FLUID AND FILTER CHANGE INTERVALS CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. To help avoid transmission damage, more frequent changes can be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating. Frequency. New vehicles delivered from the OEM with a mixture of TranSynd™ and non TranSynd™ fluid must follow fluid/filter change recommendations outlined in Schedule 1 of the Transmission and Fluid Change table. If the customer fills the transmission with TranSynd™ or TES-295 equivalent, the change recommendations of Schedule 1 must be followed. Upon the next oil change, if the customer reinstalls TranSynd™ or TES 295 equivalent, the fluid/filter change recommendations outlined in Schedule 2 may be used. The recommendations in Schedule 2 are based upon Allison fluid change procedures and the transmission containing 100% of TranSynd™ fluid. For transmissions that contain a mixture of TranSynd™ and non-TranSynd™ fluids, refer to Schedule 3. NOTE: Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of 100 percent of the used fluid.

Allison Transmission requires an initial filter change for the Spin-On Control Main Filter during the first 8000 km (5000 miles) or 200 hrs of service, whichever comes first. Following the initial filter change, change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first. See Transmission and Fluid Change table for recomendations. The transmission sump filter is permanent and does not require replacement except at overhaul. Severe Vocations include On/Off Highway, Refuse, City Transit, Shuttle, and Motorhomes. General Vocations includes all other vocations. Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allision Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. The following tables are given only as a general guide for fluid and filter change intervals.

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Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™ /Non- TES 295 Fluid) Filters Vocation General

Severe

Fluid 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

Control Main 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

Internal Overhaul

Overhaul

Lube/ Auxiliary 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™ /TES 295 Fluid) Filters Vocation General

Severe

Fluid 160 000 km (100,000 miles) 48 months 80 000 km (50,000 miles) 24 months

Control Main 80 000 km (50,000 miles) 24 months 80 000 km (50,000 miles) 24 months

Internal Overhaul

Overhaul

Lube/ Auxiliary 80 000 km (50,000 miles) 24 months 80 000 km (50,000 miles) 24 months

Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd™ and Non-TranSynd™ Fluids Vocation General

Severe

Fluid 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

Control Main 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

Filters Internal Overhaul

Overhaul

Lube/Auxillary 80 000 km (50,000 miles) 24 months 40 000 km (25,000 miles) 12 months

* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd™ that is required to fill the transmission to the proper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-TranSynd™ other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3.

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Abnormal Conditions. Transmissions used in high cycle rate applications should use fluid analysis to be certain that a proper fluid change interval is established. Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor, or by fluid analysis. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. Fluid Analysis. Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in the following table. Fluid oxidation can be monitored through a fluid analysis firm and/or by using an oil analysis kit. • Fluid analysis firms—Consult your local telephone directory for fluid analysis firms. To ensure consistent and accurate fluid analysis, use only one fluid analysis firm. Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information. • Oil analysis kits, part number 29537805, are available through your normal Allison Transmission parts source. Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information. Fluid Oxidation Measurement Limits Test Viscosity Total Acid Number

Limit ±25% change from new fluid +3.0* change from new fluid

* mg of KOH required to neutralize a gram of fluid.

TRANSMISSION FLUID CONTAMINATION Fluid Examination. At each fluid change, examine the drained fluid for evidence of dirt or water. A normal amount of condensation will appear in the fluid during operation. Water. Obvious water contamination of the transmission fluid or transmission fluid in the cooler water (in heat exchanger) indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. NOTE: Cooler water can also be contaminated by engine oil; be sure to locate the correct source of cooler water contamination.

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Engine Coolant. CAUTION: If the transmission fluid is contained by water, 0.2 percent by volume, or any trace of ethylene glycol, disassemble the transmission and replace the following: • Seals • Gaskets • Clutch plates • Bearings • Torque converters that cannot be disassembled • Components that have rusted • Solenoids that do not meet resistance specifications Remove all traces of ethylene glycol and varnish deposits. Failure to follow this procedure decreases transmission reliability and durability.

Metal. Metal particles in the fluid (except for the minute particles normally trapped in the oil filter) indicate internal transmission damage. If these particles are found in the sump, the transmission must be disassembled and closely inspected to find their source. Metal contamination requires complete transmission disassembly. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge.

COOLER FLUSHING PROCEDURE Metal contamination requires complete transmission disassembly and cleaning. Clean all internal and external hydraulic circuits, transmission cooler, and all areas where metal and other particles could lodge. Special tool J 46550 Transmission Cooler Kiwk-Flsuh Cart is now an essential tool for all overhaul and maintenance service outlets, J 46550 or an approved cooler flushing device that meets Allison cooler flushing requirements and procedures. 1. Flush contaminated fluid from the cooler by flowing transmission fluid through the cooler in the reverse direction of normal flow. Use a flushing pump that pumps fluid in a pulsating flow at a minimum mean rate of 0.5 liters/sec (8.0 gpm) and 275–345 kPa (40–50 psi). The J 46550 Transmission Cooler Kwik-Flush Cart meets these requirements. 2. After flushing the contaminated fluid, use the flushing pump to circulate clean transmission fluid through the cooler in a closed loop back to a 10–micron filter. Circulate fluid in the closed loop for a minimum of five minutes. CAUTION: After flushing the cooler, be sure to check the external cooler circuit restriction. If circuit pressure drop is above specification, the cooler has excessive trapped particles and must be replaced.

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NOTE: When equipment to flush the oil cooler is not available, install a filter in the cooler line between the oil cooler and the transmission “from cooler” port. The cooler circuit pressure drop specifications must still be met (see AS64–071 or AS64–072 in the Allison Sales Tech Data book). Frequent initial changes of this filter element may be required as debris is flushed out of the oil cooler circuit. Closely monitoring change in cooler circuit pressure drop will indicate when a filter change is needed.

TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE Drain Fluid. 1. Drain the fluid when the transmission is at normal operating sump temperature of 71–93°C (160–200°F). Hot fluid flows quicker and drains more completely. 2. Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container. 3. Examine the fluid as described in the TRANSMISSION FLUID CONTAMINATION paragraph in this Section. Replace Control-Main Filter (refer to Figure 8). 1. Using a standard strap-type filter wrench or the J 45023, remove the control-main filter by rotating it in the counterclockwise direction. 2. Remove the magnet from the filter attachment tube or from the top of the filter element. 3. Clean any metal debris from the magnet. Report any metal pieces larger than dust to your maintenance personnel. 4. Reinstall the magnet onto the filter attachment tube. 5. Lubricate the gasket on the control-main filter with transmission fluid. 6. Install, by hand, the control-main filter until the gasket on the control-main filter touches the converter housing or cooler manifold. CAUTION: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter. 7. Using the J 45023 or by hand, turn the filter ONE FULL TURN ONLY after gasket contact. 8. Reinstall the drain plug and sealing washer. Tighten the drain plug to 30–40 N·m (22–30 lb ft). 66

MAGNET TE

V06712.01.00

Figure 8. Replacing the Control-Main Filter Refill Transmission. The amount of refill fluid is less than the amount used for the initial fill. Fluid remains in the external circuits and transmission cavities after draining the transmission. After refill, check the fluid level using the TRANSMISSION FLUID CHECK paragraph of this Manual.

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OM3063EN_200306.pdf

8/18/04

4:04:40 PM

Transmission Fluid Capacity Transmission 1000/2000/2400

Sump Standard Shallow

Initial Fill * Liters Quarts 14 14.8 12 12.7

* Approximate quantities, do not include external lines and cooler hose.

Liters 10 7

Refill* Quarts 10.6 7.4

VENT ASSEMBLY Location and Purpose. The vent assembly is located at the top left-rear of the transmission main housing. The vent assembly prevents air pressure buildup within the transmission and its passage must be kept clean and open.

C

M

CAUTION: Do not spray steam, water, or cleaning solution directly at the vent assembly (breather). Spraying steam, water, or cleaning solution at the vent assembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid. Seal all openings and the vent assembly (breather) before spraying steam, water, or cleaning solutions on the transmission.

Y

CM

MY

Maintenance. The amount of dust and dirt encountered will determine the frequency of vent assembly cleaning. Use care when cleaning the transmission.

CY

CMY

K

68

DIAGNOSTICS

DIAGNOSTIC CODES AND TOOLS Diagnostic features are provided with the transmission control system to assist in the troubleshooting of malfunctions. These features include a red or amber CHECK TRANS light or some type of Malfunction Indicator Light (MIL), a PC-based diagnostic program, and an optional hand-held scan tool. The CHECK TRANS and MIL lights are located on the dash panel. For vehicles which are compliant to industry On Board Diagnostics II (OBD II) requirements, an MIL Light will be present. For vehicles which are not compliant to industry OBD II requirements, a CHECK TRANS light will be present. The PC-based diagnostic program can troubleshoot all transmissions. The hand-held scan tool can troubleshoot only some transmissions. Illumination of the CHECK TRANS light at any time after start-up indicates that the TCM has registered a diagnostic trouble code (DTC). Diagnostic codes are used to identify and clarify the nature of the malfunction. Diagnostic codes are read and cleared through the PC-based diagnostic program or the hand-held scan tool. Illumination of the MIL Light at any time after start-up may indicate a problem with the engine or transmission. For further information, consult an authorized Allison Transmission distributor or service dealer or the website www.allisontransmission.com. Reference the Sales and Service Directory (SA2229) for the current listing of Allison Transmission authorized distributor and service dealers.

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CUSTOMER SERVICE

OWNER ASSISTANCE The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission Division (ATD), its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world that are eager to meet your parts and service needs with: • • • • •

Expert service by trained personnel Emergency service 24 hours a day in many areas Complete parts support Sales teams to help determine your transmission requirements Product information and literature

Normally, any situation that arises in connection with the sale, operation, or service of your transmission will be handled by the distributor or dealer in your area (check the telephone directory for the Allison Transmission service outlet nearest you). Refer to Worldwide Sales and Service Directory (SA2229EN) for the current listing of Allison Transmission authorized distributor and service dealers. This directory is available from SGI, Inc. We recognize, however, that despite the best intentions of everyone concerned, misunderstandings may occur. To further assure your complete satisfaction, we have developed the following three-step procedure to be followed in the event a problem has not been handled satisfactorily. Step One—Discuss the problem with a member of management from the distributorship or dealership. Frequently, complaints are the result of a breakdown in communication and can quickly be resolved by a member of management. If you have already discussed the problem with the Sales or Service Manager, contact the General Manager. All ATD dealers are associated with an ATD distributor. If the problem originates with a dealer, explain the matter to a management member of the distributorship with whom the dealer has his service agreement. The dealer will provide his ATD distributor’s name, address, and telephone number on request.

70

Step Two—When it appears the problem cannot be resolved readily at the distributor level without additional assistance, contact the Allison Transmission Regional Office responsible for the local distributor. You will be assisted by a member of the Regional Service Manager’s staff, depending on the nature of your problem. For prompt assistance, please have the following information available. • Name and location of authorized distributor or dealer • Type and make of equipment • Transmission model number, serial number, and assembly number (if equipped with electronic controls, also provide the TCM assembly number) • Transmission delivery date and accumulated miles and/or hours of operation • Nature of problem • Chronological summary of unit’s history Step Three—If you contacted a regional office and you are still not satisfied, present the entire matter to the Home Office by writing to the following address or calling the phone number below: Allison Transmission Manager, Warranty Administration – PF9 P.O. Box 894 Indianapolis, IN 46206-0894 800–252–5283 The inclusion of all pertinent information will assist the Home Office in expediting the matter. If an additional review by the Home Office of all the facts involved indicates that some further action can be taken, the Regional Office will be advised. When contacting the Regional or Home Office, please keep in mind that ultimately the problem will likely be resolved at the distributorship or dealership utilizing their facilities, equipment, and personnel. Therefore, it is suggested the above steps be followed in sequence when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.

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SERVICE LITERATURE Additional service literature is available. This service literature provides fully illustrated instructions for the operation, maintenance, service, overhaul, and parts support of your transmission. To ensure that you get maximum performance and service life from your unit, you may order publications from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888–666–5799 INTERNATIONAL: 317–471–4995 www.allisontransmission.com 1000/2000/2400 Series Service Literature Automatic Transmission Fluid Technician’s Guide *Mechanic’s Tips *Operator’s Manual Parts Catalog Parts Catalog CD-ROM Principles of Operation Retail Literature Catalog Service Manual Troubleshooting Manual Worldwide Sales & Service Directory * Also available on the internet at www.allisontransmission.com

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GN2055EN MT3190EN OM3063EN PC3062EN CD3062EN PO3065EN GN2798EN SM3191EN TS3192EN SA2229EN

ALLISON TRANSMISSION DISTRIBUTORS EASTERN REGION Atlantic Detroit Diesel-Allison, LLC 180 Route 17 South Lodi, NJ 07644 201-489-5800

Penn Detroit Diesel-Allison, Inc. 8330 State Road Philadelphia, PA 19136-2986 215-335-0500

Covington Detroit Diesel-Allison 8015 Piedmont Triad Parkway Greensboro, NC 27409 336-292-9240

Western Branch Diesel, Inc. 3504 Shipwright Street Portsmouth, VA 23703 757-673-7000

Johnson & Towers, Inc. 2021 Briggs Road Mount Laurel, NJ 08054 856-234-6990

Williams Detroit Diesel-Allison Southeast, Inc. 2849 Moreland Avenue, S.E Atlanta, GA 30315-0037 404-366-1070

New England Detroit Diesel-Allison, Inc. 90 Bay State Road Wakefield, MA 01880-1095 781-246-1810

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CENTRAL REGION Caribe Detroit Diesel-Allison Division of GT Corporation Ceramic Ind. Park, Campo Rico Ave., Block C Carolina, Puerto Rico 00982 787-750-5000

Inland Detroit Diesel-Allison, Inc. 210 Alexandra Way Carol Stream, IL 60188 630-871-1111

Central Detroit Diesel-Allison, Inc. 9200 Liberty Drive Liberty, MO 64068 816-781-8070

Inland Diesel, Inc. 13015 West Custer Avenue Butler, WI 53007-0916 262-781-7100

Clarke Detroit Diesel-Allison, Inc. 3133 East Kemper Road Cincinnati, OH 45241 513-771-2200

Interstate Detroit Diesel 2501 East 80th Street Minneapolis, MN 55425 952-854-5511

Florida Detroit Diesel-Allison, Inc. 5105 Bowden Road Jacksonville, FL 32216 904-737-7330

Williams Detroit Diesel-Allison Midwest, Inc. 1176 Industrial Parkway North Brunswick, OH 44212-2342 330-225-7751

SOUTHWESTERN REGION Detroit Diesel-Allison De Mexico S.A. Stewart & Stevenson Services, Inc. de C.V. 2707 North Loop West Av. Santa Rosa No. 58 Houston, TX 77008 Col. Ampliacion Norte 713-868-7700 Tlalnepantla, Estado de Mexico C.P. 54160 (525)6-333-1800 Stewart & Stevenson Power, Inc. 5840 Dahlia Street Commerce City, CO 80022 303-287-7441

United Engines, LLC 5555 West Reno Avenue Oklahoma City, OK 73127 405-947-3321

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WESTERN REGION Pacific Detroit Diesel-Allison Company Valley Detroit Diesel-Allison, Inc. 7215 South 228th Street 425 South Hacienda Boulevard Kent, WA 98032 City of Industry, CA 91745-1123 253-854-0505 626-333-1243 Smith Detroit Diesel-Allison, Inc. 250 West 3900 South Salt Lake City, UT 84107 801-415-5000

Williams Detroit Diesel-Allison Southwest, Inc. 2602 S. 19th Avenue Phoenix, AZ 85009 602-257-0561

Stewart & Stevenson 1755 Adams Avenue San Leandro, CA 94577-1001 510-635-8991 CANADIAN REGION Detroit Diesel-Allison British Columbia Ltd. 9300 192nd Street Surrey, British Columbia V4N 3R8 604-888-1211

Midwest Detroit Diesel-Allison Ltd. 1460 Waverley Street Winnipeg, Manitoba R3T OP6 204-452-8244

Detroit Diesel-Allison Canada East Div. of Integrated Power Systems Corp 2997 Rue Watt Ste. Foy, Quebec G1X 3W1 418-651-5371

Waterous Detroit Diesel-Allison (Div. of Integrated Power Systems Corp) 10025 51st Avenue Edmonton, Alberta T6E OA8 780-437-3550

Harper Detroit Diesel Ltd. 10 Diesel Drive Toronto, Ontario M8W 2T8 416-259-3281

75

ALLISON TRANSMISSION REGIONAL OFFICES EASTERN REGION P. O. Box 400 Columbus , NJ 08022-0400 609-298-2541

WESTERN REGION 39465 Paseo Padre Parkway Suite 3500 Fremont, CA 94538 510-498-5208

CENTRAL REGION P. O. Box 894, Speed Code PF06 Indianapolis, IN 46206-0894 317-242-2327

CANADIAN REGION P. O. Box 5160 Station A London, Ontario N6A 4N5 519-452-5256

SOUTHWESTERN REGION Av. Ejercito Nacional No. 843 Colonia Granada Mexico, D.F. C.P. 11520 525-901-3057 Texas Office: 936-321-4248 936-321-4278 To find the closest authorized distributor or dealer of Allison Transmission product and services visit the sale and service locator on the Allison Transmission web site—www.allisontransmission.com.

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OM3063EN 200306

www.allisontransmission.com

Printed in USA 200309

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Service Manual 1000, 2000, 2000MH, 2400 Series On-Highway Transmissions SM3191EN

SM3191EN

Service Manual

Allison Transmission 1000 Series™ 2000 Series™ 2000MH Series 2400 Series™

2003 MAY

Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46202-0894 www.allisontransmission.com

Printed in the U.S.A.

Copyright © 2003 General Motors Corp.

INTRODUCTION TRADEMARK USAGE The following trademarks are the property of the companies indicated: • Biobor JF® is the registered trademark for a biological inhibitor manufactured by Hammonds • • • • • • • • • •

Fuel Additives Company. DEXRON® is a registered trademark of General Motors Corporation. Loctite® is a registered trademark of the Loctite Corporation. Spiralock® is a registered trademark of Spiralock of Michigan. Teflon® is a registered trademark of the DuPont Corporation. TranSynd™ is a trademark of Castrol Ltd. 1000 Series™ is a trademark of General Motors Corporation. 2000 Series™ is a trademark of General Motors Corporation. 2400 Series™ is a trademark of General Motors Corporation. Windows™ is a trademark of Microsoft Corporation. Allison DOC™ and Allison Diagnostic Optimized Connection™ are trademarks of General Motors Corporation.

NOTE: This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by the date on the title page. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions — Truck, Tractor, etc.

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Copyright © 2003 General Motors Corp.

IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cautions described in this Service Manual. These Warnings and Cautions advise against the use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. It is, however, important to understand that these Warnings and Cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair are important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special tools should be used when and as recommended.

WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: WARNING! is used when an operating procedure, practice, etc., which, if not correctly followed, could result in personal injury or loss of life.

CAUTION: is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment.

NOTE: is used when an operating procedure, practice, etc., is essential to highlight.

Copyright © 2003 General Motors Corp.

iii

LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

Operation with excessive loads can cause transmission damage and unexpected vehicle movement. To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg (26,000 lbs) GCW or the OEM vehicle rating, whichever is less. If ignition is turned “OFF” and then “ON” while the CHECK TRANS light is displayed, the transmission may remain in neutral until the code is cleared. Leave ignition “ON” until you are in a safe place to stop. For vehicles containing 1000 and 2400 models, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the P (Park) range by slowly releasing the service brake. • Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. For vehicles containing 2000 models with auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. • Apply the emergency brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. For vehicles containing 2000 models without auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • • • • •

Bring the vehicle to a complete stop using the service brake. Make sure the engine is at low idle rpm. Put the transmission in N (Neutral). Apply the emergency brake and/or parking brake and make sure they are properly engaged. If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. Observe safety precautions during hydraulic pressure check procedures. All personnel must stand clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges (vacuum, pressure, tachometer) have extended lines so that they can be read from inside the vehicle.

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Copyright © 2003 General Motors Corp.

LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in P (Park) or N (Neutral)…and • Apply the parking brake and service brake…and • Chock the vehicle wheels and take any other steps necessary to keep the vehicle from moving…and • Warn personnel to keep clear of the vehicle and its path. Use appropriate safety equipment such as safety glasses, safety shoes, and gloves. Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®. Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing. Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct contact with the hot fluid or the hot sump may result in bodily injury. Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary if vehicle is on a lift or jackstands. Be sure the torque converter is moving rearward with the transmission as it is removed. Do not allow the torque converter to become disengaged from the oil pump or to fall and injure yourself or others. The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage. NEVER tilt the converter end down unless a torque converter retaining device is installed. The 1000/2000/2400 Series transmission dry weights are approximately 150 kg (330 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the transmission. • Get help when lifting the transmission. Assistance from a hoist or another person may be required. • Make sure that the lifting equipment can properly support the transmission. If the transmission is not secured properly to the adapter plate, it could fall. To help avoid personal injury and/or property damage: • Use at least 5 bolts to support the transmission. • Use M10 x 1.5 bolts with 19-25 mm (3⁄4-1 inch) thread engagement. If the proper bolt is not used, the PTO bolt holes may be damaged.

Copyright © 2003 General Motors Corp.

v

LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

The 1000/2000/2400 Series torque converter dry weights are approximately 29 kg (63 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the torque converter. • Get help when lifting the torque converter. Assistance from a hoist or another person may be required. • Make sure that the lifting equipment can properly support the torque converter. The 1000/2000/2400 Series converter housing/front support module dry weights are approximately 27 kg (60 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the converter housing/front support module. • Get help when lifting the converter housing/front support module. Assistance from a hoist or another person may be required. • Make sure that the lifting equipment can properly support the converter housing/front support module. Always remove or install the P3 planetary carrier assembly by holding onto the output shaft. Holding onto the P3 carrier assembly instead of the output shaft may allow the output shaft to fall causing personal injury and/or property damage. All pressure from the torque converter must be exhausted before loosening the test fixture nut. Failure to relieve the pressure could cause personal injury and/or property damage. The rotating clutch housing and turbine shaft are held together by a retaining ring. Removal of the retaining ring will allow the turbine shaft and the rotating clutch housing to move freely. Ensure that the rotating clutch housing and the turbine shaft are restrained from moving when removing the retaining ring. Personal injury and/or property damage may result from the movement of the rotating clutch housing or the turbine shaft. Pressing the P3 planetary carrier from the bearing race requires the P3 carrier to fall from the bearing race. Ensure that the P3 carrier is safely caught when freed from the bearing race. An uncontrolled fall of the P3 carrier could cause personal injury and/or property damage.

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Copyright © 2003 General Motors Corp.

TABLE OF CONTENTS Paragraph

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Section 1. GENERAL INFORMATION

Section 2. PREVENTIVE MAINTENANCE

1–1. SCOPE OF MANUAL a. Content and Organization . . . . . . . . . . . . 1–1 b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–1 c. Maintenance Information . . . . . . . . . . . . 1–1

2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

1–2. SUPPLEMENTARY INFORMATION . . . . 1–1 1–3. ORDERING PARTS a. Transmission Nameplate . . . . . . . . . . . . . 1–1 b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–1 1–4. GENERAL DESCRIPTION a. Transmission Design Features. . . . . . . . . 1–4 b. Model Nomenclature. . . . . . . . . . . . . . . . 1–6 1–5. DIAGNOSIS a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–6 b. CHECK TRANS Light . . . . . . . . . . . . . . 1–6 c. Range Inhibit Indicator . . . . . . . . . . . . . . 1–6 d. Personal Computer (PC)-Based Diagnostic System . . . . . . . . . . . . . . . . . . 1–7 e. Troubleshooting When No Diagnostic Codes are Present. . . . . . . . . . . . . . . . . . . 1–7 f. Troubleshooting Intermittent Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–7 1–6. PRESERVATION AND STORAGE a. Storage (New Transmissions, Before Installation) . . . . . . . . . . . . . . . . . 1–8 b. Preservation Methods . . . . . . . . . . . . . . . 1–8 c. One Year Storage (Without Fluid). . . . . . 1–8 d. One Year Storage (With Fluid) . . . . . . . . 1–8 1–7. RESTORING TRANSMISSION TO SERVICE a. Transmission Exterior . . . . . . . . . . . . . . . 1–9 b. Sealed Vent Assembly and Openings . . . 1–9 c. New Transmissions . . . . . . . . . . . . . . . . . 1–9 d. Stored Without Fluid . . . . . . . . . . . . . . . . 1–9 e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 1–9 1–8. OPERATING INSTRUCTIONS . . . . . . . . . 1–9 1–9. SPECIFICATIONS AND DATA . . . . . . . . . 1–9 1–10. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE . . . . . . . 1–18

2–2. PERIODIC INSPECTION AND CARE a. Transmission Inspection . . . . . . . . . . . . . 2–1 b. Vehicle Inspection . . . . . . . . . . . . . . . . . . 2–1 c. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–3. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL . . . . . . . . 2–1 2–4. TRANSMISSION FLUID CHECK a. Fluid Check Procedure . . . . . . . . . . . . . . 2–2 b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4 c. Hot Check Procedure . . . . . . . . . . . . . . . . 2–4 d. Consistency of Readings . . . . . . . . . . . . . 2–5 2–5. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–5 2–6. FLUID RECOMMENDATIONS . . . . . . . . . 2–5 2–7. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 2–6 b. Abnormal Conditions. . . . . . . . . . . . . . . . 2–6 c. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–6 d. Fluid and Filter Change Intervals . . . . . . 2–6 2–8. TRANSMISSION FLUID CONTAMINATION a. Fluid Examination . . . . . . . . . . . . . . . . . . 2–6 b. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 c. Engine Coolant. . . . . . . . . . . . . . . . . . . . . 2–9 d. Flush Oil Cooler. . . . . . . . . . . . . . . . . . . . 2–9 2–9. TRANSISSION FLUID AND FILTER CHANGE PROCEDURE a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . . 2–9 b. Replace Control-Main Filter . . . . . . . . . . 2–9 c. Refill Transmission . . . . . . . . . . . . . . . . . 2–9 2–10. VENT ASSEMBLY a. Location and Purpose. . . . . . . . . . . . . . . 2–10 b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 2–10 2–11. MAIN PRESSURE CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 2–10 2–12. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 b. Stall Test Results . . . . . . . . . . . . . . . . . . 2–12 c. Neutral Cool-Down Check Procedure. . 2–13

Copyright © 2003 General Motors Corp.

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2–13. FLUID LEAK DIAGNOSIS a. Finding the Leak . . . . . . . . . . . . . . . . . . b. Powder Method . . . . . . . . . . . . . . . . . . . c. Black Light and Dye Method . . . . . . . . d. Repairing the Leak . . . . . . . . . . . . . . . .

2–13 2–14 2–14 2–14

2–14. ON-VEHICLE MAINTENANCE . . . . . . . 2–14

Section 3. GENERAL OVERHAUL INFORMATION 3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–2. TOOLS AND EQUIPMENT a. Improvised Equipment . . . . . . . . . . . . . 3–1 b. Special Tools . . . . . . . . . . . . . . . . . . . . . 3–1 c. Mechanic’s Tools and Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1 3–3. REPLACEMENT PARTS a. Ordering Information . . . . . . . . . . . . . . . 3–9 b. Parts Normally Replaced at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 3–9 3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–9 3–5. CLEANING AND INSPECTION a. Dirt Causes Malfunction . . . . . . . . . . . . . 3–9 b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . 3–9 c. Cleaning Bearings . . . . . . . . . . . . . . . . . 3–9 d. Keeping Bearings Clean. . . . . . . . . . . . . 3–9 e. Inspecting Bearings . . . . . . . . . . . . . . . . 3–10 f. Inspecting Cast Parts and Machined Surfaces . . . . . . . . . . . . . . . . 3–10 g. Inspecting Bushings and Thrust Washers . . . . . . . . . . . . . . . . . . . 3–10 h. Inspecting Sealrings and Gaskets. . . . . 3–10 i. Inspecting Gears. . . . . . . . . . . . . . . . . . 3–11 j. Inspecting Splined Parts. . . . . . . . . . . . 3–11 k. Inspecting Threaded Parts . . . . . . . . . . 3–11 l. Inspecting Retaining Rings . . . . . . . . . . 3–11 m. Inspecting Springs. . . . . . . . . . . . . . . . . 3–11 n. Inspecting Clutch Plates . . . . . . . . . . . . 3–11 o. Inspecting Swaged and Interference-Fit Parts . . . . . . . . . . . . . . 3–12 p. Inspecting Sealing Surfaces . . . . . . . . . 3–12 viii

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3–6. ASSEMBLY PROCEDURES a. Parts Lubrication . . . . . . . . . . . . . . . . . . 3–12 b. Grease Used for Assembly . . . . . . . . . . 3–12 c. Sealing Compounds and Nonsoluble Greases . . . . . . . . . . . . . . . 3–12 d. Clutches and Pistons . . . . . . . . . . . . . . 3–12 e. Threaded Plugs and Hydraulic Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . 3–12 g. Butt-Joint Sealrings . . . . . . . . . . . . . . . 3–13 h. Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 3–13 i. Electrical Components . . . . . . . . . . . . . 3–13 3–7. REMOVING (OR INSTALLING) TRANSMISSION a. Draining Transmission . . . . . . . . . . . . . 3–13 b. Disconnecting Controls . . . . . . . . . . . . 3–14 c. Uncoupling From Driveline, Engine, and Vehicle . . . . . . . . . . . . . . . 3–14 d. Removing the Transmission. . . . . . . . . 3–14 e. Transmission Installation . . . . . . . . . . . 3–14 3–8. WEAR LIMITS. . . . . . . . . . . . . . . . . . . . . . 3–15 3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–15 3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–15

Section 4. TRANSMISSION DISASSEMBLY 4–1. INSTALLATION OF TRANSMISSION INTO REPAIR STAND . . . . . . . . . . . . . . . . 4–1 4–2. INPUT SPEED SENSOR REMOVAL (IF PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 4–2 4–3. TURBINE SPEED SENSOR REMOVAL . 4–3 4–4. OUTPUT SPEED SENSOR REMOVAL (2WD TRANSMISSIONS ONLY) . . . . . . . 4–3 4–5. NSBU SWITCH REMOVAL (IF PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 4–3 4–6. VENT HOSE REMOVAL (IF PRESENT) . 4–4 4–7. TORQUE CONVERTER REMOVAL . . . . 4–5 4–8. CONVERTER HOUSING/FRONT SUPPORT MODULE REMOVAL . . . . . . . 4–6 4–9. ROTATING CLUTCH ASSEMBLY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 4–10. OIL PAN AND SUCTION FILTER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

Copyright © 2003 General Motors Corp.

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4–11. WIRING HARNESS ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 4–12. CONTROL VALVE ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 4–13. REAR BALL BEARING REMOVAL . . . . 4–12 4–14. REAR COMPONENTS REMOVAL . . . . . 4–14 4–15. PARK PAWL REMOVAL . . . . . . . . . . . . . 4–16 4–16. P2 PLANETARY MODULE AND MAIN SHAFT REMOVAL . . . . . . . . . . . . . . . . . . 4–16 4–17. C5 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–17 4–18. P1 PLANETARY MODULE . . . . . . . . . . . 4–17 4–19. C4 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–18 4–20. C4 CLUTCH PISTON ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 4–21. C3 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–21 4–22. C3 CLUTCH PISTON ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–23

Section 5. MODULE REBUILD 5–1. TORQUE CONVERTER ASSEMBLY a. Preliminary Inspection . . . . . . . . . . . . . . 5–1 b. End Play Check . . . . . . . . . . . . . . . . . . . . 5–1 c. Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 d. Inspection of Torque Converter. . . . . . . . 5–3 5–2. ELECTRONIC COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–3. CONVERTER HOUSING/FRONT SUPPORT MODULE DISASSEMBLY . . . 5–6 5–4. TORQUE CONVERTER HOUSING (WITHOUT COOLER MANIFOLD) a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–9 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–10 5–5. TORQUE CONVERTER HOUSING (DIRECT MOUNT; WITHOUT COOLER MANIFOLD) a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–11 b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–11 5–6. TORQUE CONVERTER HOUSING (WITH COOLER MANIFOLD) a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–12 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13

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5–7. MAIN PUMP ASSEMBLY a. Main Pump Disassembly. . . . . . . . . . . . 5–15 b. Main Pump Inspection . . . . . . . . . . . . . . 5–16 c. Main Pump Bushing Replacement . . . . 5–19 d. Main Pump Dowel Pin Replacement. . . 5–20 e. Wear Plate Inspection . . . . . . . . . . . . . . 5–21 f. Main Pump Assembly . . . . . . . . . . . . . . 5–21 5–8. FRONT SUPPORT ASSEMBLY a. Front Support Disassembly . . . . . . . . . . 5–22 b. Ground Sleeve Inspection . . . . . . . . . . . 5–27 c. Ground Sleeve Replacement . . . . . . . . . 5–28 d. Ground Sleeve Needle Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . 5–30 e. Ground Sleeve Bushing Replacement . . 5–31 f. Front Support Thrust Washer Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–32 g. Front Support Assembly . . . . . . . . . . . . 5–32 5–9. CONVERTER HOUSING/FRONT SUPPORT MODULE ASSEMBLY. . . . . . 5–37 5–10. ROTATING CLUTCH MODULE a. Disassembly of Rotating Clutch Module . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40 b. Turbine Shaft Inspection . . . . . . . . . . . . 5–47 c. Turbine Shaft Bushing Replacement . . . 5–48 d. Rotating Clutch Housing Inspection . . . 5–49 e. Rotating Clutch Housing Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . 5–50 f. Rotating Clutch Housing Tone Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . 5–51 g. C1 Clutch Friction Plate Inspection. . . . 5–53 h. C1 Clutch Reaction Plate Inspection . . . 5–54 i. C1 Clutch Backplate Inspection . . . . . . 5–55 j. C2 Clutch Friction Plate Inspection. . . . 5–56 k. C2 Clutch Reaction Plate Inspection . . . 5–56 l. C1 Piston Housing Inspection . . . . . . . . 5–57 m. Rotating Clutch Thrust Washer Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–57 n. Assembly of Rotating Clutch Module . . 5–58 5–11. MAIN HOUSING ASSEMBLY a. Disassembly of Selector Shaft and Detent Lever . . . . . . . . . . . . . . . . . . 5–66 b. Assembly of Selector Shaft and Detent Lever. . . . . . . . . . . . . . . . . . . . . . 5–68 c. Nameplate Replacement . . . . . . . . . . . . 5–70

Copyright © 2003 General Motors Corp.

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d. Main Housing Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . 5–70 e. Replacement of Fill Tube Plug . . . . . . . 5–71 f. Replacement of Vent Assembly . . . . . . 5–71

d. Output Shaft Bushing Inspection (4WD Transmissions Only) . . . . . . . . . 5–91 e. Output Shaft Bushing Replacement . . . 5–92 f. Assembly of Rear Cover . . . . . . . . . . . . 5–93

5–12. RING GEAR AND CLUTCH COMPONENT INSPECTIONS a. C3 Clutch Component Inspection . . . . 5–71 b. C3 Clutch Backplate Assembly Thrust Plate Replacement . . . . . . . . . . . 5–75 c. C4 Clutch Component Inspection . . . . . 5–76 d. C5 Clutch Component Inspection . . . . . 5–78 e. P1 Planetary Gear Inspection . . . . . . . . 5–80

5–18. OUTPUT YOKE INSPECTION . . . . . . . . 5–94

5–13. MAIN SHAFT INSPECTION . . . . . . . . . . 5–80 5–14. P1 PLANETARY MODULE a. P1 Planetary Module Disassembly . . . . b. P1 Planetary Carrier Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . c. P2 Planetary Ring Gear Inspection . . . . d. P1 Planetary Carrier Bushing Replacement . . . . . . . . . . . . . . . . . . . . . e. P1 Planetary Carrier Thrust Washer Inspection . . . . . . . . . . . . . . . . . . . . . . . f. P1 Planetary Module Assembly . . . . . . 5–15. P2 PLANETARY MODULE a. P2 Planetary Module Disassembly . . . b. P2 Planetary Carrier Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . c. P3 Planetary Ring Gear Inspection . . . . d. P2 Planetary Carrier Bushing Replacement . . . . . . . . . . . . . . . . . . . . . e. P2 Planetary Module Assembly . . . . . .

5–81 5–81 5–82 5–82 5–83 5–83

Section 6. TRANSMISSION ASSEMBLY 6–1. C3 CLUTCH INSTALLATION. . . . . . . . . . 6–1

5–84

6–2. P1 PLANETARY MODULE AND C4 CLUTCH INSTALLATION. . . . . . . . . . 6–3

5–84 5–85

6–3. C5 CLUTCH REACTION PLATE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6–6

5–85 5–86

5–16. P3 PLANETARY CARRIER ASSEMBLY a. P3 Planetary Carrier Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–86 b. P3 Planetary Carrier Bearing Race Replacement . . . . . . . . . . . . . . . . . . . . . 5–87 5–17. REAR COVER ASSEMBLY a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–88 b. Rear Cover Housing Retaining Ring Replacement . . . . . . . . . . . . . . . . . . . . . 5–90 c. Output Shaft Bushing Inspection (2WD Transmissions Only) . . . . . . . . . 5–91

x

5–19. CONTROL VALVE MODULE a. Disassembly of Control Valve Assembly . . . . . . . . . . . . . . . . . . 5–95 b. Disassembly of Shift Valve Body. . . . . 5–99 c. Disassembly of Modulated Main Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–102 d. A/B Solenoid Bracket Inspection . . . . 5–103 e. Assembly of Shift Valve Body . . . . . . 5–103 f. Disassembly of the Main Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–106 g. Dowel Pin Replacement . . . . . . . . . . . 5–108 h. Assembly of the Main Valve Body. . . 5–109 i. Assembly of Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–110 j. Assembly of Modulated Man Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–115

6–4. P2 PLANETARY MODULE AND MAIN SHAFT INSTALLATION . . . . . . . . 6–8 6–5. C5 CLUTCH INSTALLATION. . . . . . . . . . 6–9 6–6. PARK PAWL INSTALLATION . . . . . . . . 6–10 6–7. OUTPUT SHAFT AND P3 PLANETARY CARRIER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–11 6–8. REAR COVER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–11 6–9. CONTROL VALVE ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–14 6–10. WIRING HARNESS ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–16

Copyright © 2003 General Motors Corp.

TABLE OF CONTENTS Paragraph

Page

Paragraph

Page

6–11. OIL PAN AND SUCTION FILTER INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–17

6–22, INPUT SPEED SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–31

6–12. ROTATING CLUTCH ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–18

6–23. TURBINE SPEED SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–32

6–13. CONVERTER HOUSING/FRONT SUPPORT MODULE INSTALLATION . . 6–19

6–24. OUTPUT SPEED SENSOR INSTALLATION (2WD TRANSMISSIONS ONLY). . . . . . . 6–32

6–14. REAR COVER SELECTIVE SPACER INSTALLATION (2WD TRANSMISSIONS ONLY). . . . . . . 6–21 6–15. REAR COVER SELECTIVE SPACER INSTALLATION (4WD TRANSMISSIONS ONLY). . . . . . . 6–22 6–16. TRANSMISSION END PLAY CHECK . . 6–23 6–17. TORQUE CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–24 6–18. NSBU SWITCH INSTALLATION (IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . 6–26 6–19. REAR SEAL INSTALLATION (2WD TRANSMISSIONS ONLY). . . . . . . 6–29

6–25. REMOVAL OF TRANSMISSION FROM REPAIR STAND. . . . . . . . . . . . . . . . . . . . . 6–33

Section 7. WEAR LIMITS AND SPRING DATA 7–1. WEAR LIMITS DATA a. Maximum Variations . . . . . . . . . . . . . . . . 7–1 b. Cleaning and Inspection. . . . . . . . . . . . . . 7–1 7–2. SPRING DATA a. Spring Replacement . . . . . . . . . . . . . . . . . 7–1 b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

6–20. OUTPUT NUT INSTALLATION (1000 SERIES™ 4WD TRANSMISSIONS ONLY) . . . . . . . . . . . . 6–29

8–1. OWNER ASSISTANCE . . . . . . . . . . . . . . . . 8–1

6–21. VENT HOSE INSTALLATION. . . . . . . . . 6–31

8–2. SERVICE LITERATURE. . . . . . . . . . . . . . . 8–2

Section 8. CUSTOMER SERVICE

Copyright © 2003 General Motors Corp.

xi

1000/2000/2400 SERIES TRANSMISSIONS LIST OF FOLDOUT ILLUSTRATIONS (Back of Service Manual) CROSS-SECTION VIEWS Foldout

1 2 3 4

1000 Series™ 2000 Series™ 2400 Series™ 1000 Series™ Direct Mount

EXPLODED VIEWS 5,A 5,B 5,C 5,D 6 6,A 7 8 9 10 11 12 13 14,A 14,B 14,C 15,A 15,B 16,A 16,B 17 18,A 18,B 18,C 18,D 19,A 19,B 19,C 19,D 20 21 22 23 24 25 26 27 28 29 30 xii

SAE No. 3 Torque Converter Housing with Integral Cooling Ports SAE No. 2 Torque Converter Housing with Manifold SAE No. 3 Torque Converter Housing with Manifold Direct Mount — Torque Converter Housing Converter Housing/Front Support Module, Rotating Clutch Housing, and C3 Clutch Components Converter Housing/Front Support Module Components Front Support Module Components Main Pump Assembly Components Front Support Assembly Components Rotating Clutch Assembly Components Oil Pan and Suction Filter Components Main Housing Components C4 and C5 Clutch Components P1 Planetary Module, P2 Planetary Module, and Main Shaft Components P2 Planetary Module Components P3 Planetary Module P1 Planetary Carrier Assembly Components P2 Planetary Carrier Assembly Components P3 Planetary Assembly, Output Shaft, C5 Piston Return Assembly, and Park Pawl Components Rear Cover Assemblies P3 Planetary Carrier Assembly Rear Cover Assembly Components, 10 x 3 Rear Cover Assembly Components, Non-Park Brake Rear Cover Assembly Components, Transfer Case Rear Cover Assembly Components, 9 x 3 Control Valve Assembly Components Shift Valve Body Assembly Components Main Valve Body Assembly Components Modulated Main Valve Body Vent Hose and Yokes/Flanges 1000/2000/2400 Series Hydraulic Schematic — Neutral/Park 1000/2000/2400 Series Hydraulic Schematic — First Range 1000/2000/2400 Series Hydraulic Schematic — Second Range 1000/2000/2400 Series Hydraulic Schematic — Third Range 1000/2000/2400 Series Hydraulic Schematic — Fourth Range 1000/2000/2400 Series Hydraulic Schematic — Fifth Range 1000/2000/2400 Series Hydraulic Schematic — Reverse (With N04 Software and Later) 1000/2000/2400 Series Hydraulic Schematic — Reverse (Prior to and Including N04 Software) 1000/2000/2400 Series Hydraulic Schematic — Default Reverse (“Limp Home”) 1000/2000/2400 Series Hydraulic Schematic — Default Forward (3rd Range “Limp Home”) Copyright © 2003 General Motors Corp.

SECTION 1 — GENERAL INFORMATION 1–1.

SCOPE OF MANUAL

a. Content and Organization. This Service Manual describes overhaul procedures for 1000/2000/2400 Series automatic transmissions (Figures 1–1 and 1–2).

3. The required tools and fixtures, listed in Table 3–1 (Section 3 of this manual), are available. 4. Reasonable and prudent maintenance practices are used.

• Major transmission components are described

and their functions explained. • Detailed instructions are provided for disassembly, rebuild, and re-assembly. • Part inspection instructions are in Section 3. • Wear limits and spring data are in Section 7.

NOTE: Service organizations and individuals are encouraged to contact their local ATD Distributor for information and guidance on any task outlined in this manual.

b. Illustrations 1. The text is supported with line drawings, exploded, and cross-sectional views. Overhaul procedures are illustrated by line drawings. Cross-sections show the relationship of assembled parts. Cross-sections and exploded views are on foldout pages in the back of the manual. 2. Illustrations show correct procedures for all models — including models not illustrated. c. Maintenance Information. Each task described in this manual has been successfully completed by service organizations and individuals. Not every service organization or individual possesses the required special tooling, training, or experience to perform all described tasks. However, any task may be performed if the following conditions are met: 1. The organization or individual has the required knowledge of the task through: • Formal instruction at Allison Transmission

Division (ATD) or a Distributor training facility. • On-the-job instruction by an ATD or

Distributor representative. • Experience in performing the task.

2. The work environment is suitable to prevent contamination or damage to transmission parts or assemblies.

1–2.

SUPPLEMENTARY INFORMATION

Supplementary information will be issued, as required, if any changes occur after publication of this manual. Check with your dealer or distributor to be sure you have the latest information.

1–3.

ORDERING PARTS

a. Transmission Nameplate. The nameplate (1) (Figure 1–3) is located on the right side of the transmission. The nameplate will be one of two styles (Figures 1–4 and 1–5). Both nameplates are imprinted with the transmission model, serial number, transmission identification number, engineering group number, engineering feature configuration number, and date of manufacture. Use all of these numbers when ordering replacement parts or requesting service information. b. Parts Catalog. Replacement parts are listed in Parts Catalog PC3062EN. Do not order by the item numbers used on exploded views in this manual. Use the Parts Catalog to determine the correct part number. Order all replacement parts from your distributor or authorized dealer. Check the Yellow Pages for your nearest authorized service outlet. Listings are under Transmission — Truck, Tractor, Etc.

Copyright © 2003 General Motors Corp.

1–1

1000/2000/2400 SERIES SERVICE MANUAL OIL VENT (BREATHER) TURBINE SPEED SENSOR INPUT SPEED SENSOR

PARKING BRAKE MOUNTING PROVISION

OUTPUT SPEED SENSOR

NSBU SWITCH SELECTOR SHAFT SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL) AVAILABLE OIL FILL TUBE LOCATION CONTROL MAIN OIL FILTER

1000 / 2000 / 2400 SERIES™ TRANSMISSION – LEFT-FRONT VIEW

V04779.03.00

Figure 1–1. 1000/2000/2400 Series Transmission — Left-Front View

INPUT SPEED SENSOR TURBINE SPEED SENSOR

OIL VENT (BREATHER) OUTPUT SPEED SENSOR

MOUNTING PAD (SAE #3 HOUSING ONLY) COOLER PORTS

PROVISION FOR CUSTOMER-SUPPLIED SPEED SENSOR OR TACHOGRAPH (OPRIONAL)

AVAILABLE OIL FILL TUBE LOCATION SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL) MAIN ELECTRICAL CONNECTOR

1000 / 2000 / 2400 SERIES™ TRANSMISSION – RIGHT-REAR VIEW Figure 1–2. 1000/2000/2400 Series Transmission — Right-Rear View

1–2

Copyright © 2003 General Motors Corp.

V04780.01.04

GENERAL INFORMATION

1

DIV. OF GENERAL MOTORS CORP. INDIANAPOLIS, INDIANA, USA

MODEL

DATE

XXXXXXXXXX XXXXX SERIAL NO.

EFCN

TID

XXXXXXXXXX XXXXXXXX XX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX

V06183

Figure 1–3. 1000/2000/2400 Series Transmission Nameplate Location

DIV. OF GENERAL MOTORS CORP. INDIANAPOLIS, INDIANA, USA

MODEL

DATE

XXXXXXXXXX XXXXX SERIAL NO.

EFCN

TID

XXXXXXXXXX XXXXXXXX XX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX V06533

Legend (1) (2) (3)

Model (Series) Date of Manufacture Engineering Feature Configuration Number

(4) (5) (6)

Transmission Identification Number Engineering Group Number Serial Number

Figure 1–4. 1000/2000/2400 Series Transmission Nameplate Components

Copyright © 2003 General Motors Corp.

1–3

1000/2000/2400 SERIES SERVICE MANUAL

D

AGR

ICULTURA

L

E ILE AEROSPAC OB

OM

UT

XXXXXXX

DA

EFCN

UNITE

XXXXXXXXXX

CA

XX

SERIAL NO.

ERI

TID

XXXXX

AM

DATE

XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX

OF

1000SERIES

WORKERS

MODEL

ENT

UAW 933

EM

DIVISION OF GENERAL MOTORS CORP. INDIANAPOLIS, INDIANA

IM

PL

AN

XX–XXXX XX–XXXX XX–XXXX XX–XXXX XX–XXXX

Legend (1) (2) (3)

Model (Series) Engineering Group Number Transmission Identification Number

(4) (5) (6)

Engineering Feature Configuration Number Serial Number Date of Manufacture

Figure 1–5. 1000/2000/2400 Series Transmission Nameplate Components

1–4.

GENERAL DESCRIPTION

a. Transmission Design Features. Allison 1000/ 2000/2400 Series transmissions (Figures 1–1 and 1–2) are torque-converter driven, fully automatic transmission systems. The 1000/2000/2400 Series transmissions have up to five forward speeds, neutral, and reverse. The fifth range has an overdrive gear ratio. The 1000/2000/2400 Series incorporates a variety of standard and optional design features.

1–4

higher speeds, the torque converter clutch (TCC) is automatically engaged to provide direct drive from the engine to the transmission. Hydraulic fluid for converter charging pressure comes from the sump and is supplied by the input pump. The torque converter clutch is applied or released by changing direction of fluid in the torque converter. An integral converter damper minimizes the need for additional engine vibration control.

1. Transmission-to-Engine Coupling. The converter housings of 1000/2000/2400 Series transmissions mate directly to SAE No. 2 or No. 3 flywheel housings or to the engine block in some cases. Flexplate drive is used for engine-to-transmission torque transfer.

3. Planetary Gearing. The planetary gear train includes three constant-mesh, helical gear planetary sets. By the engagement of the clutches in various combinations, the planetary sets act singly or together to provide five forward ranges, neutral, and reverse.

2. Torque Converter. Several torque converters are available to match the transmissions to a wide variety of diesel and gasoline engines. The torque converter is a single-stage, polyphase, three-element unit, consisting of a pump, stator, and turbine. At lower output speeds, the torque converter multiplies torque and provides a fluid coupling to the engine. At

4. Clutches. Five clutches (two rotating and three stationary) direct the flow of torque through the transmission. All range clutches are hydraulically-actuated and spring-released, with automatic wear compensation. Clutches are cooled by the transmission fluid. The transmission electronic control module signals solenoid valves to apply and release clutches based on

Copyright © 2003 General Motors Corp.

GENERAL INFORMATION speed and power combinations and the range selected by the operator.

transmission fluid to either water or air depending upon the cooler type used.

5. Hydraulic System. A common hydraulic system serves the torque converter and the transmission. Transmission fluid for all hydraulic operations, lubrication, and cooling comes from the sump and is supplied by the charging pump.

9. Oil Fill Tube/Dipstick Provisions. All 1000/ 2000/2400 Series models have a fill tube/ dipstick provision on both sides of the transmission. The fill tube and dipstick are OEM-installed and adapted as specified by the vehicle manufacturer. A plug is installed in the unused location.

6. Transmission Fluid Filtration. Fluid filtration is provided by two filter systems. A suction filter, located in the sump, provides general protection to the entire hydraulic system by filtering large particulates. A spin-on filter provides full-time protection for the control solenoids and multipass protection for the entire system. The spin-on filter is externally located on the converter housing at the lower left front of the transmission. 7. Electronic Controls • A microcomputer provides electronically-

controlled automatic gear selection and automatic engagement of the torque converter clutch. The microcomputer is an independent controller and is referred to as a Transmission Control Module, or TCM. • The electronic control system uses adaptive

logic to provide optimum shift quality. Driving efficiency is improved by shifting at the exact programmed transmission shift point for every engine/transmission/vehicle combination. The electronic controls can be customized for four-speed or five-speed operation to meet vocational requirements. 8. Remote Oil Cooler. Ports for remote-mount oil cooler lines are located on the bottom surface of the converter housing near the converter housing/main housing splitline or on the right side of the direct-mount converter housing. Remote oil-to-water coolers require plumbing for transmission fluid and engine-cooling water. Remote oil-to-air coolers may also be used and only transmission fluid lines need to be provided. Heat is transferred from the

10. Parking Pawl/Parking Brake • All 1000 Series™ and 2400 Series™

transmissions have a PARK pawl. The internal parking pawl is engaged by selection of the PARK position on the shift selector. The parking pawl is not available on 2000 Series™ models. • Some 1000/2000/2400 Series models are

available with an optional rear cover that accommodates an OEM-installed two-shoe, expanding-type drum brake. All parking brake controls and linkages are OEM-supplied. 11. Power Takeoff. The 1000/2000/2400 Series transmissions have a provision to mount and drive a power takeoff (PTO) unit on the left and/or right side of the transmission housing. The optional PTO drive gear is driven by the transmission torque converter turbine, with speed and torque reflecting engine input and characteristics of the torque converter. PTO units and associated controls are provided by the vehicle manufacturer and/or body builder. 12. Output Yokes/Flanges. A variety of output yokes or flanges are available to meet vehicle driveline requirements. Yokes or flanges are OEM-installed and are adapted as specified by the vehicle manufacturer.

WARNING! Operation with excessive loads can cause transmission damage and unexpected vehicle movement. To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg (26,000 lbs) GCW or the OEM vehicle rating, whichever is less.

Copyright © 2003 General Motors Corp.

1–5

1000/2000/2400 SERIES SERVICE MANUAL b. Model Nomenclature. Several transmission configurations are available within the 1000/2000/ 2400 Series. Models are identified as follows: 1000*

Heavy-duty automatic transmission with parking pawl Maximum GVW 22,000 lb (motor home only)

2000*

Maximum GVW 19,850 lb Maximum GCW 26,000 lb Heavy-duty automatic transmission without parking pawl

Maximum GVW 30,000 lb Maximum GCW 30,000 lb 2000MH* Heavy-duty automatic transmission without parking pawl Limited release in motor home applications only Maximum GVW 28,000 lb 2400*

Maximum GCW 28,000 lb Heavy-duty automatic transmission with parking pawl Maximum GVW 26,000 lb Maximum GCW 26,000 lb

*

GVW rating, GCW rating, or OEM axle rating, whichever is less.

NOTE: The CHECK ENGINE light may serve the CHECK TRANS function for vehicles which are compliant to industry On Board Diagnostics II (OBD-II) requirements. 3. When the CHECK TRANS light is “ON”, shifts may be restricted by the Transmission Control Module (TCM) as follows:

WARNING! If ignition is turned “OFF” and then “ON” while the CHECK TRANS light is displayed, the transmission may remain in neutral until the code is cleared. Leave ignition “ON” until you are in a safe place to stop. • When the TCM senses abnormal conditions. • The transmission may be locked in the range it

was in when the problem was detected. • The transmission may continue to operate with

inhibited shifting. • The TCM may not respond to shift selector

requests. • Direction changes and shifts from neutral-to-

1–5.

range may not occur.

DIAGNOSIS

• Whenever the CHECK TRANS light is

NOTE: Refer to the TS3192EN 1000/2000/2400 Series Troubleshooting Manual for in-depth troubleshooting procedures.

a. Before Starting. Before attempting to repair the transmission, the faulty condition and its probable cause should be identified.

displayed, the TCM logs a diagnostic code in memory. These diagnostic codes can be accessed through the PC-based Allison DOC™ diagnostic systems. NOTE: Diagnostic codes can be logged without illuminating the CHECK TRANS light. This occurs when the TCM senses a problem, but determines the problem won’t cause immediate transmission damage or dangerous performance.

b. CHECK TRANS Light 1. The CHECK TRANS light is original equipment manufacturer (OEM)-supplied and usually located on the vehicle’s instrument panel. 2. The CHECK TRANS light is illuminated briefly during vehicle start-up as a bulb check. 1–6

c. Range Inhibit Indicator 1. Some conditions detected by the TCM cause the transmission to be locked in one range. When this occurs, the torque converter clutch is automatically disengaged. Shifts out of N (Neutral) may be inhibited.

Copyright © 2003 General Motors Corp.

GENERAL INFORMATION 2. At the same time these events occur, a required OEM-supplied RANGE INHIBITED light, mounted on the dash or near the shift selector, is illuminated. This notifies the driver that shifting is inhibited and the shift selector may not respond to shifts requested. d. Personal Computer (PC)-Based Diagnostic System 1. Control system diagnostics are done using a “Windows” PC operating system and interface/ software which is available through Allison Transmission tool sources. The PC is a receiver/transmitter/display medium that allows the service technician to communicate with the TCM. Typical troubleshooting activities performed are installation checkout and diagnostic code retrieval. 2. Allison Diagnostic Optimized Connection™ (Allison DOC™) provides tabular, graphical, and chart displays of real-time and recorded TCM data. A Help system is incorporated into the Allison DOC™ software and a printed User Guide is shipped with each Allison DOC™ Installation CD-ROM. 3. The User Guide and User’s Manual contains information for performing the following: • Display (retrieve) diagnostic trouble codes

(DTCs). Transmission diagnostic codes begin with P0, P1, U1, or U2 followed immediately by three additional numbers. For a complete list of codes and more detailed information, refer to TS3192EN, Electronic Troubleshooting Manual. • Clear diagnostic codes • Obtain transmission data such as input

— Make sure batteries are properly connected and charged. — Make sure throttle is closed and engine speed is below 900 rpm. — Make sure electrical connections are properly made. — Check support equipment for proper installation and operation. • If the shifting process is rough, give the shifts

time to adapt to “converged” state before assuming there is a problem. • Refer to Section 7 “General Troubleshooting of

Performance Complaints” in the 1000/2000/2400 Series Troubleshooting Manual TS3192EN. — These troubleshooting charts list a variety of conditions that may or may not relate to the TCM. — Some conditions and suggested checks include mechanical and hydraulic items. • If the troubleshooting charts refer you to a

TCM check, use the diagnostic code troubleshooting information that best applies to the situation. f. Troubleshooting Intermittent Diagnostic Codes 1. Intermittent codes are a result of conditions which are not always present. 2. When conditions causing the code exist, the code is logged in memory. The code stays in memory until it is manually cleared or cycled out by forty code-free warm-up cycles. 3. When intermittently occurring codes exist, check for the following items:

speed or sump fluid temperature • Dirty, damaged or corroded harness

• A solenoid test

connectors and terminals

• Clutch diagnostics (including torque

converter clutch) e. Troubleshooting When No Diagnostic Codes Are Present

• Terminals not fully seated in connectors • Damaged harnesses (due to poor routing,

chafing, excessive heat, tight bends, etc.) • Improperly mounted electronic control

• Always start with the basics:

components

— Make sure the shifter is in the appropriate range.

• Poor connector seals (where applicable)

— Check the fluid level.

• Exposed harness wires Copyright © 2003 General Motors Corp.

1–7

1000/2000/2400 SERIES SERVICE MANUAL • EMI generating components and

accessories

assembly. • Repeat Steps (2) through (6).

• Loose ground connections

4. To help locate intermittents, it sometimes helps to place the appropriate tester on the suspect component or circuit and simulate operating conditions — wiggle, pull, bump, and bend while watching the tester.

1–6.

• Remove all tape from openings and the vent

PRESERVATION AND STORAGE

a. Storage (New Transmissions, Before Installation). New transmissions are filled with transmission fluid and drained before shipment. The residual fluid in the transmission provides adequate protection to safely store the transmission without further treatment for one full year if stored indoors, in conditions of normal climate, and with all shipping plugs installed. b. Preservation Methods. When the transmission is stored or inactive for an extended period (one or more years), specific preservation methods are required to prevent damage from rust, corrosion, and organic growth in the transmission fluid. Preservation methods described are for storage with or without transmission fluid. The methods are the same whether a transmission is in or out of a vehicle.

d. One Year Storage (With Fluid) 1. Drain the fluid and replace the oil filter elements. 2. Fill the transmission to operating level with a mixture of one part VCI #10 (or equivalent) to 30 parts TranSynd™ or DEXRON®-III transmission fluid. Add 3 ml of Biobor® JF (or equivalent) for every 10 liters (1⁄4 teaspoon per gallon) of fluid in the system. NOTE: When calculating the amount of Biobor® JF required, use the total volume of the system, not just the quantity required to fill the transmission. Include external lines, filters, and the cooler. 3. Operate the transmission for approximately five minutes at 1500 rpm with the transmission in neutral. 4. Make sure the transmission shifts through all ranges and that the lockup clutch is also activated. 5. Continue operating the transmission in neutral at 1500 rpm until normal operating temperature is reached.

c. One Year Storage (Without Fluid)

CAUTION:

1. Drain the fluid. 2. Remove the vent assembly per Paragraph 5–11f. 3. Spray 30 ml (one ounce) of VCI #10 (or equivalent) into the transmission through the vent assembly hole. Also, spray 30 ml (one ounce) through the fill tube hole. 4. Install the vent assembly per Paragraph 5–11f.

6. If normal operating temperature is less than 107°C (225°F), shift the transmission to forward range and stall the converter. Do not exceed 107°C (225°F).

5. Seal all openings and the vent assembly with moisture-proof tape.

7. As soon as the transmission is cool enough to touch, seal all openings and the vent assembly with moisture-proof tape.

6. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C11796, Class 2).

8. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C11796), Class 2.

7. If additional storage time is required, do the following at yearly intervals. • Wash all external grease from the

transmission with mineral spirits.

1–8

If the unit does not have a converter-out temperature gauge, do not stall the converter.

9. If additional storage time is required, repeat Steps 2 through 8 at yearly intervals, except, it is not necessary to drain the transmission each year. Just add VCI #10 and Biobor® JF (or equivalents).

Copyright © 2003 General Motors Corp.

GENERAL INFORMATION 1–7.

RESTORING TRANSMISSION TO SERVICE

a. Transmission Exterior. Wash all external grease from the transmission with mineral spirits.

Check for proper fluid level. Add or drain transmission fluid, as required, to obtain the proper level.

1–8.

OPERATING INSTRUCTIONS

b. Sealed Vent Assembly and Openings. Remove all tape from openings and the vent assembly. c. New Transmissions. If the transmission is new, drain the residual preservative oil. Refill the transmission to the proper level with DEXRON®-III. d. Stored Without Fluid. If the transmission was prepared for storage without fluid, drain the residual fluid and replace the oil filter elements. Refill the transmission to the proper level with DEXRON®-III or an Allison approved C-4 transmission fluid.

CAUTION: When a transmission has been stored, the TCM must be reset to unadapted shifts. Resetting to unadapted shifts erases previous shift adaptations and allows the transmission to begin using Fast Adaptive mode to regain adapted shifts. Use Allison DOC™ to reset to unadapted shifts. e. Stored With Fluid. If the transmission was prepared for storage with fluid, it is not necessary to drain and refill the transmission with new transmission fluid.

WARNING! Operation with excessive loads can cause transmission damage and unexpected vehicle movement. To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg (26,000 lbs) GCW or the OEM vehicle rating, whichever is less.

Detailed transmission operation information is in the 1000/2000/2400 Series Principles of Operation Manual, PO3065EN or 1000/2000/2400 Series Operator’s Manual, OM3063EN. Refer to the latest edition.

1–9.

SPECIFICATIONS AND DATA

The following specifications and data provide a quick reference to the major characteristics of the transmission. More detailed information may be obtained from Tech Data Book SA3018EN.

Copyright © 2003 General Motors Corp.

1–9

1000/2000/2400 SERIES SERVICE MANUAL Table 1–1. Specifications And Data Chart* INPUT/OUTPUT RATINGS (1000 SERIES™): General*** 4600 rpm 2200 rpm 900 rpm 500 rpm

Refuse (On-Highway) 4600 rpm 2200 rpm 900 rpm 500 rpm

Motor Home 4600 rpm 2200 rpm 900 rpm 500 rpm

Transit Bus 4600 rpm 2200 rpm 900 rpm 500 rpm

254 kW (340 hp)

254 kW (340 hp)

254 kW (340 hp)

134 kW (180 hp)

705 N·m (520 lb ft)

705 N·m (520 lb ft)

705 N·m (520 lb ft)

603 N·m (445 lb ft)

1152 N·m (850 lb ft)

1152 N·m (850 lb ft)

1152 N·m (850 lb ft)

1017 N·m (750 lb ft)

5000 rpm

5000 rpm

5000 rpm

5000 rpm

Gross Vehicle Weight (GVW)

9000 kg (19,850 lbs)

7500 kg (16,540 lbs)

9980 kg (22,000 lbs)

7500 kg (16,540 lbs)

Gross Combined Weight (GCW)

11 800 kg (26,000 lbs)

N/A

11 800 kg (26,000 lbs)

N/A

24 (38)

24 (38)

24 (38)

24 (38)

38 (62)

38 (62)

38 (62)

38 (62)

18.5 Degrees

18.5 Degrees

18.5 Degrees

18.5 Degrees

Input Speed** Max Full Load Gov. Speed Min Full Load Gov. Speed Max Idle Speed in Drive Min Idle Speed in Drive Input Power Maximum Net Input Torque Maximum Net Turbine Torque Maximum Net Output Shaft Speed Maximum Speed Other

Min Vehicle N/V Ratio Output rpm/kmph (Output rpm/mph) Max Vehicle N/V Ratio Output rpm/kmph (Output rpm/mph) Max Angular Rotation of Output Shaft After Static Apply of Park Provision

* All data and specifications are subject to change without notice. ** Engines with full load governed speed greater than 3800 rpm require Shift Energy Management (SEM) and additional calibration development. *** Includes truck, school buses, one-way rental trucks, and road sweepers. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

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Copyright © 2003 General Motors Corp.

GENERAL INFORMATION Table 1–1. Specifications And Data Chart* (cont’d) INPUT/OUTPUT RATINGS (2000 SERIES™ — All models except the 2000MH Series): Refuse Input Speed** General*** (On-Highway) Road Sweeper Max Full Load Gov Speed 4500 rpm 4500 rpm 4500 rpm Min Full Load Gov Speed 2200 rpm 2200 rpm 2200 rpm Max Idle Speed in Drive 900 rpm 900 rpm 900 rpm Min Idle Speed in Drive 500 rpm 500 rpm 500 rpm

Transit Bus 4500 rpm 2200 rpm 900 rpm 500 rpm

Input Power 224 kW (300 hp)

224 kW (300 hp)

224 kW (300 hp)

134 kW (180 hp)

705 N·m (520 lb ft)

705 N·m (520 lb ft)

705 N·m (520 lb ft)

603 N·m (445 lb ft)

1152 N·m (850 lb ft)

1152 N·m (850 lb ft)

1152 N·m (850 lb ft)

1017 N·m (750 lb ft)

4500 rpm

4500 rpm

4500 rpm

4500 rpm

Gross Vehicle Weight (GVW)

13 600 kg (30,000 lbs)

10 550 kg (23,250 lbs)

14 515 kg (32,000 lbs)

12 000 kg (26,500 lbs)

Gross Combined Weight (GCW)

13 600 kg (30,000 lbs)

N/A

N/A

N/A

Min Vehicle N/V Ratio*** Output rpm/kmph (Output rpm/mph)

24 (38)

24 (38)

24 (38)

24 (38)

Max Vehicle N/V Ratio*** Output rpm/kmph (Output rpm/mph)

38 (62)

38 (62)

38 (62)

38 (62)

Maximum Net Input Torque Maximum Net Turbine Torque Maximum Net Output Shaft Speed Maximum Speed Other

* All data and specifications are subject to change without notice. ** Engines with full load governed speed greater than 3800 rpm require Shift Energy Management (SEM) and additional calibration development. *** Includes truck, school buses, one-way rental trucks, and road sweepers. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

Copyright © 2003 General Motors Corp.

1–11

1000/2000/2400 SERIES SERVICE MANUAL Table 1–1. Specifications And Data Chart* (cont’d) INPUT/OUTPUT RATINGS (2000MH SERIES): Input Speed Motor Home Max Full Load Gov Speed 2800 rpm Min Full Load Gov Speed 2200 rpm Max Idle Speed in Drive 900 rpm Min Idle Speed in Drive 500 rpm Input Power Maximum Net

205 kW (275 hp)

Input Torque Maximum Net

813 N·m*** (600 lb ft)

Turbine Torque Maximum Net Output Shaft Speed Maximum Speed

1152 N·m (850 lb ft) 4500 rpm

Other Gross Vehicle Weight (GVW)

12 700 kg (28,000 lbs)

Gross Combined Weight (GCW)

12 700 kg (28,000 lbs)

Min Vehicle N/V Ratio** Output rpm/kmph (Output rpm/mph)

24 (38)

Max Vehicle N/V Ratio** Output rpm/kmph (Output rpm/mph)

38 (62)

* All data and specifications are subject to change without notice. ** Min/Max N/V ratio values for the 2000 Series™ are guidelines only. *** With Shift Energy Management. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

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Copyright © 2003 General Motors Corp.

GENERAL INFORMATION Table 1–1. Specifications And Data Chart* (cont’d) INPUT/OUTPUT RATINGS (2400 SERIES™): General*** 4500 rpm 2200 rpm 900 rpm 500 rpm

Refuse (On-Highway) 4500 rpm 2200 rpm 900 rpm 500 rpm

Transit Bus 4500 rpm 2200 rpm 900 rpm 500 rpm

224 kW (300 hp)

224 kW (300 hp)

134 kW (180 hp)

705 N·m (520 lb ft)

705 N·m (520 lb ft)

603 N·m (445 lb ft)

1152 N·m (850 lb ft)

1152 N·m (850 lb ft)

1017 N·m (750 lb ft)

4500 rpm

4500 rpm

4500 rpm

Gross Vehicle Weight (GVW)

11 800 kg (26,000 lbs)

10 550 kg (23,250 lbs)

11 800 kg (26,000 lbs)

Gross Combined Weight (GCW)

11 800 kg (26,000 lbs)

N/A

N/A

Min Vehicle N/V Ratio Output rpm/kmph (Output rpm/mph)

24 (38)

24 (38)

24 (38)

Max Vehicle N/V Ratio Output rpm/kmph (Output rpm/mph)

38 (62)

38 (62)

38 (62)

18.5 Degrees

18.5 Degrees

18.5 Degrees

Input Speed** Max Full Load Gov Speed Min Full Load Gov Speed Max Idle Speed in Drive Min Idle Speed in Drive Input Power Maximum Net Input Torque Maximum Net Turbine Torque Maximum Net Output Shaft Speed Maximum Speed Other

Max Angular Rotation of Output Shaft After Static Apply of Park Provision

* All data and specifications are subject to change without notice. ** Engines with full load governed speed greater than 3800 rpm require Shift Energy Management (SEM) and additional calibration development. *** Includes truck, school buses, one-way rental trucks, and road sweepers. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

Copyright © 2003 General Motors Corp.

1–13

1000/2000/2400 SERIES SERVICE MANUAL Table 1–1. Specifications And Data Chart* (cont’d) MAIN PRESSURE SCHEDULES✝: Pressure During Normal Operation Main Pressure @ 600 rpm Forward/Rev Converter w/ G solenoid active

Main Pressure @ 2100 rpm

590–720 kPa (85–105 psi)

634–758 kPa (92–110 psi)

700–1380 kPa (101–200 psi)

1515–1795 kPa (220–260 psi)

*Forward Lock-up w/G active

N/A

510–627 kPa (74–91psi)

Forward Lock-up w/G inactive

N/A

1000–1170 kPa (145–170 psi)

590–720 kPa (85–105 psi)

N/A

800–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi)

Forward Converter w/ G inactive

Neutral/ Park w/G solenoid active Neutral/Park

✝ With modulated main pressure. Refer to Table 2–5 Main pressure Test Conditions for main pressure schedules for transmissions prior to and starting with S/N 6310004116. * Medium duty gasoline engines only.

FITTINGS — METRIC AND ENGLISH: The cooler ports and main pressure tap are the only non-metric fittings on the transmission. DRY WEIGHTS:

1000 Series™ 150 kg (330 lb)

2000 Series™ 150 kg (330 lb)

2400 Series™ 150 kg (330 lb)

DRIVE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flexplate

DRIVE RANGE AND SHIFT CONTROL: . . . . . . . . . . . .

Mechanical (external)

ROTATION (viewed from input): Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise

Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise

CLUTCHES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil-cooled, hydraulically-actuated, springreleased, self-compensating for wear

* All data and specifications are subject to change without notice. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

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Copyright © 2003 General Motors Corp.

GENERAL INFORMATION Table 1–1. Specifications And Data Chart* (cont’d) DRIVE RANGE AND SEQUENCES — ALL 1000 AND 2400 MODELS: Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 3 (Third) 1 (First)

Range Neutral† Reverse Neutral 1–5 1–4 1–3 1

Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 2 (Second) 1 (First)

Range Neutral† Reverse Neutral 1–5 1–4 1–2 1

Shift Selector Position P (Park) R (Reverse) N (Neutral) D (Drive) 3 (Third) 2 (Second) 1 (First)

Range Neutral† Reverse Neutral 1–5 (1–4)†† 1–3 1–2 1

† with Park Pawl engaged †† 1–4 in Trailering Mode or 4 Speed Calibration

DRIVE RANGE AND SEQUENCES — ALL 2000 MODELS WITH AUTO-APPLY PARKING BRAKE: Shift Selector Position PB (Auto-Apply Parking Brake) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 3 (Third) 1 (First)

Range Neutral† Reverse Neutral 1–5 1–4 1–3 1

Shift Selector Position PB (Auto-Apply Parking Brake) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 2 (Second) 1 (First)

Range Neutral† Reverse Neutral 1–5 1–4 1–2 1

Shift Selector Position PB (Auto-Apply Parking Brake) R (Reverse) N (Neutral) D (Drive) 3 (Third) 2 (Second) 1 (First)

Range Neutral† Reverse Neutral 1–5 (1–4)†† 1–3 1–2 1

† with Auto-Apply Parking Brake engaged †† 1–4 in Trailering Mode or 4 Speed Calibration

DRIVE RANGE AND SEQUENCES — ALL 2000 MODELS WITHOUT AUTO-APPLY PARKING BRAKE: Shift Selector Position R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 3 (Third) 1 (First)

Range Reverse Neutral 1–5 1–4 1–3 1

Shift Selector Position R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 2 (Second) 1 (First)

Range Reverse Neutral 1–5 1–4 1–2 1

Shift Selector Position R (Reverse) N (Neutral) D (Drive) 3 (Third) 2 (Second) 1 (First)

Range Reverse Neutral 1–5 (1–4)†† 1–3 1–2 1

†† 1–4 in Trailering Mode or 4 Speed Calibration

* All data and specifications are subject to change without notice.

Copyright © 2003 General Motors Corp.

1–15

1000/2000/2400 SERIES SERVICE MANUAL Table 1–1. Specifications And Data Chart* (cont’d) GEAR DATA: Type . . . . . . . . . . . . . . . . Range First Second Third Fourth Fifth Reverse

Planetary, constant mesh, helical 1000 Series™*** 3.10:1 1.81:1 1.41:1 1.00:1 0.71:1 –4.49:1

2000 Series™*** 3.51:1 1.90:1 1.44:1 1.00:1 0.74:1 –5.09:1

2400 Series™*** 3.51:1 1.90:1 1.44:1 1.00:1 0.74:1 –5.09:1

*** The ratios shown do not include the torque multiplication characteristics of the transmission torque converter.

HYDRAULIC SYSTEM: 2000MH Series models must use a TES-295 fluid such as TranSynd™; all other models may use TranSynd™ or DEXRON®-III. Filters . . . . . . . . . . . . . . . Internal suction filter in the sump; Control main spin-on multipass filter externally mounted to the converter housing. Temperature Oil Temperature Limits . . . . . . . . . . . . . . Location Limit –27C (–17ºF) Minimum Start-up, DEXRON®-III Minimum start-up, TranSynd™ –30ºC (–22ºF) Minimum continuous sump 40ºC (100ºF) Typical continuous sump 93ºC (200ºF) Maximum intermittent sump 121ºC (250ºF) Typical continuous converter-out 121ºC (250ºF) Maximum intermittent converter-out 149ºC (300ºF)

Fluid type . . . . . . . . . . . .

Initial Transmission Fill Quantities (Transmission Only)**

Refill Transmission Fill Quantities (Transmission Only)**

Sump

Fill Quantity

Standard

14 liters (15 qts)

Shallow

12 liters (13 qts)

Sump Standard Shallow

Fill Quantity 10 liters (10.5 qts) 7 liters (7.5 qts)

* All data and specifications are subject to change without notice. ** Quantities are approximate and do not include external lines and cooler hose. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

1–16

Copyright © 2003 General Motors Corp.

GENERAL INFORMATION Table 1–1. Specifications And Data Chart* (cont’d) OPERATIONAL EQUIPMENT: Engine Adaptation . . . . . . . . . . . . . . . . .

Adaptation 1000 2000 2400 X X X SAE No. 2 X X X SAE No. 3 X Direct Mount Throttle Position Input Signal . . . . . . . . . . . . . . . . . . . . . . . . Throttle position sensor Pulse-width-modulated (PWM) signal Throttle position signal from an SAE J1850 or SAE J1939 serial communication link Range Shift Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable, air actuation, electric, electronic Output Yokes and Flanges (customer supplied) . . . . . . . . . . . 1000/2000 2WD/Fixed yoke 2WD/Slip yoke 4WD/Slide together

REGULATION EQUIPMENT: Tachograph Provision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start/ Back-Up Switch (NSBU) Parking Brake (customer supplied) . . . . . . . . . . . . . . . . . . . .

6 tooth tone wheel 9 inch x 3 inch; 10 inch x 3 inch

ASSOCIATED EQUIPMENT: POWER TAKEOFFS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine Driven Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional for 1000/2000/2400 Series Pad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 6 Bolt Pad Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:00 and 9:00 Power Takeoff Drive Gear Ratings: Transmission Configuration Rating With PTO on One Side 339 N·m (250 lb ft) With PTO on Both Sides — Each 271 N·m (200 lb ft) TORQUE CONVERTERS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One stage, three element, polyphase Stall torque ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC210–2.05:1; TC211–2.00:1; TC221–1.73:1; TC222–1.58:1 PARK PAWL Maximum GVW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 818 kg (26,000 lb) Static Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4067 N·m (3000 ft lb) Disengagement Effort at Static Capacity . . . . . . . . . . . . . . . . <34 N•m (<25 ft lb) Impact Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 kph (2.5 mph) Engagement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6–4.8 kph (1–3 mph) during deceleration N/V Range** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–38 output rpm/kmph (38–62 output rpm/mph) Maximum Vehicle Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm (5.91 inches) when engaged on a 10 percent grade * All data and specifications are subject to change without notice. ** Min/Max N/V ratio values for the 2000 Series™ are guidelines only. NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not necessarily equivalent.

Copyright © 2003 General Motors Corp.

1–17

1000/2000/2400 SERIES SERVICE MANUAL 1–10. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic systems. Allison Transmission electronic transmission controls comply with Federal Communications Commission (FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation electronics. The position of Allison Transmission Division of General Motors is that manufacturers and installers of Electromagnetic Interference (EMI)/Radio Frequency Interference (RFI) emitting equipment are responsible for adhering to FCC regulations and other guidelines

1–18

concerning emitted radio frequency interference for transportation electronics. Some radio-telephone or two-way communication radios (land-mobile radio), or the manner in which they are installed, can adversely affect vehicle operation or be affected by other vehicle components. Expenses incurred to protect vehicle-related systems from EMI/ RFI emissions by radio-telephone or two-way communications radios (land-mobile radio) or to integrate such devices into vehicles are not the responsibility of Allison Transmission. Refer to the latest edition of the TS3192EN 1000/ 2000/2400 Series Troubleshooting Manual for detailed instructions regarding EMI problems.

Copyright © 2003 General Motors Corp.

SECTION 2 — PREVENTIVE MAINTENANCE 2–1.

SCOPE

Proper care and regular maintenance enables the transmission to meet its duty requirements. Perform the maintenance procedures described in this section on a regular basis to prevent premature transmission or support equipment failure. Allison transmissions are manufactured to provide long term, efficient service in their designed applications.

2–2.

PERIODIC INSPECTIONS AND CARE

a. Transmission Inspection

CAUTION: When cleaning the transmission, do not spray steam, water, or cleaning solution directly at the vent assembly. Spraying steam, water, or cleaning solution at the vent assembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid. Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of these inspections. Inspect the transmission for:

b. Vehicle Inspection. Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler. c. Welding

CAUTION: When welding on the vehicle: • DO NOT WELD on the vehicle without disconnecting from the TCM all control system wiring harness connectors. • DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads. • DO NOT WELD on any control components. DO NOT CONNECT welding cables to any control components.

A label describing on-vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place. A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on-vehicle welding label (ST2067EN).

• loose bolts—transmission and mounting • • • • • • •

components fluid leaks—repair immediately loose, dirty, or improperly adjusted throttle sensor or shift selector linkage damaged or loose hoses worn, frayed, or improperly routed electrical harnesses worn or frayed electrical connections dented, worn, or out-of-phase driveline U-joints and slip fittings clogged or dirty vent assembly

2–3.

IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL

Transmission fluid cools, lubricates, and transmits hydraulic power. Always maintain proper fluid level. If fluid level is too low, the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats. If the level is too high, the fluid aerates—causing the transmission to shift erratically and overheat. Fluid may be expelled through the vent assembly or dipstick tube when the fluid level is too high.

Copyright © 2003 General Motors Corp.

2–1

1000/2000/2400 SERIES SERVICE MANUAL 2–4.

TRANSMISSION FLUID CHECK

WARNING! For vehicles containing 1000 and 2400 models, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the P (Park) range by slowly releasing the service brake. • Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.

WARNING! For vehicles containing 2000 models with autoapply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Park-

ing Brake). Make sure that the parking brake is properly engaged.

WARNING! For vehicles containing 2000 models without auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brake and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. NOTE: Be sure that the fill tube and dipstick meet Allison Transmission specifications. Requirements for the standard oil pan are shown in Figure 2–1 and requirements for the shallow oil pan are shown in Figure 2–2. Refer to Tech Data Book SA3018EN for relevant AS drawings. When checking a long dipstick calibration: • Be sure the dipstick contacts the oil pan surface as shown in Figures 2–1 and 2–2. • Take measurements from the end of the dipstick. When checking a short dipstick calibration: • Remove the oil pan. • Take measurements from the oil pan splitline.

• Apply the emergency brake, if present, and

make sure it is properly engaged. • If the operator’s station will be unoccupied

with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.

2–2

a. Fluid Check Procedure. Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using the following procedure and report any abnormal fluid levels to your maintenance persons.

Copyright © 2003 General Motors Corp.

PREVENTIVE MAINTENANCE 5.0 mm (0.20 in)

TRANSMISSION CENTERLINE

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

TRANSMISSION CENTERLINE

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in)

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

HOT RUN

5.0 mm (0.20 in)

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in) HOT RUN

TYPICAL COLD CHECK BAND

TYPICAL COLD CHECK BAND

101.9 mm (4.01 in) Dipstick must contact oil pan

LONG FILL TUBE AND DIPSTICK* *Check measurements from end of dipstick

SHORT FILL TUBE AND DIPSTICK V05803

Figure 2–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)

5.0 mm (0.20 in)

TRANSMISSION CENTERLINE

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

TRANSMISSION CENTERLINE

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in) HOT RUN

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

5.0 mm (0.20 in)

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in)

TYPICAL COLD CHECK BAND

HOT RUN

TYPICAL COLD CHECK BAND

88.5 mm (3.48 in) Dipstick must contact oil pan

LONG FILL TUBE AND DIPSTICK* *Check measurements from end of dipstick

SHORT FILL TUBE AND DIPSTICK V05804

Figure 2–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)

Copyright © 2003 General Motors Corp.

2–3

1000/2000/2400 SERIES SERVICE MANUAL b. Cold Check Procedure. The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made.

CAUTION:

the hydraulic system. Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly release the service brakes. • With the engine running, remove the dipstick

The fluid level rises as fluid temperature increases. DO NOT fill above the “COLD CHECK” band if the transmission fluid is below normal operating temperatures.

from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove.

Check the fluid level reading. Repeat the check procedure to verify the reading. • If the fluid level is within the “COLD CHECK”

• Park vehicles containing 1000 and 2400 models

as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in P (Park). — Engage the P (Park) range by slowly releasing the service brake. — Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • Park vehicles containing 2000 models with auto-

apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged. • Park vehicles containing 2000 models without

auto-apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in N (Neutral). — Apply the emergency brake and/or parking brake and make sure they are properly engaged. • Chock the wheels and take any other steps

necessary to keep the vehicle from moving. • Run the engine for at least one minute. Apply

the service brakes and shift to D (Drive), then to N (Neutral), and then shift to R (Reverse) to fill 2–4

band, the transmission may be operated until the fluid is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band. • Perform a hot check at the first opportunity

after the normal operating sump temperature of 71˚C–93˚C (160˚F–200˚F) is reached. c. Hot Check Procedure

CAUTION: The fluid must be hot for an accurate check. The fluid level rises as temperature increases. • Operate the transmission in D (Drive) range until

normal operating temperature is reached: — Sump temperature 71˚C–93˚C (160˚F–200˚F) — Converter-out temperature 82˚C–104˚C (180˚F–220˚F) — If a transmission temperature gauge is not present, check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour. • Park vehicles containing 1000 and 2400 models

as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in P (Park). — Engage the P (Park) range by slowly releasing the service brake. — Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged.

Copyright © 2003 General Motors Corp.

PREVENTIVE MAINTENANCE • Park vehicles containing 2000 models with auto-

apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged. • Park vehicles containing 2000 models without

2–5.

KEEPING FLUID CLEAN

Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay the dipstick in a clean place while filling the transmission.

CAUTION: Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause the clutch plates to fail.

auto-apply parking brakes as follows:

2–6.

— Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure the engine is at low idle rpm. — Put the transmission in N (Neutral). — Apply the emergency brake and/or parking brake and make sure they are properly engaged.

Hydraulic fluids (oils) used in the transmission are important influences on transmission performance, reliability, and durability. Only TranSynd™ or a TES-295 fluid is acceptable for use in the 2000MH transmissions. For all other models, only fluids meeting DEXRON®-III specifications are acceptable. TranSynd™ fluids fully meet the DEXRON®-III specifications.

• Chock the wheels and take any other steps

necessary to keep the vehicle from moving. • With the engine running, remove the dipstick

from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove.

Check fluid level reading. Repeat the check procedure to verify the reading. NOTE: Safe operating level is within the “HOT RUN” band on the dipstick. See Figures 2–1 and 2–2. The width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal operating sump temperature. • If the fluid level is not within the “HOT RUN”

band, add or drain as necessary to bring the fluid level to within the “HOT RUN” band. d. Consistency of Readings. Always check the fluid level at least twice using the procedure described above. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer.

FLUID RECOMMENDATIONS

To make sure the fluid is qualified for use in Allison transmissions, check for a DEXRON®-III fluid license or approval numbers on the container, or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types.

CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life.

When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or geographical location must be taken into consideration. Table 2–1 lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) for a minimum of 20 minutes before attempting range operation. Table 2–1. Transmission Fluid Operating Temperature Requirements

Viscosity Grade DEXRON®-III TranSynd™

Copyright © 2003 General Motors Corp.

Ambient Temperature Below Which Preheat is Required Celsius Fahrenheit –27 –17 –30 –22 (Ref. SIL 13-TR-90)

2–5

1000/2000/2400 SERIES SERVICE MANUAL 2–7.

TRANSMISSION FLUID AND FILTER CHANGE INTERVALS

CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. More frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating. a. Frequency. Table 2–3 is given only as a general guide for fluid and filter change interval. b. Abnormal Conditions. Transmissions used in high cycle rate applications should use fluid analysis to be certain that a proper fluid change interval is established. Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor, or by fluid analysis. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. c. Fluid Analysis. Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 2–2. Fluid oxidation can be monitored through a fluid analysis firm or by using an oil analysis kit.

• Oil analysis kits, part number 29537805, are

available through your Transmission parts source.

normal

Allison

Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information. Table 2–2. Fluid Oxidation Measurement Limits Test

Limit

Viscosity

±25% change from new fluid

Total Acid Number

+3.0* change from new fluid

Water

0.2% by volume maximum

* mg of KOH required to neutralize a gram of fluid.

d. Fluid and Filter Change Intervals. Change the control main filter at the first 8000 km (5000 miles) then follow the appropriate schedule in Table 2–3.

2–8.

TRANSMISSION FLUID CONTAMINATION

a. Fluid Examination. At each fluid change, examine the drained fluid for evidence of excessive dirt or water. A normal amount of condensation will appear in the fluid during operation. b. Water. Obvious water contamination of the transmission fluid or transmission fluid in the cooler water (in heat exchanger) indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers.

• Fluid analysis firms—Consult your local

telephone directory for fluid analysis firms. For consistent and accurate fluid analysis, use only one fluid analysis firm. Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information.

2–6

NOTE: Cooler water can also be contaminated by engine oil; be sure to locate the correct source of cooler water contamination.

Copyright © 2003 General Motors Corp.

Lube/Auxiliary 25,000 Miles (40 000 km) 12 Months

Fluid 50,000 Miles (80 000 km) 24 Months

GENERAL VOCATION Filters Control Main Internal 50,000 Miles Overhaul (80 000 km) 24 Months

Lube/Auxiliary 50,000 Miles (80 000 km) 24 Months

Copyright © 2003 General Motors Corp.

Lube/Auxiliary 50,000 Miles (80 000 km) 24 Months

Fluid 100,000 Miles (160 000 km) 48 Months

GENERAL VOCATION Filters Control Main Internal Overhaul 50,000 Miles (80 000 km) 24 Months

NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first. Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and 2000MH models. General Vocation: All other vocations.

Fluid 50,000 Miles (80 000 km) 24 Months

SEVERE VOCATION Filters Control Main Internal Overhaul 50,000 Miles (80 000 km) 24 Months

Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)

Lube/Auxiliary 50,000 Miles (80 000 km) 24 Months

Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of 100 percent of the used fluid. Recommendations in Schedule 2 are based upon standard Allison fluid change procedures.

NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd™ fluid. For transmissions that contain a mixture of TranSynd™ and non-TranSynd™ fluids, refer to Schedule 3.

Fluid 25,000 Miles (40 000 km) 12 Months

SEVERE VOCATION Filters Control Main Internal 25,000 Miles Overhaul (40 000 km) 12 Months

Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)

1000/2000/2400/2000MH Series

Table 2–3. Transmission Fluid and Filter Change

PREVENTIVE MAINTENANCE

2–7

2–8

Fluid 50,000 Miles (80 000 km) 24 Months

Lube/Auxiliary 50,000 Miles (80 000 km) 24 Months

Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd™ that is required to fill the transmission to the proper level. A mixture of TranSynd™ or TES 295 equivalent vs. nonTranSynd™ other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3.

Lube/Auxiliary 25,000 Miles (40 000 km) 12 Months

GENERAL VOCATION Filters Control Main Internal 50,000 Miles Overhaul (80 000 km) 24 Months

Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. Filters must be changed at or before recommended intervals.

Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and 2000MH models. General Vocation: All other vocations.

NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.

*

Fluid 25,000 Miles (40 000 km) 12 Months

SEVERE VOCATION Filters Control Main Internal 25,000 Miles Overhaul (40 000 km) 12 Months

Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd™ and Non-TranSynd™ Fluids

1000/2000/2400/2000MH Series

Table 2–3. Transmission Fluid and Filter Change (cont’d)

1000/2000/2400 SERIES SERVICE MANUAL

Copyright © 2003 General Motors Corp.

PREVENTIVE MAINTENANCE c. Engine Coolant

• Remove the drain plug from the oil pan and al-

CAUTION:

• Examine the fluid as described in Paragraph 2–8.

low the fluid to drain into a suitable container. Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious damage. Completely disassemble, inspect, and clean the transmission. Remove all traces of the coolant, and varnish deposits resulting from engine coolant contamination. Replace the torque converter, all seals, gaskets, bearings, friction clutch plates, solenoids, and all rusted parts. d. Flush Oil Cooler. Transmission failures can cause the oil cooler to become restricted or plugged. Flush the oil cooler whenever the transmission is removed for repair. Using the J 46550 Transmission Cooler Flush Cart or an approved flushing device that can perform the following: 1. Flow clean transmission fluid through the cooler and hoses in the opposite direction of normal flow. Use a minimum pulsating flow rate of 0.5 liter/sec (8.0 gpm), at 275–345 kPa (40–50 psi). Flush the cooler and hoses thoroughly to remove all contaminated fluid. 2. After thoroughly flushing contaminated fluid, circulate clean transmission fluid through the cooler in a closed loop that includes a 10 micron filter. 3. Circulate clean transmission fluid through the filter for 5 minuets or more, the longer the filtering process the cleaner the fluid. 4. Determine the pressure drop in the external cooler. 5. If the pressure drop is above specification, the cooler has excessive trapped particles and must be repaired or replaced.

2–9.

TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE

a. Drain Fluid

b. Replace Control-Main Filter (Figure 2–3) 1. Remove the control-main filter by rotating it in the counterclockwise direction. Use a standard strap-type filter wrench or the J 45023. 2. Remove the magnet from the filter attachment tube or from the top of the filter element. 3. Clean any metal debris from the magnet. Report any metal pieces larger than dust to your maintenance personnel. 4. Reinstall the magnet onto the filter attachment tube. 5. Lubricate the gasket on the control-main filter with transmission fluid. 6. Install, by hand, the control-main filter until the gasket on the control-main filter touches the converter housing or cooler manifold.

CAUTION: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter. 7. Using the J 45023 or by hand, turn the filter ONE FULL TURN ONLY after gasket contact. 8. Reinstall the drain plug and sealing washer. Tighten the drain plug to 30–40 N·m (22– 30 lb ft). c. Refill Transmission. The amount of refill fluid is less than the amount used for the initial fill. Fluid remains in the external circuits and transmission cavities after draining the transmission. After refill, check the fluid level using the procedure described in Paragraph 2–4. Table 2–4. Transmission Fluid Capacity Initial Fill* Transmission

• Drain the fluid when the transmission is at nor-

mal operating sump temperature—71˚C–93˚C (160˚F–200˚F). Hot fluid flows quicker and drains more completely.

1000/2000/2400

Sump

Liters Qts

Refill* Liters

Qts

Standard

14

14.8

10

10.6

Shallow

12

12.7

7

7.4

* Approximate quantities, do not include external lines and cooler hose.

Copyright © 2003 General Motors Corp.

2–9

1000/2000/2400 SERIES SERVICE MANUAL

MAGNET FILTER

V06694.01.00

Figure 2–3. Control-Main Filter

2–10. VENT ASSEMBLY

stand) preparation, recording of data, and comparing recorded data against specifications provided.

a. Location and Purpose. The vent assembly is located at the top left-rear of the transmission main housing. The vent assembly prevents air pressure buildup within the transmission and its passage must be kept clean and open. b. Maintenance. The amount of dust and dirt encountered will determine the frequency of vent assembly cleaning. Use care when cleaning the transmission.

CAUTION: When cleaning the transmission, do not spray steam, water, or cleaning solution directly at the vent assembly. Spraying steam, water, or cleaning solution at the vent assembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid.

2–11. MAIN PRESSURE CHECK PROCEDURE Checking main pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical problem. Properly making these pressure checks requires transmission and vehicle (or test 2–10

WARNING! Observe safety precautions during hydraulic pressure check procedures. All personnel must stand clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges (vacuum, pressure, tachometer) have extended lines so that they can be read from inside the vehicle. 1. All transmission fluid checks must be made temperatures 71–93ºC 82–104ºC (180–220ºF) transmission fluid level.

level and pressure at normal operating (160–200ºF) sump; converter-out. Check

2. Connect a 0–300 psi (0–2070 kPa), 0.4375-20 UNF-2B inch series oil pressure gauge at the main pressure tap (Figure 2–4). Use Allison DOC™ to check engine rpm. See Table 2–5 for main pressure levels. 3. Disconnect the driveshaft. 4. With brakes applied, check main pressure with the engine running at 2100 rpm and 600 rpm. 5. Continue the procedure for all ranges.

Copyright © 2003 General Motors Corp.

PREVENTIVE MAINTENANCE MAIN PRESSURE TAP

BOTTOM VIEW V05742

Figure 2–4. Main Pressure Check Point

Table 2–5. Main Pressure Test Conditions Range Forward (Converter) Forward (Torque Converter Clutch Applied) Reverse Neutral/Park

Range Forward (Converter) Forward (Torque Converter Clutch Applied) Reverse Neutral/Park

(Used Prior To S/N 6310004116) Main Pressure @ 600 rpm 800–1380 kPa (115–200 psi)

Main Pressure @ 2100 rpm 1515–1795 kPa (220–260 psi)

—

1000–1170 kPa (145–170 psi)

800–1380 kPa (115–200 psi) 900–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi) 1515–1795 kPa (220–260 psi)

(Used Starting With S/N 6310004116) Main Pressure @ 600 rpm 700–1280 kPa (101–186 psi)

Main Pressure @ 2100 rpm 1515–1795 kPa (220–260 psi)

—

1000–1170 kPa (145–170 psi)

700–1280 kPa (101–186 psi) 800–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi) 1515–1795 kPa (220–260 psi)

(Transmissions with Modulated Main “G” solenoid) Main Pressure @ 600 rpm Main Pressure @ 2100 rpm Forward/Rev Converter w/ G 590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi) solenoid active Forward Converter w/ G inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi) *Forward Lock-up w/G active N/A 510–627 kPa (74–91psi) Forward Lock-up w/G inactive N/A 1000–1170 kPa (145–170 psi) Neutral/ Park w/G solenoid active 590–720 kPa (85–105 psi) N/A Neutral/Park 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi) * Medium duty gasoline engines only.

Copyright © 2003 General Motors Corp.

2–11

1000/2000/2400 SERIES SERVICE MANUAL 2–12.

TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK

a. Purpose. When a vehicle is performing unsatisfactorily, use the stall test to determine if the malfunction is in the engine or in the transmission. The neutral cooldown check uses a two minute cooling period after the stall to gather fluid temperature data for troubleshooting. NOTE: The stall test should only be performed by a qualified service technician.

NOTE: The engine manufacturer’s test data must be available for the stall test. This data can be obtained from the engine manufacturer or from the equipment dealer or distributor or from SCAAN. • The engine stall rpm under load is compared to

the engine manufacturer’s specified rpm for the stall test.

CAUTION: DO NOT conduct a stall test in R (Reverse) range. The torque produced in reverse range can damage the vehicle driveline or axle.

CAUTION: The stall condition causes a rapid rise in fluid temperature; never maintain the stall for more than 30 seconds at any one time. Do not let the converterout fluid temperature exceed 149˚C (300˚F). During stall conditions, converter-out temperatures rise much faster than internal temperatures. Do not use internal fluid temperature to determine the length of the stall condition. If the stall test is repeated, do not let the engine overheat. • Shift the transmission into a forward range. • With the vehicle blocked and wheels chocked,

parking and service brakes applied, hold the engine at wide-open throttle and record the maximum engine speed reached. This is the stall speed. • Reduce engine rpm to idle and shift to

N (Neutral).

NOTE: Allison DOC™ can read sump temperature to show when normal operating temperatures have been reached and the temperature has stabilized.

• Raise engine speed to 1200–1500 rpm for 2–3

minutes to allow the transmission to cool down. • Monitor converter-out temperature.

• Connect a tachometer (Allison DOC™ can read

engine rpm) of known accuracy to the engine and install a temperature probe into the converter-out (to cooler) hose. Bring the transmission to the normal operating temperature range of 71˚C–93˚C (160˚F–200˚F).

WARNING! To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in P (Park) or N (Neutral)…and • Apply the parking brake and service brake…and • Chock the vehicle wheels and take any other steps necessary to keep the vehicle from moving…and • Warn personnel to keep clear of the vehicle and its path. 2–12

b. Stall Test Results NOTE: Environmental conditions, such as ambient temperature, altitude, engine accessory loss variations, etc., affect the power input to the converter. Under such conditions, stall speed can vary from specification by ±150 rpm and still be accepted as within normal range. • If engine stall speed is more than 150 rpm be-

low the stall speed specified by the engine manufacturer, an engine problem is indicated. If engine stall speed is more than 150 rpm above specification, a transmission problem is indicated, such as slipping clutches, cavitation, aeration, or torque converter failure.

Copyright © 2003 General Motors Corp.

PREVENTIVE MAINTENANCE • An extremely low stall speed (such as 33 per-

cent of the specified engine stall rpm), during which the engine does not smoke, could indicate a freewheeling stator in the converter. • Perform a neutral cool-down check if engine stall-speed tests meet specifications, but cause the transmission fluid to overheat. • If the engine stall speed meets the specification and the cool-down check shows that transmission fluid cools properly, an electronic control problem may exist. Refer to the 1000/2000/ 2400 Series Electronic Control Troubleshooting Manual TS3192EN. c. Neutral Cool-Down Check Procedure • The neutral cool-down check determines if the

• •

•

•

transmission fluid cools following an engine load condition. Perform this check immediately after the maximum engine rpm has been recorded in the stall test. Record the converter-out fluid temperature. Reduce the engine rpm to idle and shift to N (Neutral). Run the engine at 1200–1500 rpm for two minutes to cool the fluid. At the end of two minutes, record the converter-out fluid temperature. Converter-out fluid temperature should return to within the normal operating temperature range. If the fluid does not cool during the two minute cool-down check, a stuck stator may be the source of the problem.

NOTE: You may use Allison DOC™ to perform stall test and clutch test procedures. Refer to the diagnostic tool’s user manual for specific instructions.

2–13. FLUID LEAK DIAGNOSIS a. Finding the Leak 1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, or hydraulic fluid from a specific vehicle system. 2. Operate the vehicle to reach normal operating temperature and park the vehicle. Inspect the vehicle to identify the source of the leak. Refer

to the following list for possible points of fluid leaks and their causes. • Transmission mating surfaces:

— Attaching bolts not correctly tightened — Improperly installed or damaged gasket — Mounting face damaged • Housing leak:

— Filler pipe or plug seal damaged or missing — Filler pipe bracket dislocated — Oil cooler connector fittings loose or damaged — Output shaft seals worn-out or damaged — Pressure port plug loose — Porous casting • Leak at converter end:

— Converter seal damaged — Seal lip cut (check converter hub for damage) — Garter spring missing from seal — Converter leak in weld area — Porous casting • Fluid comes out of fill tube:

— Overfilled—incorrect dipstick calibration — Plugged vent (breather) — Water or coolant in fluid—fluid will appear milky — Drain-back holes plugged 3. Visually inspect the suspected area. Inspect all the gasket mating surfaces for leaks.

CAUTION: When cleaning the transmission, do not spray steam, water, or cleaning solution directly at the vent assembly. Spraying steam, water, or cleaning solution at the vent assembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid. 4. If the leak still cannot be identified, then clean the suspected area with a degreaser, steam, or spray solvent. Clean and dry the area. Operate the vehicle for several miles at varying speeds. Inspect the vehicle for leaks. If the source of the leak is still not identified, use the powder

Copyright © 2003 General Motors Corp.

2–13

1000/2000/2400 SERIES SERVICE MANUAL method, and/or black light and dye method as explained below.

— Improperly tightened fasteners or dirty/ damaged threads — Warped flanges or sealing surfaces

b. Powder Method

— Scratches, burrs, or other damage to a sealing surface

• Clean the suspected area. • Apply an aerosol-type white powder. • Operate the vehicle under normal operating

conditions. • Visually inspect the suspected area and trace

the leak path over the white powder surface to the source.

— Damaged or worn-out gasket — Cracked or porous casting adjacent to the gasket — Improper sealant used (where applicable) • Seals:

— Fluid level/pressure is too high NOTE: Dye and black light kits are available for finding leaks. Refer to the manufacturer’s directions when using the kits. See kit directions for the color of the fluid dye mix.

— Damaged seal bore — Damaged or worn-out seal — Improper installation — Cracks in component

c. Black Light and Dye Method • Pour the specified amount of dye into the trans-

mission fill tube. • Operate the vehicle in normal operating condi-

tions. • Direct the black light toward the suspected

area. The dyed fluid will appear as a brightly colored path leading to the source. d. Repairing the Leak. Once the leak has been traced back to its source, inspect the leaking part for the following conditions, and repair the leaking part. • Gaskets:

— Fluid level/pressure is too high — Plugged vent or drain-back holes

2–14

— Plugged vent or drain-back holes

— Output shaft surface scratched, nicked, or damaged — Loose or worn-out bearing causing excess seal wear • Sealing Flange:

— Inspect the sealing flange for bends; replace the part with the damaged flange.

2–14. ON-VEHICLE MAINTENANCE For service procedures performed with the transmission mounted in the vehicle, refer to 1000/ 2000/2400 Series In-chassis Maintenance job aid booklet, JA3664EN.

Copyright © 2003 General Motors Corp.

SECTION 3 — GENERAL OVERHAUL INFORMATION 3–1.

SCOPE

3–2.

This section provides general information for transmission overhaul. The information provided includes:

TOOLS AND EQUIPMENT

a. Improvised Tools and Equipment. The following items may be improvised.

•

Tools and equipment required for overhaul

•

Replacement parts information

•

Cleanliness and careful handling

•

Cleaning and inspection

•

Assembly procedures

•

Transmission removal and installation

•

Locating wear data

•

Locating spring specifications

•

Common hand tools, metric where required

•

Locating torque specifications for plugs, bolts, and nuts

•

Metric wrench set (sockets, box-end wrenches, and Allen wrenches)

•

Work Table — 500 kg (1000 lb) capacity (Figure 3–1)

•

Overhaul Stand — J 29109 or equivalent (Table 3–1)

b. Special Tools. Special tools are illustrated and identified in Table 3–1. c. Mechanic’s Tools and Shop Equipment. The following tools, in addition to the common tools ordinarily required, should be available.

120 cm (48 in.) 200 cm (78 in.)

OIL DRAIN

60 cm (24 in.) OIL DRAIN (BOTH SIDES)

10x10 cm (4x4 in. LEGS)

STEEL TOP

TROUGH 16-GAUGE SHEET STEEL 35 mm (11⁄ 2 in.) DEEP 35 mm (11⁄ 2 in.) WIDE 5x15 cm (2x6 in. BOARD) FOR TOP FRAME AND LEG BRACKETS V00660.02

Figure 3–1. Work Table

Copyright © 2003 General Motors Corp.

3–1

1000/2000/2400 SERIES SERVICE MANUAL •

Snapring pliers

•

Micrometer (metric preferred)

•

3–2

Depth micrometer (metric preferred)

•

Clean, lint-free shop cloths (do not use waste cloths)

•

Containers for parts

•

Supply of wood blocks

•

Petrolatum

•

Container of water for leak testing the torque converter

•

Container of mineral spirits for cleaning parts

•

Dial indicator set (metric preferred)

•

Metric headless guide bolts set

•

M10 eye bolt

•

M16 eye bolt

•

Suitable hoist — 500 kg (1000 lb) capacity

CAUTION:

•

A 12 N·m (100 lb in.) torque wrench

Caustic cleaning compounds will damage some transmission parts. Use only mineral spirits to clean transmission parts.

•

A 350 N·m (250 lb ft) torque wrench

•

A press for disassembly and assembly of spring-loaded clutches and interference-fit parts

WARNING! Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION Table 3–1. Special Tools and Equipment* Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 24204-2 Bar and Stud Assembly

J 5959 Dial Indicator Set

J 24204-2

J 5959

J 7872 Dial Indicator Clamp and Adapter

J 24420-B Universal Puller

J 24420-B

J 7872

J 24446 Rear Bearing Installer

J 8092 Universal Driver

J 24446

J 8092

J 21369-F Torque Converter Leak Test Fixture

J 24459-5 Spring Compressor Adapter

J 24459-5 J 21369-F

Copyright © 2003 General Motors Corp.

3–3

1000/2000/2400 SERIES SERVICE MANUAL Table 3–1. Special Tools and Equipment* (cont’d) Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 26941 Front Support Needle Bearing Remover

J 26941

J 41364-A NSBU Switch Adjusting Tool

J 41364-A

J 43763 Torque Converter Leak Test Plug

J 29109 Repair Stand

J 43763

J 29109

J 43764 Torque Converter End Play Gauge

J 33163 Valve Tray Set

J 33163

J 43764

J 43765 Ground Sleeve Installer/Remover

J 39354 Rivet Installer

J 39354 J 43765

3–4

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION Table 3–1. Special Tools and Equipment* (cont’d) Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 43770 Main, Lube, Converter Relief Valve Spring Compressor

J 43766 Selector Shaft Spring Pin Installer

J 43770

J 43766

J 43771 Pump Bushing Installer/Remover

J 43767 Tone Wheel Staker

J 43771

J 43767

J 43768 Tone Wheel Driver

J 43768

J 43772 Oil Pump Seal Installer

J 43772

J 43769 Spanner Nut Wrench — 4WD

J 43769

J 43773 Valve Spring Compressor

J 43773

Copyright © 2003 General Motors Corp.

3–5

1000/2000/2400 SERIES SERVICE MANUAL Table 3–1. Special Tools and Equipment* (cont’d) Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 43774 Ground Sleeve Bushing Installer

J 43774

J 43778 Rotating Clutch Bushing Installer

J 43778

J 43775 Front Support Needle Bearing Installer

J 43779 Dowel Pin Installer

J 43779

J 43775

J 43776 C2 Piston Return Spring Compressor

J 43776

J 43780 Main Housing Dowel Pin Installer

J 43780

J 43777 C1 Piston Return Spring Spring Compressor

J 43777

3–6

J 43781 P1 Bushing Remover/ Installer

J 43781

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION Table 3–1. Special Tools and Equipment* (cont’d) Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 43782 Output Shaft Seal Installer

J 43782

J 43909 Selector Shaft Seal Installer

J 43909

J 43910 Output Bearing Puller Leg Set

J 43783 Output Shaft Seal Installer

J 43910

J 43783

J 43911 Selector Shaft Seal Remover

J 43785 P2 Bushing Remover/ Installer

J 43911

J 43785

J 43791 Output/Turbine Shaft Bushing Installer

J 44247 Wiring Harness Connector Installer

J 44247

J 43791

J 43797 P3 Carrier Bearing Race Installer

J 43797

J 44525 C1 Clutch Backplate Selector

J 44525

Copyright © 2003 General Motors Corp.

3–7

1000/2000/2400 SERIES SERVICE MANUAL Kent-Moore Tool No.**/ Description

Illustration

Kent-Moore Tool No.**/ Description

Illustration

J 44526 Output/Turbine Shaft Bushing Remover

J 44587 Main Shaft Holder

J 44587

J 44526

J 44528 P3 Carrier Bearing Race Remover

J 44723 Transmission/Stand Adapter Plate

J 44528

J 44723

J 44529 Ground Sleeve Bushing Remover

J 45023 Control Main Filter Wrench

J 45023

J 44529

J 46550 Transmission Cooler Flush Cart

J 44530 C3/C4 Piston Spring Compressor

J 44530 J 46550

* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these firms, or for any such items that may be available from other sources. ** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066

3–8

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION 3–3.

REPLACEMENT PARTS

a. Ordering Information. Refer to the latest version of Parts Catalog PC3062EN for parts information. Do not order replacement parts using the reference numbers in this service manual. b. Parts Normally Replaced at Overhaul. The following parts are normally replaced at each transmission overhaul: •

Gaskets

•

Lockstrips

•

Washers or retaining rings damaged by removal or abnormal wear

•

Oil seals and piston sealrings

•

Suction filters

3. Clean fluid passages by working a piece of soft wire through the passages and flushing them with mineral spirits. Dry the passages with compressed air. 4. Examine parts, especially fluid passages, after cleaning to make certain they are entirely clean. Re-clean parts if necessary.

1. Bearings that have been in service should be thoroughly cleaned in volatile mineral spirits.

Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®.

CAREFUL HANDLING

Handle parts and subassemblies carefully to prevent nicking, scratching, and denting. Parts that fit together closely and have a specific operating clearance can bind if damaged. Parts that depend upon smooth surfaces for sealing may leak if scratched. Control valve body assembly parts are especially susceptible to leaking if scratched. Valves, when dry, must move freely by their own weight. Handle these parts carefully and protect them during removal, cleaning, inspection, and installation. Keep control valve body assembly parts in clean containers until installation.

3–5.

2. Dry all parts, except bearing assemblies, with compressed air. To prevent rust, lubricate steam-cleaned parts as soon as they are dry.

c. Cleaning Bearings

WARNING!

3–4.

steam-cleaning or with volatile mineral spirits. Do not use caustic soda solution for steamcleaning. Clean friction-faced clutch plates and bearings with mineral spirits only.

CLEANING AND INSPECTION

a. Dirt Causes Malfunction. All parts must be clean to permit effective inspection. Do not allow dirt or foreign material to enter the transmission during assembly. Even minute particles can cause close-fit parts, such as valves, to malfunction.

2. Soak particularly dirty bearings or ones filled with hardened grease in mineral spirits before trying to clean them.

WARNING! Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing. 3. Before inspection, lubricate the bearings with transmission fluid. d. Keeping Bearings Clean. Ball or roller bearing failures are usually caused by dirt or grit in the bearing. Keep bearings clean during removal and installation. Observe the following rules for maximum bearing life: •

Do not unwrap new bearings until they are to be installed.

•

Do not remove the grease in which new bearings are packed until they are to be installed.

•

Do not lay bearings on a dirty bench. Place bearings on clean, lint-free paper.

b. Cleaning Parts 1. Clean all metallic transmission parts, except bearings and friction-faced clutch plates, by

Copyright © 2003 General Motors Corp.

3–9

1000/2000/2400 SERIES SERVICE MANUAL •

If a bearing is not installed immediately, wrap or cover the lubricated bearing with clean paper or lint-free cloth to keep out dust.

e. Inspecting Bearings 1. Inspect bearings for rough rotation. Replace a bearing if its rotation is still rough after cleaning and lubrication. 2. Inspect bearings for scored, pitted, scratched, cracked, or chipped races, and for excessive roller or ball wear. Replace the bearing if any defects are found. 3. Inspect a defective bearing’s bore and mating shaft for grooved, burred, or galled conditions that indicate the bearing has been turning in the bore or on the shaft. If the damage cannot be repaired with crocus cloth, replace the defective part. 4. When removing a bearing, do not apply pressure across the balls. This can cause brinelling and bearing failure. 5. If a bearing must be removed or installed without the proper tool, press only on the race which is adjacent to the mounting surface. If a press is not available, carefully seat the bearing with a drift and hammer. f. Inspecting Cast Parts and Machined Surfaces

The output shaft has Spiralock® threaded holes. If the Spiralock® threads are damaged, replace the output shaft. 5. Inspect the ribs inside the main housing for reaction plate wear grooves in the side of the ribs. 6. Replace housings or other cast parts that are cracked. 7. Inspect all machined surfaces for damage that could cause fluid leakage or other malfunction. Rework or replace defective parts. 8. Inspect the oil tracks of the control module and main housing for porosity, broken lands, cracks, dirt, and land surface imperfections. These imperfections will cause severe fluid leakage leading to transmission failure. g. Inspecting Bushings and Thrust Washers 1. Inspect bushings for scores, burrs, sharp edges, and evidence of overheating. Remove scores with crocus cloth. Remove burrs and sharp edges with a scraper or knife blade. Before reinstalling, carefully check bushings for signs of distress.

CAUTION:

1. Inspect bores for wear, scratches, grooves, and dirt. Remove scratches and burrs with crocus cloth. Clean the part. Replace parts that are deeply scratched or grooved. 2. Inspect all fluid passages for obstructions. If an obstruction is found, remove it with compressed air, or by working a soft wire back and forth through the passage and flushing it out with mineral spirits. 3. Inspect mounting faces for nicks, burrs, scratches, and foreign matter. Remove any defects with crocus cloth or a soft stone. Clean the part. If scratches are deep, replace the defective part. 4. Inspect threaded openings for damaged threads. Clean damaged threads with the correct size tap. 3–10

CAUTION:

When removing a defective bushing do not damage the bushing bore. 2. Replace bushings that are out-of-round, deeply scored, or excessively worn. Inspect parts mated to bushings to make sure they are not damaged or worn beyond use. 3. Inspect thrust washers for distortion, scores, burrs, and wear. Replace a thrust washer if defective or worn. h. Inspecting Sealrings and Gaskets 1. Inspect piston sealrings and lip-type seals for nicks, cuts, tears, splits, and pattern damage. A damaged seal can indicate rough or sharp edges in piston grooves or on a mating surface that could damage a new seal. 2. Replace all composition gaskets.

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION 3. Inspect hook-type sealrings for wear, broken hooks, and distortion. 4. Install a new hook-type sealring if the old ring shows any wear on its outside diameter, or if there is excessive side wear. 5. Inspect clutch housing sealing surfaces for nicks, burrs, dents, or displaced metal that could interfere with mating parts or damage the piston seal. Remove raised metal, sharp edges, burrs, or nicks with a soft stone and crocus cloth. Thoroughly clean all residue from the housing before assembly. 6. Inspect piston sealring grooves for nicks, burrs, dents, or displaced metal that could damage the seal. Remove raised metal, sharp edges, burrs, or nicks with a soft stone and crocus cloth. Thoroughly clean all residue from the piston before assembly. i. Inspecting Gears 1. Inspect gears for scuffed, nicked, burred, or broken teeth. If a defect cannot be removed with a soft stone, replace the gear. 2. Inspect gear teeth for wear that has changed the original tooth shape. If this condition is found, replace the gear. 3. Inspect the thrust face of gears for scores, scratches, and burrs. Remove such defects with a soft stone. If scratches and scores cannot be removed with a soft stone, replace the gear. 4. Inspect gears for load pattern and signs of distress. Any sign of distress indicates that a gear failure during operation is possible. Reusing distressed gears is an individual customer decision based on experience. Backlash cannot be used to establish critical gear wear. Backlash tolerances are of such nature that a gear usually pits, scuffs, scores, or galls long before gear wear becomes critical. j. Inspecting Splined Parts 1. Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs with a soft stone. Replace the part if other defects are found. Spline wear is not considered harmful except where it affects the fit of the splined parts.

2. Spline wear is determined by comparing feeler gauge thickness with the thickness of the worn area on the spline. Replace parts having excessive spline wear. (Refer to Wear Limits, Section 7.) 3. Backlash cannot be used to establish critical spline wear. Accurate backlash measurement requires the mating parts to be concentrically located. k. Inspecting Threaded Parts. Inspect threaded parts for burred or damaged threads. Remove burrs with a soft stone or fine file. Replace damaged parts. l. Inspecting Retaining Rings. Inspect all retaining rings for nicks, distortion, or excessive wear. Replace the retaining ring if any defects are found. The retaining ring must snap tightly into its groove to function properly. m. Inspecting Springs. Inspect springs for signs of overheating, permanent set, or wear due to rubbing adjacent parts. Replace the spring if any one of these defects are found. (Refer to Spring Data, Table 7–2 in Section 7.) n. Inspecting Clutch Plates (Figure 3–2) 1. Inspect friction-faced clutch plates (C1 clutch plates are externally tanged; all other clutch plates are internally splined) for burrs, embedded metal particles, severely pitted faces, loose faces, excessive wear, cone, cracks, distortion, shallow oil groove depth, or damaged spline teeth. Remove burrs using a soft honing stone. Replace plates which have any defects. 2. Inspect steel plates (C1 clutch plates are internally splined; all other clutch plates are externally tanged) for burrs, scoring, excessive wear, excessive cone, distortion, imbedded metal, galling, cracks, breaks, or damaged tangs. Remove burrs and minor surface irregularities using a soft stone. Replace plates which have any defects. 3. The amount of clutch plate cone is determined by measuring the distance between the inside diameter of the plate and a level surface (Figure 3–2). Discard plates having excessive cone (refer to Wear Limits, Section 7).

Copyright © 2003 General Motors Corp.

3–11

1000/2000/2400 SERIES SERVICE MANUAL

LEVEL SURFACE

b. Grease Used for Assembly. During assembly use oil-soluble grease with a low melting point (petrolatum) to temporarily retain parts, butt-joint sealrings, scarf-cut sealrings, and hook-type sealrings.

CLUTCH PLATE

Measure here for cone V00493.01

Figure 3–2. Method of Measuring Clutch Plate Cone

4. Determine oil groove depth with a depth micrometer by measuring from the smooth surface to the bottom of the oil groove. Replace plates not having the minimum oil groove depth (refer to Wear Limits, Section 7). o. Inspecting Swaged and Interference-Fit Parts. If there is evidence of looseness, the assembly should be replaced. p. Inspecting Sealing Surfaces

2. Inspect surfaces in contact with spring-loaded, lip-type seals for nicks, scratches, roughness, or other surface irregularities. Inspect for embedded particles, step-wear, and dirt on flanges or other components exposed to external contamination. Remove the defects and restore the finish. Replace the part if scores or scratches permit fluid leakage.

ASSEMBLY PROCEDURES

a. Parts Lubrication. During final assembly, lubricate all moving parts with transmission fluid. The fluid will help protect friction surfaces and ferrous metals until the unit is in service.

3–12

d. Clutches and Pistons 1. Soak each friction-faced clutch plate (twominute minimum) in transmission fluid before final assembly. 2. Apply a generous amount of transmission fluid to the piston cavity before final assembly. 3. Assemble clutch plates so that the cone of each plate faces the same direction. e. Threaded Plugs and Hydraulic Fittings

1. Inspect surfaces in contact with hook-type, scarf-cut, and butt-joint sealrings for stepwear, nicks, scratches, and scoring. Use a soft stone or crocus cloth to remove only the raised metal portion of these defects. Polishing the area to remove a defect is neither necessary nor desirable. If the defects are too severe to correct, replace the defective part.

3–6.

c. Sealing Compounds and Nonsoluble Greases. Do not use gasket-type sealing compounds, fibrous greases, or nonsoluble vegetable-base cooking compounds inside the transmission or where they could be flushed into the transmission hydraulic system.

CAUTION: • Do not use Teflon® tape on threaded parts. Slivers can cause the transmission to malfunction. • Improperly installed plugs or fittings can cause leakage and cracked housings. Tighten all pipe plugs to the specified torque in the assembly procedure and on the exploded views. Tighten other fittings sufficiently to prevent leakage. f. Lip-Type Seals 1. When replacing lip-type seals, make sure the spring-loaded lip is toward the fluid to be sealed (toward the inside of the unit). Coat the inside of the seal with petrolatum to protect the seal during shaft installation and to provide lubrication during initial operation. 2. The circumference of some seals is precoated with a dry sealant. The sealant is usually colored for easy identification. Precoated seals do not require any additional sealant before installation.

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION g. Butt-Joint Sealrings

CAUTION: If humidity is allowed to penetrate and expand a butt-joint sealring, the sealring can be damaged during installation. A damaged sealring will leak fluid from the clutch piston cavity and cause clutch slippage. Do not open the sealed package until you are ready to install the sealring.

i. Electrical Components. For inspection and repair of electrical components, refer to the Allison Transmission 1000/2000/2400 Series Troubleshooting Manual TS3192EN.

3–7.

REMOVING (OR INSTALLING) TRANSMISSION

WARNING! 1. Butt-joint sealrings require special handling during assembly. The sealrings contain materials that absorb moisture from the atmosphere causing the sealring to expand. The sealrings are shipped in airtight packages. Do not open the sealed package until the butt-joint sealring is ready to be installed into the transmission. Check sealring end clearance before installation to make sure the sealring has not expanded. 2. Remove the sealring from its package and place it in its operational position inside the bore that it will be sealing. 3. Using a feeler gauge, check the end clearance of the sealring. The end clearance must be greater than 0.38 mm (0.015 inch).

Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct contact with the hot fluid or the hot sump may result in bodily injury.

CAUTION: Whenever a transmission is overhauled, exchanged, or has undergone repairs, the Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS.” This will cause the TCM to erase previous adaptive information and begin to adapt in Fast Adaptive Mode from the base calibration. Use Allison DOC™ to reset the TCM to fast adaptive mode. Refer to the appropriate user guide for “Reset To Fast Adaptive” instructions. a. Draining Transmission

4. If the end clearance is less than minimum specifications, bake the sealring in an oven at 93–149°C (200–300°F) for 24 hours or get a new sealring. Repeat Steps (2) and (3). 5. Pack the sealring and its groove with a liberal amount of oil-soluble grease. 6. Roll up the sealring to about half its free diameter and hold it for about 10 seconds. Being careful not to spread the sealring more than necessary, slide it onto the hub. Place one end of the sealring into the groove and gradually work the seal into the groove. h. Bearings. If a bearing must be removed or installed without an installation sleeve, drive or press only on the race which is adjacent to the mounting surface. If a press is not available, carefully seat the bearing with a drift and a hammer, driving against the supported race.

Drain the transmission fluid before removing the transmission from the vehicle. • Remove the drain plug from the oil pan. Examine

the drained fluid for evidence of contamination (refer to Paragraph 2–8). Reinstall the drain plug. • Remove the transmission fill tube if it interferes

with transmission removal. Plug the fill tube hole in the main housing to keep dirt from entering the transmission. NOTE: A significant amount of fluid may drain from the hydraulic lines when they are disconnected from the transmission. • Disconnect

all hydraulic lines from the transmission. Remove the lines from the vehicle if they interfere with transmission removal. Plug

Copyright © 2003 General Motors Corp.

3–13

1000/2000/2400 SERIES SERVICE MANUAL all openings to keep dirt from entering the hydraulic system. b. Disconnecting Controls •

•

Disconnect the external wiring harness from the main electrical connector, three speed sensors and the NSBU switch. Prevent dirt or moisture from entering a disconnected connector. Position the wiring harness so it does not interfere with transmission removal. Disconnect linkage from the customerfurnished transmission shift lever. Position the disconnected linkage so it does not interfere with transmission removal. Leave the shift lever and NSBU switch on the transmission.

•

If PTO(s) is (are) used, disconnect the PTO(s) wiring harness(es).

•

If a parking brake is present, disconnect linkage.

c. Uncoupling From Driveline, Engine, And Vehicle

Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary if all wheels are off the ground. •

Disconnect the vehicle drive shaft from the transmission output flange or yoke. Position the disconnected shaft to avoid interference when removing the transmission.

•

If PTO equipped, disconnect PTO connections such as: — PTO hydraulic hoses

•

Remove all bolts, nuts, washers, spacers, and supports that attach the transmission to the vehicle and the engine.

NOTE: It may be necessary to remove an engine flywheel housing access cover to remove flexplate or flexplate adapter bolts. This is the engine to transmission connection. d. Removing The Transmission

CAUTION: Do not pull the transmission away from the torque converter assembly. The torque converter drive cover must be entirely free of any restraint by the flexplate drive or crankshaft pilot when the transmission separates from the engine.

Be sure the torque converter is moving rearward with the transmission as it is removed. Do not allow the torque converter to become disengaged from the oil pump or to fall and injure yourself or others. •

Move the transmission away from the engine, approximately 34.6 mm (1.36 inch) for a number 2 flywheel housing or 44.2 mm (1.74 inch) for a number 3 flywheel housing, until it is completely clear of the engine. If used, remove the adapter ring and/or gasket.

•

Raise or lower the transmission as necessary to remove it from the vehicle.

— PTO-powered equipment drive shaft

e. Transmission Installation

If transmission mountings support the rear of the engine, place a jack or other support under the engine.

CAUTION:

CAUTION: To avoid damage to the NSBU switch, make sure the transmission jack safety strap or chain does not bear on the NSBU switch. 3–14

Securely support the transmission with a hoist, jack, or other suitable removal equipment.

WARNING!

WARNING!

•

•

To avoid damage to the NSBU switch, make sure the transmission jack safety strap or chain does not bear on the NSBU switch. 1. Use a transmission jack to raise the transmission into mounting position. Mount the transmission.

Copyright © 2003 General Motors Corp.

GENERAL OVERHAUL INFORMATION 2. Make all connections from vehicle to transmission. 3. Verify all mechanical and electrical connections. 4. Fill the transmission with transmission fluid (Paragraphs 2–4 through 2–9) and road test after installation.

3–8.

WEAR LIMITS

Refer to Wear Limits Data Table 7–1, for information covering parts fits, clearances, and wear limits.

3–9.

SPRING SPECIFICATIONS

Refer to Spring Data Table 7–2 for spring identification and specifications.

3–10.

TORQUE SPECIFICATIONS

Assembly procedures in Sections 5 and 6 specify the torque requirements for all plugs, bolts, and nuts. Torque values are also presented with the foldout illustrations in the back of this manual. Torque values specified are for dry assembly, except when otherwise noted. Bolts and washers should be washed and dried before assembly.

Copyright © 2003 General Motors Corp.

3–15

SECTION 4 — TRANSMISSION DISASSEMBLY 4–1.

INSTALLATION OF TRANSMISSION INTO REPAIR STAND

Tools Required • J 44723

Transmission/Stand Adapter Plate

• J 29109

Repair Stand

WARNING! The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage.

WARNING! The 1000/2000/2400 Series transmission dry weights are approximately 150 kg (330 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the transmission. • Get help when lifting the transmission. Assistance from a hoist or another person may be required. • Make sure that the lifting equipment can properly support the transmission. 1. Position the transmission on the work table so that the oil pan is facing down. 1

2. If present, remove the PTO(s).

2

3

3. If present, remove twelve PTO cover bolts (3). 4. If present, remove two PTO covers (2). NOTE: PTO Cover Gasket (2) has been redesigned. The former and current designs are interchangeable. The former design may be reused unless replacement is necessary or the design is no longer available. DO NOT use a PTO cover gasket to mount a PTO.

1 2 3

V07702.02.00

5. If present, remove two PTO gaskets (1).

Copyright © 2003 General Motors Corp.

4–1

1000/2000/2400 SERIES SERVICE MANUAL 6. Install adapter plate J 44723 (2) onto repair stand J 29109 (1).

1

2

D2

7. Attach a sling to the transmission (2). 8. Attach a hoist to the sling. Raise the transmission to adapter plate J 44723 (1).

1 2

WARNING! If the transmission is not secured properly to the adapter plate, it could fall. To help avoid personal injury and/or property damage: • Use at least 5 bolts to support the transmission. • Use M10 x 1.5 bolts with 19-25 mm (3⁄4-1 inch) thread engagement. If the proper bolt is not used, the PTO bolt holes may be damaged. 9. Secure transmission (2) to the adapter plate J 44723 (1) using the PTO mounting pad as the attachment point. V08141.01.00

1

2

10. Remove the sling from the transmission.

4–2.

3

INPUT SPEED SENSOR REMOVAL (IF PRESENT)

1. Position the main housing so that the oil pan is facing down. 2. If present, remove sensor shipping cover (4).

4

3. Remove bolt (1) that holds speed sensor (2) to the converter housing. 4. Remove speed sensor (2). 5. Remove O-ring (3) from the speed sensor.

D4b

4–2

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4–3.

TURBINE SPEED SENSOR REMOVAL

1

2

1. If present, remove sensor shipping cover (4).

3

2. Remove bolt (1) that holds speed sensor (2) to the main housing. 3. Remove speed sensor (2). 4

4. Remove O-ring (3) from the speed sensor.

D4a

4–4.

OUTPUT SPEED SENSOR REMOVAL (2WD TRANSMISSIONS ONLY)

1 2 3

1. If present, remove sensor shipping cover (4). 2. Remove bolt (1) that holds speed sensor (2) to the rear cover. 3. Remove speed sensor (2). 4. Remove O-ring (3) from the speed sensor.

4

4–5.

D4

NSBU SWITCH REMOVAL (IF PRESENT)

1. With a wrench keeping selector lever (1) from rotating, turn nut (3) counter-clockwise and remove from the selector shaft (2). 2. Inspect the selector shaft for a shoulder or a burr. Remove any shoulder or burr with a file before removing the NSBU switch. 3. Remove the selector lever from the selector shaft.

®

6

5

4

3

2 1 V08085.00.00

Copyright © 2003 General Motors Corp.

4–3

1000/2000/2400 SERIES SERVICE MANUAL 4. Remove front splash shield (4) from the selector shaft. 5. Inspect selector shaft (3) for burrs or a shoulder. Remove burr or shoulder with a file. 6. Remove two bolts (2). 7. Remove NSBU switch (1) from the main housing and selector shaft.

1 3 2

4 2

V07746.02.00

4–6.

VENT REMOVAL

1. Gently pry on the shoulder below the cap and remove vent (1).

1

V07744.00.00

4–4

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4–7.

TORQUE CONVERTER REMOVAL

1

1

2

WARNING!

2

The 1000/2000/2400 Series torque converter dry weights are approximately 29 kg (63 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the torque converter. • Get help when lifting the torque converter. Assistance from a hoist or another person may be required. • Make sure that the lifting equipment can properly support the torque converter.

1 1

D9

1. Position the transmission so that the front of the converter housing is facing up. 2. If present, remove four bolts (1) and two shipping brackets (2).

3. If present, remove one bolt (2), two nuts (4), two bolts (1), and shipping bracket (3).

2

1

1

3

4

4

D9a

Copyright © 2003 General Motors Corp.

4–5

1000/2000/2400 SERIES SERVICE MANUAL 4. Attach a sling to torque converter (1). 5. Attach a hoist to the sling and raise torque converter (1) from converter housing (2). 1

6. Place torque converter (1) on the work table. Remove the sling.

4–8.

CONVERTER HOUSING/FRONT SUPPORT MODULE REMOVAL

2

WARNING!

D9b

The 1000/2000/2400 Series converter housing/ front support module dry weights are approximately 27 kg (60 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the converter housing/front support module. • Get help when lifting the converter housing/ front support module. Assistance from a hoist or another person may be required. Make sure that the lifting equipment can properly support the converter housing/front support module.

CAUTION: The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are, however, shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid torque converter housing bolts from being installed into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to help avoid main housing damage. 1

1 1

1

1. For SAE No. 2 or No. 3 torque converter housings, remove the following.

1

1

1

• 15 bolts (1) 1

• 5 bolts (2)

1 1 1 1 1

2 2 2

2

2

1 1

D10

4–6

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 2. For direct mount torque converter housings, remove the following. • 18 bolts (1) 1

• 1 bolt (2)

1

1

1

• 1 bolt (3) 1

1 1

1 1

1 1

1

1 1

1 2 1

1

1

3 D10a

3. Attach a sling to converter housing (1). 1

4. Attach a hoist to the sling. 5. Remove converter housing/front support module (1) from main housing (4) and turbine shaft (2). 6. Place the converter housing/front support module on the work table. 7. Remove the sling.

2 3

8. Remove and discard main housing/separator plate gasket (3). 4

D12

4–9.

ROTATING CLUTCH ASSEMBLY REMOVAL

1. Remove rotating clutch module (1).

1

2

D17a

Copyright © 2003 General Motors Corp.

4–7

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: The thrust bearing assembly may be attached to the rotating clutch module or the P1 planetary module. 1

2. Remove thrust bearing assembly (1) from rotating clutch assembly or P1 planetary module.

V07725.00.00.eps

4–10. OIL PAN AND SUCTION FILTER REMOVAL

1 2

7

3

1. Position the main housing so that the oil pan is facing up.

4

2. Remove drain plug (1). 3. Remove drain plug seal (2) from drain plug (1). 4. Remove twelve oil pan bolts (7).

5

5. Remove oil pan (3). 6. Remove oil pan gasket (4).

6

7. Remove suction filter (5). 8. Remove suction filter seal (6). V07773.01.00

9. Inspect and clean magnet (1) in oil pan (2).

1

2

V07726.00.00.eps

4–8

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4–11. WIRING HARNESS ASSEMBLY REMOVAL 1. If present, cover (1).

remove

connector

shipping

1 V07819.02.00

2. Using a 30–32 mm (13⁄16 inch) deepwell socket or box end wrench, depress the four tabs on internal wiring harness connector (1). 3. With the tabs depressed, gently pop the connector into and through main housing (2) with the palm of the hand.

1 V07820.02.00

4. Disconnect internal wiring harness (2) from the following components.

1 2

A trim solenoid (8) B trim solenoid (6) E ON/OFF shift solenoid (5) D ON/OFF shift solenoid (4) F trim solenoid (3) C ON/OFF shift solenoid (7) Pressure switch assembly (9) • The G ON/OFF modulated main solenoid (11) • • • • • • •

5. Remove solenoid retainers (1) from solenoids (4) and (5). 6. Remove internal wiring harness (2) from main valve body (10). 7. Install solenoid retainers (1).

11

10

9

Copyright © 2003 General Motors Corp.

4 8

6 7

3

5 V07821.01.00

4–9

1000/2000/2400 SERIES SERVICE MANUAL

1

4–12. CONTROL VALVE ASSEMBLY REMOVAL

1

1. Remove two detent spring bolts (1).

2

4

2. Remove detent spring assembly (2).

3

V08120.00.00

3. Remove 15 control valve assembly bolts (1). 2 1 2 1

1 1 1

1

1

1 1 1

1 1 1

V08121.00.00

1 2

NOTE: Installing a lint-free cloth into the park pawl apply assembly guide hole prevents the selector valve pin from falling into the transmission. 4. Install a lint-free cloth (1) in the park pawl apply assembly guide hole in main housing (2).

V08122.00.00

4–10

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY CAUTION: The main selector valve can be easily damaged. Do not drop the main selector valve when removing or installing the control valve assembly onto or from the main housing.

1

2

NOTE: Putting an index finger over the end of the manual selector valve hole during the removal of the control valve module from the main housing is highly recommended. 5. Lift control valve assembly (2) until two dowel pins (1) of the control valve assembly are disengaged from the main housing.

V08123.00.00

6. Slide the control valve assembly to the side and disengage selector valve pin (3) from detent lever (1). 7. Remove the control valve assembly from the main housing.

1 2

3

D23a

8. Remove, as a unit, manual selector valve (2) and selector valve pin (3) from shift valve body (1). 9. Remove selector valve pin (3) from manual selector valve (2).

1 2

3 V08124.00.00

Copyright © 2003 General Motors Corp.

4–11

1000/2000/2400 SERIES SERVICE MANUAL 10. Remove the lint free cloth from the park pawl apply assembly guide hole. 1 2

D21d

4–13. REAR BALL BEARING REMOVAL 1

Tools Required

2

• J 43910

Output Shaft Bearing Puller Leg Set

• J 24420-B

Universal Puller

• J 43769

Spanner Nut Wrench—4WD

1. Position the transmission so that the rear of the transmission is facing up. 2. If present, remove oil seal assembly (1).

R105

NOTE: The fullest clockwise position of the selector shaft is P (Park), which engages the park pawl.

20.9° 1

3. For 1000 Series™ 4WD transmissions only, use a wrench on selector shaft flats (1) to rotate the selector shaft to its fullest clockwise position.

1 2 P

OD R N

D

23.2° 34.3° 45.5° 56.2° 67.0° 77.8° R63d

4–12

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4. For 1000 Series™ 4WD transmissions only, do the following. • Install J 43769 (1) onto output nut (2). • Remove output nut (2).

1 2 3

V08031.00.00

5. Remove retaining ring (1). 1

A24f

6. Assemble three J 43910 legs with puller J 24420-B. 7. Place the foot of each leg between two bearing balls.

4 1 2 3

8. Twist each leg until the foot of the leg is forced under the bearing races. 9. Adjust center screw (4) and each leg nut (1) until the body of J 24420-B is perpendicular to the rear face of the main housing. 10. Tighten center screw (4) until ball bearing assembly (3) is dislodged. 11. Remove the J tools from the ball bearing assembly. R106

Copyright © 2003 General Motors Corp.

4–13

1000/2000/2400 SERIES SERVICE MANUAL 12. Remove selective spacer (1). 1

2

R107

4–14. REAR COMPONENTS REMOVAL

3

2

1

1. If a park brake cable bracket is present, do the following.

3 2 3 3 3 3 3

3

3

3

3

3

3

CAUTION: The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are, however, shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid torque converter housing bolts from being installed into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to help avoid main housing damage.

D24f

• Remove three bolts (2). • Remove bracket (1) from the rear cover. • Remove thirteen bolts (3).

4–14

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 2. If a park brake cable bracket is not present, do the following.

1

2

1

CAUTION:

2

The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are, however, shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid torque converter housing bolts from being installed into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to help avoid main housing damage.

2

2 2

2 2 1

2

• Remove four bolts (1).

1

• Remove twelve bolts (2).

2

2

2

2

3. Disengage rear cover module (1) from main housing dowel pin (4) and pawl support pin (5).

V08023.00.00

1

4. Remove rear cover module (1). 5. Remove and discard rear cover gasket (2).

2

5 3

WARNING!

4

Always remove or install the P3 planetary carrier assembly by holding onto the output shaft. Holding onto the P3 carrier assembly instead of the output shaft may allow the output shaft to fall causing personal injury and/or property damage. 6. Remove, as a unit, output shaft (2) and P3 planetary carrier assembly (1).

D24

1 3

2 4

7. Remove output shaft (2) from P3 planetary carrier (1). 8. Remove P3 sun gear (4). NOTE: The thrust bearing assembly may be attached to the output shaft or the P3 sun gear. 9. Remove thrust bearing (3) from output shaft (2) or P3 sun gear (4). Copyright © 2003 General Motors Corp.

D25

4–15

1000/2000/2400 SERIES SERVICE MANUAL 4–15. PARK PAWL REMOVAL 1. For transmissions with park pawls, do the following.

1 2

• Disengage pawl return spring (2) from main 4

3

housing (4). • Remove, as a unit, park pawl (1) and pawl return spring (2) from pawl support pin (3). • Remove the pawl return spring from the park pawl.

D26

2. Remove pawl support pin (2) from the main housing.

1

3. If present, remove apply assembly guide (3).

2

4. Remove C5 piston return spring assembly (1).

3

D27

4–16. P2 PLANETARY MODULE AND MAIN SHAFT REMOVAL 1

1. Remove, as a unit, main shaft (3), P2 sun gear (2), and sun gear spacer (1).

3 2

2. Remove sun gear spacer (1) and P2 sun gear (2) from the main shaft.

D28

4–16

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 3. Remove P2 planetary module (2).

1

NOTE: The thrust bearing assembly may be attached to P2 planetary module or the P2 sun gear.

2

4. Remove thrust bearing assembly (1) from P2 planetary module (2) or the P2 sun gear.

D29

4–17. C5 CLUTCH REMOVAL

1

1. Remove selective reaction plate (1). 2. Remove six C5 clutch friction plates (2) and five C5 clutch reaction plates (3).

2 3

3. Remove C5 clutch backplate (4).

4

D30

4–18. P1 PLANETARY MODULE

1

1. Remove P1 planetary module (2). NOTE: The thrust bearing assembly may be attached to the P1 planetary module or the P2 planetary module.

2

2. Remove thrust bearing assembly (1) from P1 planetary module (2) or the P2 planetary module.

D31

Copyright © 2003 General Motors Corp.

4–17

1000/2000/2400 SERIES SERVICE MANUAL 4–19. C4 CLUTCH REMOVAL

1 2 3

Tools Required

4 5

• J 24204-2

Bar and Stud Assembly

• J 44530

C3/C4 Piston Spring Compressor

CAUTION: DO NOT install special tools (J tools) onto the gear thrust plate rivets of the C3 clutch backplate assembly. The special tools could damage the gear thrust plate rivets.

6 6

1. Install J 24204-2 (1) and J 44530 (2) into the main housing. Make sure that J 24204-2 does not touch gear thrust plate rivets (6) on the C3 clutch backplate assembly.

D32

2. Compress piston return spring assemblies (5) until a gap is visible below retaining rings (3) and (4). 3. Remove retaining ring (3). 4. Remove spiral retaining ring (4). 5. Remove J 24204-2 (1) and J 44530 (2) from the main housing.

6. Remove C4 clutch backplate (1). 1

D33a

4–18

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 7. Remove five C4 clutch friction plates (1) and four C4 clutch reaction plates (2). 8. Remove, as a unit, C4 spring plate (4) and three piston return spring assemblies (3).

3 1 4

2

D33

NOTE: The piston return spring assemblies snap off.

1 1

2

9. Remove three piston return spring assemblies (1) from C4 spring plate (2).

1 D34

10. Remove P1 ring gear (1).

1

D35

Copyright © 2003 General Motors Corp.

4–19

1000/2000/2400 SERIES SERVICE MANUAL 4–20. C4 CLUTCH PISTON ASSEMBLY REMOVAL

1

NOTE: The preferred method of dislodging the C4 clutch piston is with compressed air. If compressed air is not available, remove the C4 clutch piston assembly using pliers. If compressed air is used, note the following. • Use a 3⁄8 inch rubber hose on the air connection

to reach into the C4 clutch annulus port. • When shooting air into the annulus port, make sure that the rubber hose covers both of the C4 clutch annulus port holes. D39a

1. Position the air connection rubber hose so that the hose covers both C4 clutch annulus holes (1). 2. Shoot air into the C4 clutch annulus port until C4 clutch piston assembly (1) is dislodged. 3. Remove C4 clutch piston assembly (1).

1

D35a

4–20

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4–21. C3 CLUTCH REMOVAL 1

Tools Required

2

• J 24204-2

Bar and Stud Assembly

• J 44530

C3/C4 Piston Spring Compressor

1. Position the main housing so that the front of the main housing is facing up.

3 4 5

CAUTION: DO NOT install special tools (J tools) onto the gear thrust plate rivets of the C3 clutch backplate assembly. The special tools could damage the gear thrust plate rivets. D36

1. Install J 24204-2 (1) and J 44530 (2) into the main housing. Make sure that J 44530 does not touch gear thrust plate rivets (3) on the C3 clutch backplate assembly. 2. Compress piston return spring assemblies (5) until a gap is visible below retaining ring (4). 3. Remove retaining ring (4). 4. Remove J 24204-2 and J 44530 from the main housing. 5. Remove C3 clutch backplate assembly (1). 1

2

D37a

Copyright © 2003 General Motors Corp.

4–21

1000/2000/2400 SERIES SERVICE MANUAL

3

6. Remove four C3 clutch friction plates (1) and three C3 clutch reaction plates (2).

1 2

7. Remove, as a unit, C3 spring plate (4) and three piston return spring assemblies (3).

4

D37

1 1

NOTE: The piston return spring assemblies snap off.

2

8. Remove three piston return spring assemblies (1) from C3 spring plate (2).

1 D38

4–22

Copyright © 2003 General Motors Corp.

TRANSMISSION DISASSEMBLY 4–22. C3 CLUTCH PISTON ASSEMBLY REMOVAL NOTE: The preferred method of dislodging the C3 clutch piston is with compressed air. If compressed air is not available, remove the C3 clutch piston assembly using pliers. If compressed air is used, note the following.

1

• Use a 3⁄8 inch rubber hose on the air connection

to reach into the C3 clutch annulus port. • When shooting air into the annulus port, make sure that the rubber hose covers both of the C3 clutch annulus port holes. D39b

1. Position the air connection rubber hose so that the hose covers both C3 clutch annulus holes (1). 2. Shoot air into the C3 clutch annulus port until C3 clutch piston assembly (1) is dislodged. 3. Remove C3 clutch piston assembly (1).

1

D39

Copyright © 2003 General Motors Corp.

4–23

1000/2000/2400 SERIES SERVICE MANUAL NOTES

4–24

Copyright © 2003 General Motors Corp.

SECTION 5 — MODULE REBUILD 5–1.

TORQUE CONVERTER ASSEMBLY

1

CAUTION: Allison Transmission Division GM recommends using only genuine Allison torque converters with 1000/2000/2400 Series Allison transmissions. Any transmission damage that may occur as a result of using a converter other than a new Allison converter or a genuine Allison replacement is the responsibility of the owner and will not be covered by Allison warranty. a. Preliminary Inspection R0

1. Remove the transmission fluid from torque converter (1). 2. Examine the transmission fluid for the following. • Evidence of foreign matter • Metal particles

3. If the torque converter is damaged, replace the torque converter. b. End Play Check Tools Required

1

• J 43764

Torque Converter End Play Gauge

• J 5959-1

Dial Indicator

• J 5959-3

Rod 1⁄4 x 101⁄2 inches

• J 5959-7

Lug Attachment

• J 7872-2

Magnetic Clamp

• J 7872-3

Swivel Adapter

7

6 5

2 3

4

1. Position torque converter (3) on the work table so that the pump hub is facing up. 2. Install J 43764 (2) into the torque converter hub.

V07740.00.00.eps

3. While holding J 43764 (2) in the converter hub, rotate the center screw until J 43764 is locked into the converter hub. Do not over tighten J 43764.

Copyright © 2003 General Motors Corp.

5–1

1000/2000/2400 SERIES SERVICE MANUAL 4. Assemble the following tools and install the tools onto the torque converter as shown.

1

• J 5959-1 (1) 7

6

• J 5959-3 (7) • J 5959-7 (6)

2

5

• J 7872-2 (4)

3

• J 7872-3 (5)

4

5. Adjust J 5959-7 (6) so that J 5959-1 (1) firmly contacts the top of J 43764 (2). 6. Set J 5959-1 (1) to read zero. Lift J 43764 (2) up as far as possible. 7. Read J 5959-1 (1) (torque converter end play). V07740.00.00.eps

8. Compare the measured end play with the allowable end play. Table 5–1. Allowable Torque Converter End Play Converter

Max End Play

New

0.762 mm (0.0300 inch)

Used

1.015 mm (0.0400 inch)

9. If the measured torque converter end play exceeds the value listed in Table 5–1, replace the torque converter. 10. Remove the J tools from the converter housing. c. Leak Test 1

Tools Required

2 3 4

• J 43763

Torque Converter Leak Test Plug

• J 21369-F

Torque Convert Leak Test Fixture

5 6

NOTE: The torque converter leak test requires a large container of water in order to submerge the torque converter. 1. Position torque converter (6) on the work table so that the pump hub is facing up.

V07741.00.00.eps

2. Move nut (3) to the middle of the center body (1) of J 43763. 3. Install J 43763 into the torque converter hub.

5–2

Copyright © 2003 General Motors Corp.

MODULE REBUILD 4. Install torque converter (8) with J 43763 (1) into J 21369-F (3). 5. Firmly tighten nut (6) in order to seal J 43763 into the torque converter.

2 1

3 4

6. Firmly tighten nut (5) in order to securely attach the torque converter to J 21369-F (3).

5 6 7

7. Connect an air hose to air fitting (1) of J 43763.

8

8. Pressurize the converter to 517 kPa (75 psi) maximum. Disconnect the air hose. 9. Submerge the torque converter in water. 10. Closely observe the torque converter for bubbles that indicate leakage. If the torque converter leaks, replace the torque converter. R2a

WARNING! All pressure from the torque converter must be exhausted before loosening the test fixture nut. Failure to relieve the pressure could cause personal injury and/or property damage. 11. Push on pressure relief valve (2) of J 43763 and release the air from the torque converter. 12. Remove the J tools from the torque converter.

d. Inspection of Torque Converter 1

NOTE: Replace the torque converter if it does not meet specifications. 1. Measure the OD of torque converter hub (1) in the bushing wear area (Dimension A). Dimension A must equal or exceed 58.250 mm (2.2933 inch). A

R3

Copyright © 2003 General Motors Corp.

5–3

1000/2000/2400 SERIES SERVICE MANUAL 2. Measure the distance between the flats of the torque converter hub (Dimension A). Dimension A must equal or exceed 51.816 mm (2.040 inch).

1

A

R3a

3. Measure the OD of the torque converter cover pilot (Dimension A). Dimension A must equal or exceed 43.080 mm (1.696 inch).

1

A

R4

5–4

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5–2.

ELECTRONIC COMPONENT INSPECTION

1. Perform the following steps for the input, turbine, and output speed sensors. • Replace speed sensor (1) if the speed sensor

shows signs of cracking and/or oil leakage. • Replace the speed sensor if the attachment

bracket is bent or damaged or the speed sensor is loose in its bore. 60°

• Make sure the speed sensor connection is

oriented as shown. • Measure the resistance of the speed sensor.

If the resistance does not meet the following specifications, replace the speed sensor. Ambient Temperature (ºC)

(ºF)

0 25 50

32 77 122

Resistance (Ohms) 2157–2637 2340–2860 2614–3195

2. Measure the resistance of A trim and B trim solenoids (1). If the resistance does not meet the following specifications, replace the solenoid. Sump Temperature (ºC)

(ºF)

0 20 40

32 68 104

R4a

1

Resistance (Ohms) 4.5 5.5 6.5

R4b

Copyright © 2003 General Motors Corp.

5–5

1000/2000/2400 SERIES SERVICE MANUAL 3. Measure the resistance of C, D, G, and E ON/ OFF shift solenoids (1). If the resistance does not meet the following specifications, replace the solenoid.

1

Sump Temperature (ºC)

(ºF)

0 20 40

32 68 104

Resistance (Ohms) 20.0 22.0 24.5

4. Measure the resistance of F trim solenoid (1). If the resistance does not meet the following specifications, replace the solenoid. Sump Temperature R4c

5–3. 1

(ºC)

(ºF)

0 20 40

32 68 104

CONVERTER HOUSING/FRONT SUPPORT MODULE DISASSEMBLY

1. Position converter housing/front support module (2) on the work table so that the torque converter housing is facing up.

2

2. Remove oil seal assembly (1).

D10c

5–6

Resistance (Ohms) 9.5 10.5 11.5

Copyright © 2003 General Motors Corp.

MODULE REBUILD 3. Remove 10 bolts (1).

1

1 1

1 1 1

1 1

1

1

V07728.00.00.eps

4. Remove seals (2) from bolts (1). 1

2

V07727.00.00.eps

CAUTION: Do not damage the separator plate when separating the torque converter housing from the front support module. 5. Remove converter housing (1) from front support module (3).

1 2

NOTE: Separator Plate Gasket (2) has been redesigned. The former and current designs are interchangeable. The former design may be reused unless replacement is necessary or the design is no longer available. 6. Remove converter housing/separator plate gasket (2) from separator plate (4). Copyright © 2003 General Motors Corp.

3 4 5 D14

5–7

1000/2000/2400 SERIES SERVICE MANUAL 7. Remove two butt joint sealrings (1 and 2) from ground sleeve (3).

1

8. Remove three butt joint sealrings (6) from the rear hub of the front support assembly.

2

9. Remove thrust washer (5).

3 4

5

6 D15

10. Remove five bolts (4) retaining main pump assembly (1) to front support assembly (3).

1

CAUTION: Do not damage the separator plate when separating the front support assembly, separator plate, and main pump assembly.

2

11. Separate front support assembly (3), separator plate (2), and main pump assembly (1). 3

4 D16

5–8

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5–4.

TORQUE CONVERTER HOUSING (WITHOUT COOLER MANIFOLD)

a. Disassembly

1

Tools Required • J 45023 Control Main Filter Wrench

1. Remove pressure tap plug (7).

8

2. Remove O-ring (6) from pressure tap plug (7).

9

6 2

5 7

3 4

3. Using J 45023 (11) or a filter strap wrench, remove control main filter (10).

10

4. Remove magnet (9) from filter attachment tube (8) or from filter (10).

11 R5

5. Remove filter attachment tube (8). 6. If present, remove two hydraulic connector assemblies (4). Remove O-rings (5) from the connector assemblies. 7. If present, remove two shipping plugs (3). Remove O-rings (2) from the shipping plugs.

Copyright © 2003 General Motors Corp.

5–9

1000/2000/2400 SERIES SERVICE MANUAL b. Assembly Tools Required • J 45023 1

8

CAUTION: Install the short-threaded end of the filter attachment tube into the converter housing. If the long-threaded end of the filter attachment tube is installed, the threads of the converter housing will be damaged.

6 2

5 9

7

Control Main Filter Wrench

3 4

10

1. Install filter attachment tube (8) by hand. Tighten the tube to 25–35 N·m (18–26 lb ft).

11 R5

2. Install magnet (9) onto the filter attachment tube. 3. Lubricate gasket on control main filter (10) with transmission fluid. 4. Install the control main filter by hand until the gasket on the control main filter touches the converter housing.

CAUTION: Turning the control main filter more than ONE FULL TURN after gasket contact will damage the filter. 5. Using J 45023 (11) or by hand, turn the filter ONE FULL TURN ONLY. 6. Install O-ring (6) onto pressure tap plug (7). Install the plug. Tighten the plug to 10–13 N·m (7–10 lb ft). 7. If present, install O-rings (5) onto hydraulic connector assemblies (4). Install two hydraulic connector assemblies (4). Tighten the connector assemblies to 20–30 N·m (15–22 lb ft). 8. If present, install O-rings (2) onto two shipping plugs (3). 9. Install plugs (3). Tighten the plugs to 2.5–3.5 N·m (2–3 lb ft).

5–10

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5–5.

TORQUE CONVERTER HOUSING (DIRECT MOUNT; WITHOUT COOLER MANIFOLD)

1 3 2

a. Disassembly Tools Required • J 45023

Control Main Filter Wrench

1. Remove pressure tap plug (5). Remove O-ring (4) from the pressure tap plug.

R0X 10

2. Using J 45023 (9) or a filter strap wrench, remove control main filter (8).

4 5

6 7 8

3. Remove magnet (7) from filter attachment tube (6) or from filter (8).

9 R5a

4. Remove filter attachment tube (6). 5. Remove bolt access cover (10). 6. If present, remove two hydraulic connector assemblies (2). Remove O-rings (3) from the connector assemblies. b. Assembly Tools Required • J 45023 Control Main Filter Wrench

CAUTION: Install the short-threaded end of the filter attachment tube into the converter housing. If the long-threaded end of the filter attachment tube is installed, the threads of the converter housing will be damaged. 1. Install filter attachment tube (6) by hand. Tighten the tube to 25–35 N·m (18–26 lb ft). 2. Install magnet (7) onto the filter attachment tube. 3. Lubricate the gasket on control main filter (8) with transmission fluid. 4. Install the control main filter by hand until the gasket on the control main filter touches the converter housing.

1 3 2

R0X 10

CAUTION: Turning the control main filter more than ONE FULL TURN after gasket contact will damage the filter. 5. Using J 45023 (9) or by hand, turn the filter ONE FULL TURN ONLY.

Copyright © 2003 General Motors Corp.

6 7 8

4 5

9 R5a

5–11

1000/2000/2400 SERIES SERVICE MANUAL 6. Install O-ring (4) onto pressure tap plug (5). 7. Install plug (5). Tighten the plug to 10–13 N·m (7–10 lb ft). 8. Install bolt access cover (10). 9. If present, install O-rings (3) onto hydraulic connector assemblies (2). Install two hydraulic connector assemblies (2). Tighten the connector assemblies to 20–30 N·m (15–22 lb ft).

1 3 2

R0X 10 4 5

6 7 8 9

R5a

5–6.

TORQUE CONVERTER HOUSING (WITH COOLER MANIFOLD)

a. Disassembly Tools Required • J 45023

Control Main Filter Wrench

1. Remove pressure tap plug (4). Remove O-ring (3) from the pressure tap plug. 5

3

6

4 7

9

2. Using J 45023 (10) or a filter strap wrench, remove control main filter (7). 3. Remove magnet (6) from filter attachment tube (5) or from filter (7).

1 2

4. Remove filter attachment tube (5). 8

5. If present, remove two shipping plugs (2). Remove O-rings (1) from the shipping plugs.

10 V07730.00.00

6. If present, remove two elbow adapters (90 degree) (8) as follows. • Mark the orientation of the elbow adapters

on the manifold. • Loosen the lock nuts on the elbow adapters. • Remove the elbow adapters from the manifold. • Remove O-rings (9) from elbow adapters (8).

5–12

Copyright © 2003 General Motors Corp.

MODULE REBUILD 7. Remove four manifold bolts (2). 8. Remove eight manifold bolts (1). 1

1

1

1

1

1

1

1

2

2

2

2

R7

9. Remove cooler manifold (4), gasket (3), channel plate (2), and gasket (1). 1

2

3

4

R9

b. Assembly Tools Required • J 45023

Control Main Filter Wrench

1. Install gasket (1), channel plate (2), gasket (3), and cooler manifold (4).

1

2

3

4

R9

Copyright © 2003 General Motors Corp.

5–13

1000/2000/2400 SERIES SERVICE MANUAL 2. Install four manifold bolts (2). 1

1

1

1

1

1

1

1

2

2

2

2

3. Install eight manifold bolts (1). Tighten bolts (1) and (2) to 24–29 N·m (18–21 lb ft).

R7

CAUTION: Install the short-threaded end of the filter attachment tube into the converter housing. If the long-threaded end of the filter attachment tube is installed, the threads of the converter housing will be damaged. 5

3

6

4 7

9

5. Install magnet (6) onto the filter attachment tube.

1 2

4. Install filter attachment tube (5) by hand. Tighten the tube to 24–29 N·m (18–21 lb ft).

6. Lubricate the gasket on control main filter (7) with transmission fluid.

8

10 R6

7. Install the control main filter by hand until the gasket on the control main filter touches the converter housing.

CAUTION: Turning the control main filter more than ONE FULL TURN after gasket contact will damage the filter. 8. Using J 45023 (10) or by hand, turn the filter ONE FULL TURN ONLY. 9. Install O-ring (3) onto pressure tap plug (4). 10. Install plug (4). Tighten the plug to 10–13 N·m (7–10 lb ft).

5–14

Copyright © 2003 General Motors Corp.

MODULE REBUILD 11. If present, install O-rings (1) onto two shipping plugs (2). Install the shipping plugs. Tighten the plugs to 2.5–3.5 N·m (2–3 lb ft). 12. If present, install two (90 degree) (8) as follows.

elbow

adapters

• Install O-rings (9) onto elbow adapters (8). • Install the elbow adapters so that they align

with the orientation marks made on the manifold. • Tighten the elbow adapters to 20–30 N·m (15–22 lb ft).

5

3

6

4 7

9

1 8

2 10

R6

5–7.

MAIN PUMP ASSEMBLY

1

a. Main Pump Disassembly NOTE: The Main Pump Assembly and Wear Plate have been redesigned. The former and current designs are interchangeable. The former design may be reused unless replacement is indicated by wear measurements or the design is no longer available.

2 3 4 5 5 6

1. Remove wear plate (1). NOTE: The main pump drive gear and driven gear have a punch mark on one side. Before the gears are removed from the main pump, the presence or absence of the punch marks on the gears must be noted so that the gears can be reinstalled in their original orientation.

V07777.00.00.eps

2. Note the presence or absence of punch marks on the drive gear and driven gear. If punch marks are absent, move the drive and driven gears for re-alignment. 3. Remove drive gear (2) and driven gear (3) from main pump body (4). 4. Remove O-ring (6).

Copyright © 2003 General Motors Corp.

5–15

1000/2000/2400 SERIES SERVICE MANUAL b. Main Pump Inspection A 1

NOTE: • Make the measurements described below at several locations. • Replace the main pump body, driven gear, and drive gear if any of the following specifications are not met. 1. Measure the depth of the main pump body gear cavity (Dimension A). The maximum depth of the gear cavity is 24.940 mm (0.9819 inch).

V07774.00.00

2. Measure the ID of the main pump body gear cavity (Dimension A). The maximum ID of the gear cavity is 109.191 mm (4.2989 inch). 1

A

V07775.00.00.eps

3. Measure the OD of the driven gear (Dimension A). The minimum OD of the driven gear is 108.987 mm (4.2908 inch). 1

A

V07729.00.00.eps

5–16

Copyright © 2003 General Motors Corp.

MODULE REBUILD 4. Measure the distance between the flats of the drive gear (Dimension A). The maximum distance between the flats is 52.165 mm (2.0537 inch).

1

A

V07711.00.00.eps

5. Align the drive gear and driven gear with the main pump so that their punch marks are in the same position as when they were originally removed.

1

6. Install the gears into main pump body (3). 2

3

V07776.00.00.eps

7. Measure the clearance between driven gear (1) and main pump body (2) (Driven Gear Diametral Clearance). The maximum Driven Gear Diametral Clearance is 0.204 mm (0.0080 inch).

2 1

V07712.00.00.eps

Copyright © 2003 General Motors Corp.

5–17

1000/2000/2400 SERIES SERVICE MANUAL 8. Measure the clearance between driven gear (1) and main pump body crescent (2) (Driven Gear/Crescent Tooth Clearance). The maximum Driven Gear/Crescent Tooth Clearance is 0.455 mm (0.0179 inch).

1

2

R17

9. Hold a straight edge across main pump body (1) and drive gear (3). Measure the clearance between the drive gear and the straight edge (Drive Gear Side Clearance). The maximum Drive Gear Side Clearance is 0.066 mm (0.0026 inch).

2

1

10. Hold a straight edge across main pump body (1) and driven gear (2). Measure the clearance between the driven gear and the straight edge (Driven Gear Side Clearance). The maximum Driven Gear Side Clearance is 0.066 mm (0.0026 inch).

3

R18

11. Remove drive gear (1) and driven gear (2) from main pump body (3).

1

2

3

V07776.00.00.eps

5–18

Copyright © 2003 General Motors Corp.

MODULE REBUILD c. Main Pump Bushing Replacement Tools Required • J 43771 • J 8092

1

Pump Bushing Removal and Installation Tool

2

Universal Driver

NOTE: The Main Pump Bushing has been redesigned. The current bushing can only be used in units with S/N 6310144856 (Indianapolis) or S/N 6320047965 (Baltimore) and later. Pump Assemblies that can use the current bushing have casting number 29539582 cast into the pump body. Service the bushing in pumps not marked with casting number 29539582 by replacing the pump assembly.

V07713.00.00.eps

1. Inspect the bushing for damage and wear. The bushing must not be damaged or worn. 2. Measure the ID of the bushing. The ID of the pump bushing must not exceed 58.458 mm (2.3015 inch). The pump bushing must have a complete burnt-orange Teflon® coating. If any portion of the Teflon® coating is worn and bronze material is visible, replace the pump. 3. Remove all gears from pump body (1). J 43771 PUMP BUSHING REMOVAL AND INSTALLATION TOOL

4. Remove the front seal from pump body (1). NOTE: The preferred method for removing or installing the bushing is to use tool J 43771 and a press. If a press is not available, use J 43771 and universal driver J 8092.

1

2

5. Support pump body (1), machined surface up, on two wooden blocks so that bushing (2) can be removed from the back. 6. Install the longer end of J 43771 into the bushing.

WOOD BLOCKS

7. Press, or drive, bushing (2) from pump body (1).

INSTALLATION

V07474.01.01

8. Clean the bushing bore of all residues. Parts must be dry before installing the bushing.

Copyright © 2003 General Motors Corp.

5–19

1000/2000/2400 SERIES SERVICE MANUAL

J 43771 PUMP BUSHING REMOVAL AND INSTALLATION TOOL 2

APPLY LOCTITE®

1

NOTE: The bushing may be oriented in any position, but the preferred orientation is with the bushing split joint aligned with the casting numbers and the centerline of the boss opposite the numbers. Position the split joint away from the boss. 9. Support pump body (1), machined surface down, on two wooden blocks.

WOOD BLOCKS

10. Install bushing (2) onto the shorter end of J 43771. 11. Apply Loctite® #620 to the bushing bore.

INSTALLATION

V07505.01.01

12. Using J 43771, press or drive the pushing into the pump body until J 43771 seats. d. Main Pump Dowel Pin Replacement Tools Required

1 2

• J 43779

Dowel Pin Installer

NOTE: Do not replace the main pump dowel pin(s) unless the dowel pin(s) are damaged. 3

1. Remove dowel pin (2) from main pump body (3).

CAUTION: V07745.00.00.eps

DO NOT mar the main pump body surface when installing the dowel pin(s). Tap gently on the J 43779 dowel pin installer tool. Heavy or continued hammering on the J 43779 will damage the main pump body surface. 2. Using J 43779 (1), install dowel pin (2). 3. Make sure the dowel pin is installed to a height of 10.7–11.3 mm (0.42–0.44 inch) above the main pump body surface.

5–20

Copyright © 2003 General Motors Corp.

MODULE REBUILD e. Wear Plate Inspection NOTE: If any of the following specifications are not met, replace the main pump wear plate. 1

1. Inspect wear plate (1) for damage. The wear plate must not be scored, nicked, or grooved. 2. Measure the thickness of the wear plate in the gear wear area. The thickness of the wear plate must not be less than 2.950 mm (0.1161 inch).

V07778.00.00.eps

f. Main Pump Assembly 1

1. Install O-ring (6) onto pump body (4). 2. Position main pump body (4) on the work table so that the pump body hub is facing down.

2

3. Lubricate pump drive gear (2) and driven gear (3).

3

CAUTION:

4

When the drive gear and driven gear are installed into the main pump, the gears must be installed in their original orientation by having their punch marks in the same position as when they were originally removed. Failure to install the drive and driven gears in their original orientation may damage the transmission.

5 5 6

V07777.00.00.eps

4. Align the drive gear and driven gear with the main pump so that their punch marks are in the same position as when they were originally removed. 5. Install the gears into pump body (4). 6. Align the dowel pin holes in wear plate (1) with dowel pins (5) in the pump body. Make sure the bolt holes in pump wear plate (1) align with the bolt holes on main pump body (4). 7. Install wear plate (1) onto dowel pins (5) and main pump body (4).

Copyright © 2003 General Motors Corp.

5–21

1000/2000/2400 SERIES SERVICE MANUAL 5–8.

FRONT SUPPORT ASSEMBLY

a. Front Support Disassembly Tools Required 2

1

• J 24459-5

Spring Compressor Adapter

• J 43770

Main, Lube, Converter Relief Valve Spring Compressor

• J 43773

Valve Spring Compressor

1. Install J 24459-5 (1) onto J 43770 (2).

V07709.00.00.eps

2. Position front support assembly (1) on the work table so that the rear of the front support assembly is facing down.

1

3. Align J 43770 (5) and J 24459-5 (4) with the front support so that: 2

• The threaded rod of J 43770 is facing down. • Two bolt holes of J 43770 align with the

3

2

bolt holes of the front support.

4

4. Install J 43770 (5) onto the front support assembly.

5

5. Install two front support retaining bolts (2). 6. Align the slot of J 24459-5 (4) with retainer pin (3).

V07732.00.00.eps

7. Turn the front support so that pin (3) is accessible and using J 24459-5 (4) and J 43770 (5), compress the main regulator valve spring until retainer pin (3) is loose. 8. Using a pick, push the pin through front support (1). 9. Turn front support (1) so that the rear is facing down. 10. Relieve main regulator valve spring tension and remove the J tools.

5–22

Copyright © 2003 General Motors Corp.

MODULE REBUILD 11. Remove stop (3), spring (2), and main regulator valve (1).

1 2 3 V07779.00.00.eps

12. Using J 43773 (2), compress the C1 clutch backfill valve spring until retaining clip (1) is loose. Remove the clip. 1

2 V07780.00.00.eps

13. Remove spring (2) and C1 clutch backfill valve (1).

1 2 V07781.00.00.eps

Copyright © 2003 General Motors Corp.

5–23

1000/2000/2400 SERIES SERVICE MANUAL 14. Align the slot of J 24459-5 (2) with retainer pin (1).

1

15. Using J 24459-5 (2), compress the lube regulator valve spring until retainer pin (1) is loose. Remove the pin.

2 V07798.00.00.eps

16. Remove stop (4), spring (2), and lube regulator valve (1). 17. Remove O-ring (3) from stop (4).

1

4 2 3 V07797.00.00 .eps

18. Using J 43773 (2), compress the converter relief valve spring until retaining clip (1) is loose. Remove the clip.

1

2 V07796.00.00.eps

5–24

Copyright © 2003 General Motors Corp.

MODULE REBUILD 19. Remove spring (2) and converter relief valve (1).

2 1 V07795.00.00.eps

20. Install J 24459-5 (1) onto J 43770 (2).

2

1

V07709.00.00.eps

Copyright © 2003 General Motors Corp.

5–25

1000/2000/2400 SERIES SERVICE MANUAL 21. Align J 43770 (5) and J 24459-5 (4) with the front support so that:

1

• Threaded rod of J 43770 is facing down. • Two J 43770 bolt holes align with two bolt

holes in the front support. 2

22. Install J 43770 assembly (1).

3

23. Install two front support retaining bolts (2).

4

24. Align the slot in J 24459-5 (4) with retainer pin (3).

5

25. Using J 24459-5 (4) and J 43770 (5), compress the converter flow valve spring until retainer pin (3) is loose.

2

(5)

onto

front

support

R21k

26. Turn the front support so that pin (3) is accessible using a pick, push the pin through front support (1). 27. Turn front support (1) so that the rear is facing down. 28. Relieve converter flow valve spring pressure and remove the J tools. 29. Remove stop (4), spring (3), and converter flow valve (2). 1

2

4 3

V07719.00.00.eps

5–26

Copyright © 2003 General Motors Corp.

MODULE REBUILD b. Ground Sleeve Inspection NOTE: • The ground sleeve bushing and bearing are replaced with the ground sleeve installed in the front support. — Replace the needle bearing if the bearing is damaged. — Replace the bushing if the bushing is damaged or the ID specification is not met. • The only time the ground sleeve is pressed from the front support is to replace the ground sleeve. — The new ground sleeve comes with a pre-installed bushing. — Replace the ground sleeve if the ground sleeve splines or sealring bore specification is not met. • The bearing must be removed to replace the ground sleeve. If the ground sleeve and the bearing both need replacing, replace the ground sleeve first. • Replace the ground sleeve if it does not meet specifications.

1

R22

1. Inspect the splines of ground sleeve (1) for damage and wear. No visible wear is allowed.

2. Measure the ID of ground sleeve (2) at the turbine shaft sealring bore (Dimension A). Maximum ID is 45.450 mm (1.7894 inch).

1 B

3. Measure the ID of ground sleeve bushing (1) (Dimension B). Maximum ID is 33.820 mm (1.3315 inch).

2

A

R23

Copyright © 2003 General Motors Corp.

5–27

1000/2000/2400 SERIES SERVICE MANUAL c. Ground Sleeve Replacement Tools Required

1

• J 43765

Ground Sleeve Installer/Remover

1. Remove the bearing per Paragraph 5–8d. 2. Position front support (2) on a press bed so that it is supported by wooden blocks and the ground sleeve is facing down.

2

3. Install the short end of J 43765-2 (1) into the rear of the front support. 4. Press the ground sleeve from front support (2).

V07710.00.00.eps

5. Position front support (2) on the work table so that the rear hub is facing down. 6. Align the ground sleeve with the front support so that the sleeve is centered over the front support and the rear of the sleeve is facing down.

1

2

V07782.00.00.eps

2

1

7. Rotate ground sleeve (1) until the lowest (and smallest) hole in the ground sleeve is aligned with fluid passage (2). Arrows indicate the holes that must align. 8. Gently tap the ground sleeve into the front support until the front support holds the ground sleeve in a vertical position.

18°

V07783.00.00.eps

5–28

Copyright © 2003 General Motors Corp.

MODULE REBUILD 9. Align J 43765-1 (1) so that the lip of the tool is down.

1

10. Install J 43765-1 (1) onto the ground sleeve.

2

R26b

11. While holding J 43765-1 (3) in place, turn over the front support/ground sleeve and place J 43765-1 on a press.

1

12. Install J 43765-3 (1) into the rear hub of front support (2). 2

13. Press on J 43765-3 until the ground sleeve seats.

3

R26c

14. Check the Total Indicated Runout (TIR) of the ground sleeve as follows. C

• Install the OD (D) of front support (1) in a

lathe. • Using a dial indicator, make sure front support (1) surface (C) is square with the OD (D) of the front support. • Check the TIR along ground sleeve axis (B) at the ground sleeve pitch diameter (A). The TIR must not exceed 0.20 mm (0.008 inch).

1

2 B

D

A

15. If the bearing does not need replacing, install the bearing per Paragraph 8–5d.

R26e

Copyright © 2003 General Motors Corp.

5–29

1000/2000/2400 SERIES SERVICE MANUAL d. Ground Sleeve Needle Bearing Replacement Tools Required 2

3

1

• J 26941

Front Support Needle Bearing Remover

• J 8092

Universal Driver

• J 43775

Front Support Needle Bearing Installer

NOTE: If the bearing has been removed, skip Steps 1 through 5.

R25

1. Position front support (3) so that it is supported by wooden blocks and the ground sleeve is facing down. 2. Install J 26941 (1) into bearing (2) so that the lips of the tool engage the bottom lip of the needle bearing race. 3. Tighten the screw of J 26941 finger tight. 4. Install a slide hammer onto the end of J 26941. 5. Remove needle bearing (2). 6. Install the large end of J 43775 (2) onto J 8092 (1).

3

7. Install a new needle bearing (3) onto J 43775 (either side up).

1

8. Drive needle bearing (3) into front support (4) until J 43775 seats.

4

9. Make sure the bearing is installed flush to 0.25 mm (0.010 inch) below ground sleeve surface.

2

R25a

5–30

Copyright © 2003 General Motors Corp.

MODULE REBUILD e. Ground Sleeve Bushing Replacement 1

Tools Required

7

• J 44529 • J 8092

Ground Sleeve Bushing Remover Universal Driver

• J 43774

Ground Sleeve Bushing Installer

2 3 4

CAUTION:

9 8 10

Always use J 44529 when removing the ground sleeve bushing to help avoid damage to the ground sleeve sealing surface. 1. Position front support (10) so that it is supported by wooden blocks and the ground sleeve is facing up.

5 6

V07742.01.00.eps

2. Install J 44529-2 (8) into J 44529-1 (7). 3. Install J 44529-2 (8) and J 44529-1 (7) into bushing (9). 4. Install washer J 44529-2 (8).

(6)

and

nut

(5)

onto

5. While holding the top of J 44529-2 (8) with a wrench, tighten nut (5) until J 44529-1 (7) engages bushing (9). 6. Install J 44529-3 (4) onto J 44529-2 (8). 7. Install bearing (3), washer (2), and nut (1) onto J 44529-2 (8). 8. While holding the top of J 44529-2 (8) with a wrench, tighten nut (1) until the bushing is dislodged. 9. Remove the J tools from the ground sleeve. 10. Remove the bushing from the J tools.

Copyright © 2003 General Motors Corp.

5–31

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: The preferred method for installing the ground sleeve bushing is to use J 43774 and a press. If a press is not available, use J 43774 and J 8092 universal driver.

1 3

11. If the bushing will be installed by hand, install the large end of J 43774 (2) onto J 8092 (1).

4

12. Install new bushing (3) onto J 43774.

2

13. Drive the bushing into ground sleeve (4) until the bushing is seated.

R27a

14. Make sure the bushing is installed flush to 0.25 mm (0.010 inch) below the ground sleeve surface. f. Front Support Thrust Washer Inspection

1

NOTE: Replace the thrust washer if any of the following specifications are not met. 1. Measure the thickness of thrust washer (1) (Dimension A).

A

2. Minimum thrust washer thickness is 1.49 mm (0.059 inches).

V07718.00.00.eps

g. Front Support Assembly Tools Required 1

• J 24459-5

Spring Compressor Adapter

• J 43770

Main, Lube, Converter Relief Valve Spring Compressor

• J 43773

Valve Spring Compressor

1. Position front support assembly (1) on the work table so that the rear of the assembly is facing down. 2. Install converter flow valve (2). 2

4

3. Install converter flow valve spring (3) and stop (4).

3 V07719.00.00.eps

5–32

Copyright © 2003 General Motors Corp.

MODULE REBUILD 4. Install J 24459-5 (1) onto J 43770 (2).

2

1

V07709.00.00.eps

5. Align J 43770 (5) and J 24459-5 (4) with the front support so that:

1

• The threaded rod of J 43770 is facing down. • Two J 43770 bolt holes align with two bolt

holes of the front support. 6. Install J 43770 (5) onto the front support assembly.

2

7. Install two bolts (2).

3

8. Align J 24459-5 (4) slot with the pin (3). 9. Using J 24459-5 (4) and J 43770 (5), compress the spring until the stop is past the pin hole.

4 2 5

10. Install retainer pin (3). Make sure the pin is below the front support surface. R21k

11. Remove the J tools.

Copyright © 2003 General Motors Corp.

5–33

1000/2000/2400 SERIES SERVICE MANUAL 12. Install converter relief valve (1).

2 1

NOTE: The Converter Relief valve spring has been redesigned. The new valve spring is 44.85 mm (1.766 inch) in free length and has 12.18 coils. The new spring is not marked with color striping. Replace the former valve spring with the current valve spring, P/N 29541296. The converter relief valve spring P/N 29541296 and lube regulator valve spring P/N 29540523 must be replaced at the same time. Refer to SIL 29-1K2K-02. 13. Install converter relief valve spring (2).

V07795.00.00.eps

14. Using J 43773 (2), compress the spring. 15. Install retaining clip (1). Make sure the retaining clip is below the front support surface.

1

2 V07796.00.00.eps

16. Install lube regulator valve (1). NOTE: The Lube Regulator valve spring has been redesigned. The new valve spring is colored light blue, is 31.43 mm (1.237 inch) in free length, and has 6.79 coils. Replace the former valve spring with the current valve spring, P/N 29540523. Lube regulator valve spring P/N 29540523 and converter relief valve spring P/N 29541296 must be replaced at the same time. Refer to SIL 29-1K2K-02. 1

4

17. Install lube regulator valve spring (2). 18. Install O-ring (3) onto lube regulator stop (4).

2 3

19. Install the lube regulator stop. V07797.00.00 .eps

5–34

Copyright © 2003 General Motors Corp.

MODULE REBUILD 20. Align J 24459-5 (2) slot with retainer pin (1).

1

21. Using J 24459-5 (2), compress the spring until the stop is past the pin hole. 22. Install retainer pin (1). Make sure the pin is below the surface of the front support.

2 V07798.00.00.eps

23. Install C1 clutch backfill valve (1). 24. Install C1 clutch backfill valve spring (2).

1 2 V07781.00.00.eps

25. Using J 43773 (2), compress the spring. 26. Install retaining clip (1). Make sure the retaining clip is below the surface of the front support.

1

2 V07780.00.00.eps

Copyright © 2003 General Motors Corp.

5–35

1000/2000/2400 SERIES SERVICE MANUAL 27. Install main regulator valve (1). 28. Install main regulator valve spring (2) and stop (3).

1 2 3 V07779.00.00.eps

29. Install J 24459-5 (1) onto J 43770 (2).

2

1

V07709.00.00.eps

5–36

Copyright © 2003 General Motors Corp.

MODULE REBUILD 30. Align J 43770 (5) and J 24459-5 (4) with the front support so that:

1

• The J 43770 threaded rod faces down. • Two J 43770 bolt holes align with two bolt

holes in the front support. 2

31. Install J 43770 (5) onto the front support assembly.

3

32. Install two bolts (2).

4

33. Align J 24459-5 (4) slot with retainer pin (3). 2

34. Using J 24459-5 (2) and J 43770 (5), compress the spring until the stop is past the pin hole. 35. Install retainer pin (3). Make sure the pin is below the front support surface.

5

V07732.00.00.eps

36. Remove the J tools.

5–9.

CONVERTER HOUSING/FRONT SUPPORT MODULE ASSEMBLY 1

Tools Required • J 43772

Oil Pump Seal Installer

1. Position main pump assembly (2) on the work table so that the rear of the pump is facing up. 2. Align the dowel pin holes in separator plate (1) with dowel pins (3) in the pump body. Align the bolt holes in separator plate (1) with the bolt holes in main pump body (2).

3

3. Install separator plate (1) onto main pump assembly (2).

2 3 A16

Copyright © 2003 General Motors Corp.

5–37

1000/2000/2400 SERIES SERVICE MANUAL 4. Position front support assembly (5) on the work table so that ground sleeve (4) is facing up.

1 2

5. Align, as a unit, main pump assembly (1) and separator plate (3) so that:

3

• Align main pump dowel pins (2) with their

holes in the front support assembly. • Align the main pump assembly bolt holes with the bolt holes of the front support assembly.

4

6. Install, as a unit, main pump assembly (1) and separator plate (3) onto front support assembly (5).

5

7. Install five bolts (6). Tighten the bolts to 24–29 N·m (18–21 lb ft).

6 A16a

8. Align the tangs of thrust washer (5) with the slots at the base of the front support assembly rear hub.

1 2

9. Install thrust washer (5) onto the front support assembly. The thrust washer should snap into place.

3

NOTE: The three butt joint sealrings on the rear hub have been replaced with three double lap joint sealrings. The butt joint and double lap joint sealrings are interchangeable for all medium duty applications regardless of transmission serial number.

4

5

6 D15

10. Install three new butt joint or double lap joint sealrings (6) onto the front support assembly rear hub.

CAUTION: Interchanging the ground sleeve butt joint sealrings on the ground sleeve may result in transmission damage. Install the correct sealring at the correct ground sleeve location. • P/N 29538158 (1) is installed on the front end of the ground sleeve. • P/N 29531038 (2) is installed on the middle of the ground sleeve. 11. Install a new butt joint sealring (2) onto the middle of ground sleeve (3). 12. Install a new butt joint sealring (1) onto the front of ground sleeve (3). 5–38

Copyright © 2003 General Motors Corp.

MODULE REBUILD 13. Position front support module (5) on the work table so that the ground sleeve is facing up. 14. Align the bolt holes of converter housing/ separator plate gasket (2) with the bolt holes in separator plate (4).

1

15. To assist in retaining gasket, apply petrolatum in spots to the gasket face nearest the separator plate.

2

16. Install the gasket onto the separator plate.

3

17. Apply petrolatum onto the OD of main pump assembly (3).

4 5 D14

18. Install two M10 x 1.5 guide bolts (2) into front support module (3). 19. Align the converter housing bolt holes with the bolt holes in the front support module. 20. Install the converter housing onto the guide bolts and onto the front support module. 1

21. Remove the guide bolts from the front support module.

2 3 A14

22. Install seals (2) onto ten bolts (1).

1 2

3 4 5 D14

Copyright © 2003 General Motors Corp.

5–39

1000/2000/2400 SERIES SERVICE MANUAL 23. Install ten bolts (1) into the converter housing to retain the front support module. In a crisscross pattern, tighten the bolts to 51–61 N·m (38–45 lb ft). 1

1 1

1 1 1

1 1

1

1

V07728.00.00.eps

24. Align oil seal assembly (2) with main pump body (3) so that the double edges face the pump body hub. 1

25. Using J 43772, install the oil seal assembly into the pump body hub. 26. Make sure the seal is installed flush to 0.25 mm (0.010 inch) below the main pump body surface.

2

3

D10d

5–10. ROTATING CLUTCH MODULE 3

a. Disassembly of Rotating Clutch Module 1 4

Tools Required • J 24204-2 • J 43776

2

• J 43777

Bar and Stud Assembly C2 Piston Return Spring Compressor C1 Piston Return Compressor

1. Position rotating clutch assembly (4) on the work table so that the rear of the assembly is up. 2. Remove retaining ring (1) from the rotating clutch assembly.

R46

5–40

3. Remove P1 sun gear (3) with P1 drive flange (2). Remove the P1 sun gear from the drive flange.

Copyright © 2003 General Motors Corp.

MODULE REBUILD 4. Remove bronze thrust washer (1) from C2 drive hub (2).

1

2

R45

5. Remove C2 drive hub (1). 5

1

NOTE: The thrust bearing assembly may stick to the C1 drive hub or the C2 drive hub. 2

6. Remove thrust bearing assembly (2) from the rear of C1 drive hub (3) or the front of C2 drive hub (1). 7. Remove C1 drive hub (3).

3 4

NOTE: The thrust bearing assembly may stick to the rear of the turbine shaft or the front of the C1 drive hub.

R43a

8. Remove thrust bearing assembly (4) from the rear of turbine shaft (5) or the front of the C1 drive hub.

Copyright © 2003 General Motors Corp.

5–41

1000/2000/2400 SERIES SERVICE MANUAL 9. Remove seven C2 clutch reaction plates (1) and six C2 clutch friction plates (2) from rotating clutch housing (3).

3 1 2

R44

10. Remove internal spiral retaining ring (1) from C1 clutch backplate (3).

1 2

11. Remove retaining ring (2) from turbine shaft (4).

3

12. Remove C1 clutch backplate (3) from turbine shaft (4).

4 5

R41

3

1

13. Remove six C1 clutch friction plates (1) and six C1 reaction clutch plates (2) from turbine shaft (3).

2

R39

5–42

Copyright © 2003 General Motors Corp.

MODULE REBUILD WARNING! The rotating clutch housing and turbine shaft are held together by a retaining ring. Removing the retaining ring allows the turbine shaft and the rotating clutch housing to move freely. Make sure the rotating clutch housing and the turbine shaft are restrained from moving when removing the retaining ring. Personal injury and/or property damage may result from the movement of the rotating clutch housing or the turbine shaft. 14. Remove retaining ring (1) from turbine shaft (3). 15. Remove rotating clutch housing (2) from the rear of the turbine shaft. 16. Remove two butt joint sealrings (4) from the turbine shaft.

1

2 3

4 R38

17. Position rotating clutch housing (2) on the work table so that the rear of the housing is facing up.

1

18. Remove retaining ring (1) from C1 piston housing (3).

3

2

R37a

19. Position rotating clutch housing (7) on the base of J 24204-2 (8) so that the rear of the housing is facing up. 20. Install J 43777 (5) onto the C1 piston return spring assembly.

1 6 2

21. Align J 43777 (5) notch with the gap in retaining ring (6). 22. Install J 43777 (4) extension onto the shaft of J 24204-2 (8).

3

4

7

5

23. Install the J 24204-2 ball bearing (3) and washer (2) onto the shaft of J 24204-2. 8

24. Install the J 24204-2 wing nut (1) onto the shaft of J 24204-2. Copyright © 2003 General Motors Corp.

R36

5–43

1000/2000/2400 SERIES SERVICE MANUAL 25. Compress the return spring assembly until retaining ring (6) can be removed.

1 6

26. Remove retaining ring (6) from its groove in the rotating clutch housing inner hub.

2

27. Remove all J tools.

3

4

28. Remove retaining ring (6) from rotating clutch housing (7).

7

5

8 R36

29. Remove C1 piston return spring assembly (1) from C1 clutch piston (3).

1

2

30. Remove C1 clutch piston (3), with C1 balance piston (2) attached, from the rotating clutch housing.

3

31. Remove C1 balance piston (2) from C1 clutch piston (3).

4

R35a

32. Remove sealrings (1) and (2) from C1 clutch piston (3).

1 2 3

R34

5–44

Copyright © 2003 General Motors Corp.

MODULE REBUILD 33. Position rotating clutch housing (8) on the base of J 24204-2 (10) so that the rear of the housing is facing up.

1 7

2

34. Align J 43776-2 (7) so that the bowl is facing down.

3

35. Install J 43776-1 (7) onto the shaft of J 24204-2 and onto the C2 piston return spring assembly. Make sure the rim of the J 43776-2 almost touches the retaining ring. 36. Install J 43776 spring (5) onto the shaft of J 24204-2.

4 8 9 5

6

NOTE: J 43776-1 has two notches. Either notch can fit over the ball of the C1 piston housing, but only one notch also leaves the holes in the retaining ring easily accessible.

10 R33

37. Align J 43776-2 (4) so that: • One notch fits over the ball of C1 piston

housing (9). • The holes in retaining ring (6) are easily accessible. 38. Install J 43776-1 (4) onto the shaft of J 24202-2. 39. Install J 24204-2 ball bearing (3) and washer (2) onto the shaft of J 24204-2. 40. Install J 24204-2 wing nut (1) onto the shaft of J 24204-2. NOTE: Make sure the J 43776-1 notch remains over the ball of the C1 piston housing while the return spring assembly is being compressed. 41. Compress the return spring assembly until retaining ring (6) can be removed. 42. Remove retaining ring (6) from its groove in the rotating clutch housing inner hub and move the retaining ring over the top of J 43776-2 (7). 43. Remove all J tools from the rotating clutch housing. 44. Remove retaining ring (6) from the rotating clutch housing.

Copyright © 2003 General Motors Corp.

5–45

1000/2000/2400 SERIES SERVICE MANUAL 45. Remove C1 piston housing (1) from rotating clutch housing (3). 1

46. Remove C2 piston return spring assembly (2) from C2 clutch piston (4). 2

4

3

R32b

1

47. Remove retaining ring (1) from the rotating clutch housing.

2

48. Remove C2 clutch piston (3) with C2 balance piston (2) attached. 49. Remove C2 balance piston (2) from C2 clutch piston (3).

3

4

R31

50. Remove O-ring (1) from the inner hub of rotating clutch housing (2). 1

2

R32a

5–46

Copyright © 2003 General Motors Corp.

MODULE REBUILD 51. Remove three piston sealrings (1), (2), and (3) from C2 clutch piston (4). 1 2 3 4

R30

b. Turbine Shaft Inspection NOTE: Replace the turbine shaft bushing if any of the following specifications are not met. 1. Inspect bushing (2) inside the end of turbine shaft (1) for damage.

1

2

A

2. Measure the ID of the turbine shaft bushing (Dimension A). Maximum ID is 20.117 mm (0.7920 inch).

R47

Copyright © 2003 General Motors Corp.

5–47

1000/2000/2400 SERIES SERVICE MANUAL c. Turbine Shaft Bushing Replacement

1 2

Tools Required

7 9

3 10

• J 44526

Output/Turbine Shaft Bushing Remover

• J 43791

Output/Turbine Shaft Bushing Installer

4 8

CAUTION: Always use J 44526 when removing the turbine shaft bushing to help avoid damage to the turbine shaft.

5 6

1. Install J 44526-2 (8) into J 44526-1 (7). R48

2. Install J 44526-2 (8) and J 44526-1 (7) into bushing (9). 3. Install washer (6) and nut (5) onto J 44526-2 (8). 4. While holding the top of J 44526-2 (8) with a wrench, tighten nut (5) until J 44526-1 (7) engages bushing (9). 5. Install J 44526-3 (4) onto J 44526-2 (8). 6. Install bearing (3), washer (2), and nut (1) onto J 44526-2 (8). 7. While holding the top of J 44526-2 (8) with a wrench, tighten nut (1) until the bushing is dislodged. 8. Remove the J tools from the turbine shaft.

5–48

Copyright © 2003 General Motors Corp.

MODULE REBUILD 9. Install a new bushing (2) onto J 43791 (1). 1

10. Drive the bushing into turbine shaft (3) until the bushing is seated. 11. Make sure the bushing is installed flush to 0.25 mm (0.010 inch) below the inner turbine shaft surface.

2 3

R48a

d. Rotating Clutch Housing Inspection NOTE: PTO gears are permanently staked to the rotating clutch housing and are not serviceable. Turbine tone wheels are serviceable. 1. Inspect the turbine tone wheel or PTO Gear (3) for damage. Make sure a tone wheel is not dented or out-of-round.

3

1

2

B

A

2. If the PTO gear is damaged, replace the rotating clutch housing. If the tone wheel is damaged, replace the tone wheel. 3. Measure the ID of the rotating seal bore of rotating clutch housing (1) (Dimension A). If the ID exceeds 74.050 mm (2.9154 inch), replace the rotating clutch housing.

R49

NOTE: Replace the rotating clutch housing bushing if any of the following specifications are not met. 4. Inspect bushing (2) inside the front of rotating clutch housing (1) for damage. 5. Measure the ID of the bushing (Dimension B). The maximum ID is 78.170 mm (3.0776 inch).

Copyright © 2003 General Motors Corp.

5–49

1000/2000/2400 SERIES SERVICE MANUAL e. Rotating Clutch Housing Bushing Replacement

1

Tools Required • J 43778

Rotating Clutch Bushing Installer

• J 8092

Universal Driver

CAUTION:

2

DO NOT score the rotating clutch housing bore when removing the clutch housing bushing. 1. Gently tap the bushing through the inside of the rotating clutch housing until the bushing becomes dislodged. R50

2. Remove bushing (2) from rotating clutch housing (1). 3. Remove any nicks or burrs with crocus cloth. 4. Position rotating clutch housing (4) on a press so that the front of the housing is facing up.

1 2

NOTE: The preferred method for installing the rotating clutch housing bushing is to use J 43778 and a press. If a press is not available, use J 43778 and J 8092 universal driver.

3 4

5. If the bushing will be installed by hand, install the large end of J 43778 (2) onto J 8092 (1). 6. Install a new bushing (3) onto J 43778 (2).

R50a

7. Using J 43778, press the new bushing into the clutch housing. 8. Make sure the bushing is installed flush to 0.25 mm (0.010 inch) below the rotating clutch housing surface.

5–50

Copyright © 2003 General Motors Corp.

MODULE REBUILD f. Rotating Clutch Housing Tone Wheel Replacement 1

Tools Required • J 43768 • J 43767

Tone Wheel Driver Tone Wheel Staker

1. Grind the stakes housing (1).

from

rotating

clutch

R50b

2. Position rotating clutch housing (2) on a press so that the front of the housing is down.

1

3. Install J 43768 (1) onto tone wheel (3). 4. Using J 43768 (1), press tone wheel (3) from rotating clutch housing (2).

2 3

R50c

5. Position rotating clutch housing (3) on a press so that the front of the housing is facing up.

1

6. Align tone wheel (2) so that the outside edge is facing up. 7. Install tone wheel (2) onto the rotating clutch housing.

2

8. Install J 43768 (1) onto the tone wheel. 9. Using J 43768 (1), press the tone wheel onto the rotating clutch housing.

3

R50d

Copyright © 2003 General Motors Corp.

5–51

1000/2000/2400 SERIES SERVICE MANUAL 10. Locate four positions on rotating clutch housing (3), 90 degrees apart, that have not been previously staked.

1

11. Align J 43767 (2) so that the staking prongs are down at two of the staking locations.

2

12. Install J 43767 (2) onto the rotating clutch housing. 3

13. Install J 43768 (1) onto J 43767 (2).

CAUTION:

R50e

Stake the tone wheel to 9 tons. The accuracy of the pressure gauges on presses varies. Start at a lower pressure and increase to 9 tons. Too great a pressure will distort the tone wheel. Too little pressure will result in stakes that will not hold. 14. Using J 43767 (2) and J 43768 (1), stake the turbine tone wheel to the rotating clutch housing. NOTE: Tapping J 43768 and J 43767 may be required to remove J 43768 and J 43767 from the rotating clutch housing. 15. Remove J 43768 (1) and J 43767 (2).

5–52

Copyright © 2003 General Motors Corp.

MODULE REBUILD 16. Align J 43767 (2) so that the staking prongs are down at the other two 2 staking locations.

1

17. Install J 43767 (2) onto the tone wheel. 18. Install J 43768 (1) onto J 43767 (2). 2

CAUTION: Stake the rotating clutch housing to 9 tons. The accuracy of the pressure gauges on presses varies. Start at a lower pressure and increase to 9 tons. Too great a pressure will distort the tone wheel. Too little pressure will result in stakes that will not hold.

3

19. Using J 43767 (2) and J 43768 (1), stake the turbine tone wheel to the rotating clutch housing.

R50e

NOTE: Tapping J 43768 and J 43767 may be required to remove J 43768 and J 43767 from the rotating clutch housing. 20. Remove J 43768 (1) and J 43767 (2).

g. C1 Clutch Friction Plate Inspection 1

NOTE: • Measure as described below at three or more locations. • Replace any C1 clutch friction plate that does not meet specifications. 1. Measure the thickness of each C1 clutch friction plate (1) (Dimension A). Minimum thickness is 2.375 mm (0.0935 inch). 2. Measure the oil groove depth of each plate (Dimension B). Minimum groove depth is 0.200 mm (0.0079 inch).

A

B V07802.00.00.eps

Copyright © 2003 General Motors Corp.

5–53

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: Check the plates for coning on a level surface.

A

3. Measure the cone of each plate (1) (Dimension A). Maximum cone is 0.255 mm (0.0100 inch).

1

R52

h. C1 Clutch Reaction Plate Inspection 1

NOTE: • Measure as described below at three or more locations. • Replace any C1 clutch reaction plate that does not meet specifications. 1. Measure the thickness of each C1 clutch reaction plate (1) (Dimension A). Minimum thickness is 2.135 mm (0.0841 inch). A

R53

NOTE: Check the plates for coning on a level surface.

A

2. Measure the cone of each plate (1) (Dimension A). Maximum cone is 0.200 mm (0.0079 inch).

1

R54

5–54

Copyright © 2003 General Motors Corp.

MODULE REBUILD i. C1 Clutch Backplate Inspection 1

NOTE: • Measure as described below at three or more locations. • Replace the C1 clutch backplate if it does not meet specifications. 1. Measure the wear surface thickness of C1 clutch backplate (1) (Dimension A). Minimum thickness is shown in the table. ID

Minimum Thickness

6221

11.840 mm (0.4661 inch)

6222

12.280 mm (0.4835 inch)

6223

12.730 mm (0.5012 inch)

6224

13.180 mm (0.5189 inch)

6225

13.630 mm (0.5366 inch)

A

R55

NOTE: Check the plates for coning on a level surface. 2. Measure the cone of backplate (1) (Dimension A). Replace backplate (1) if any cone is present.

A 1

R56

Copyright © 2003 General Motors Corp.

5–55

1000/2000/2400 SERIES SERVICE MANUAL j. C2 Clutch Friction Plate Inspection 1

NOTE: • Measure as described below at three or more locations. • Replace any C2 clutch friction plate that does not meet specifications. 1. Measure the thickness of each C2 clutch friction plate (1) (Dimension A). Minimum thickness is 2.375 mm (0.0935 inch).

A

2. Measure the oil groove depth of each plate (Dimension B). Minimum groove depth is 0.200 mm (0.0079 inch).

B R57

NOTE: Check the plates for coning on a level surface. 3. Measure the cone of each plate (1) (Dimension A). Maximum cone is 0.225 mm (0.0089 inch). A

1

R58

k. C2 Clutch Reaction Plate Inspection 1

NOTE: • Measure as described below at three or more locations. • Replace any C2 clutch reaction plate that does not meet specifications. 1. Measure the thickness of each C2 clutch reaction plate (1) (Dimension A). Minimum thickness is 2.135 mm (0.0841 inch).

A

R59

5–56

Copyright © 2003 General Motors Corp.

MODULE REBUILD

NOTE: Check the plates for coning on a level surface. 2. Measure the cone of plate (1) (Dimension A). Maximum cone is 0.240 mm (0.0094 inch). A

1

R60

l. C1 Piston Housing Inspection NOTE: • Measure as described below at three or more locations. • Replace the C1 piston housing if it does not meet specifications.

1 2

1. Inspect C1 piston housing (1) for damage. 2. Make sure ball (2) moves freely and has a minimum of 1.0 mm (0.04 inch) travel parallel to the centerline of the C1 piston housing. R60b

m. Rotating Clutch Thrust Washer Inspection 1

NOTE: Replace the thrust washer if any of the following specifications are not met. 1. Measure the thickness of thrust washer (1) (Dimension A). 2. The minimum (0.102 inches).

thickness

is

2.59

mm A

R60a

Copyright © 2003 General Motors Corp.

5–57

1000/2000/2400 SERIES SERVICE MANUAL n. Assembly of Rotating Clutch Module Tools Required 1 2 3 4

R30

• J 24204-2

Bar and Stud Assembly

• J 43776

C2 Piston Return Spring Compressor

• J 43777

C1 Piston Return Compressor

• J 44525

C1 Clutch Backplate Selector

NOTE: The C2 clutch piston has been redesigned to eliminate the 1 mm (0.040 in.) bleed hole. For medium duty applications the current and former C2 Clutch pistons are interchangeable regardless of transmission serial number. 1. Install three piston sealrings (1), (2), and (3) onto C2 clutch piston (4). 2. Lubricate C2 balance piston seal (3), the piston ID and OD, and sealrings (1) and (2) with petrolatum.

3. Position rotating clutch housing (2) on the work table so that the rear of the housing is facing up.

1

4. Install O-ring (1) into the bottom groove on the inner hub of rotating clutch housing (2).

2

R32a

5–58

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5. Position C2 clutch piston (3) on the work table so that the rear of the piston is facing up.

1

6. Align C2 balance piston (2) so that the rubber seal is facing down.

2

7. Install C2 balance piston (2) onto C2 clutch piston (3). 8. Lubricate the rubber seals on C2 balance piston (2) with petrolatum.

3

9. Install C2 clutch piston (3) with C2 balance piston (2) attached into rotating clutch housing (4). Make sure the C2 clutch piston is seated on the rotating clutch housing.

4

10. Push C2 balance piston (2) below the retaining ring groove on rotating clutch housing (4).

R31

11. Install retaining ring (1) into rotating clutch housing (4). Make sure the retaining ring is seated completely around the rotating clutch housing. 12. Align C2 piston return spring assembly (2) so that the notches of the spring assemblies are facing and aligned with the tangs of C2 clutch piston (4).

1

13. Install C2 piston return spring assembly (2) into C2 clutch piston (4).

2

14. Align C1 piston housing (1) so that the rear of the housing is facing up. 15. Install C1 piston housing (1) into C2 clutch piston (4).

4

3

R32b

Copyright © 2003 General Motors Corp.

5–59

1000/2000/2400 SERIES SERVICE MANUAL 16. Position rotating clutch housing (8) on the base of J 24204-2 (10) so that the rear of the housing is facing up.

1 7

2 3

17. Install J 43776-1 (7) onto the shaft of J 24204-2 with the bowl down. 18. Install retaining ring (6) onto the surface of J 43776-2 (7).

4 8

19. Install J 43776 spring (5) onto the shaft of J 24204-2.

9 5

20. Install J 43776-2 (4) onto the shaft of J 24204-2.

6 10 R33

21. Align a notch of J 43776-2 (4) with the ball of the C1 piston housing. 22. Install J 24204-2 ball bearing (3) washer (2) onto the J 24204-2 shaft.

and

23. Install J 24204-2 wing nut (1) of onto the shaft of J 24204-2. 24. Compress the C2 piston return spring assembly until the retaining ring groove on the inner hub of the rotating clutch housing is visible. 25. Install retaining ring (6) onto the rotating clutch housing inner hub. Make sure the retaining ring is seated all around the clutch housing. 26. Remove all J tools except for the base of J 24204-2. 27. Install C1 piston ID sealring (1) and C1 piston OD sealring (2) onto C1 clutch piston (3). Lubricate the sealrings with petrolatum.

1 2 3

R34

5–60

Copyright © 2003 General Motors Corp.

MODULE REBUILD 28. Position rotating clutch housing (3) on the work table so that the rear of the housing is facing up.

1

29. Align C1 clutch piston (2) so that the spring indents are facing up. 2

30. Install C1 clutch piston (2) into C1 piston housing (4). Make sure the C1 clutch piston is seated in the C1 piston housing.

3 4

31. Align C1 piston return spring assembly (1) so that the springs are facing and aligned with the spring pockets of C1 clutch piston (2). 32. Install C1 piston return spring assembly (1) into C1 clutch piston (2).

R35

33. Position rotating clutch housing (7) on the base of J 24204-2 (8) so that the rear of the housing is facing up. 34. Place retaining ring (6) into the inner hub of the rotating clutch housing.

1 6 2 3

35. Install J 43777 (5) onto the shaft of J 24204-2 (8). 36. Center J 43777 on the C1 piston return spring assembly. 37. Install J 43777 extension (4) onto the shaft of J 24204-2. 38. Install J 24202-2 ball bearing (3) washer (2) onto the shaft of J 24204-2.

and

4

7

5

8 R36

39. Install J 24204-2 wing nut (1) on the shaft of J 24204-2. 40. Compress the C1 piston return spring assembly until the retaining ring groove on the rotating clutch housing inner hub is visible. 41. Install retaining ring (6) onto the rotating clutch housing inner hub. 42. Remove all J tools.

Copyright © 2003 General Motors Corp.

5–61

1000/2000/2400 SERIES SERVICE MANUAL 43. Position rotating clutch housing (3) on the work table so that the rear of the housing is facing up.

1

44. Lubricate the rubber seals on C1 balance piston (2) with petrolatum. 2

45. Align C1 balance piston (2) so that the rubber seal is facing down. 46. Install the C1 balance piston between the C1 clutch piston and the C1 piston housing.

3

47. Press C1 balance piston (2) into the C1 piston housing until the C1 balance piston is below the retaining ring groove on the C1 piston housing. 48. Install retaining ring (1). Make sure the retaining ring is seated in its groove.

R37

49. Install two butt joint sealrings (4) onto turbine shaft (3).

1

50. Position turbine shaft (3) on the work table so that the rear of the shaft is facing up. 2

51. Align rotating clutch housing (2) with the rear of turbine shaft (3) so that the rear of the clutch housing is facing up.

3

52. Install rotating clutch housing (2) onto the larger splined diameter of turbine shaft (3). 53. Install retaining ring (1) onto the turbine shaft. Make sure the retaining ring is seated completely around the turbine shaft.

4 R38

3

1 2

54. Starting with a C1 clutch reaction plate, alternately install six C1 clutch reaction plates (2) and six C1 clutch friction plates (1) onto turbine shaft (3).

R39

5–62

Copyright © 2003 General Motors Corp.

MODULE REBUILD 55. Align J 44525-2 (3) with the turbine shaft so that the countersunk holes of J 44525-2 are facing up.

1 2

56. Install J 44525-2 (3) onto the turbine shaft. 57. Align J 44525-1 (2) with the turbine shaft so that the inner ridge of J 44525-1 is facing down.

3

4

58. Slide the inner ridge of J 44525-1 (2) into the turbine shaft retaining ring groove. 59. Align the holes in J 44525-1 (2) with the countersunk holes of J 44525-2 (3). 60. Hand install two J 44525 bolts (1) into the holes of the J 44525-1 (2).

R40

61. Torque J 44525-1 bolts (1) to 5.4 N·m (48 lb in.). NOTE: The shift quality of the transmission depends heavily on selecting the correct C1 clutch backplate. 62. Do the following for each tab of J 44525-3 (1). • Place the flat surface (tabbed end) of

J 44525-3 (1) onto the top surface of J 44525-2 (3). • Try to slide a tab of J 44525-3 (1) into the retaining ring groove on the turbine shaft.

1 2 3 4

NOTE: At most, two of the different tabs will fit into the retaining ring groove. • If a tab fits into the retaining ring groove,

record the four digit ID number, located on the stem of J 44525-3, associated with the tab.

R40a

63. Select a C1 clutch backplate so that: • If no tab of J 44525-3 fits into the retaining

ring groove, select the C1 clutch backplate with ID No. 6221 or 8521.

Copyright © 2003 General Motors Corp.

5–63

1000/2000/2400 SERIES SERVICE MANUAL • If one or more tabs of J 45525-3 fit into the

retaining ring groove, select the C1 clutch backplate with an ID No. corresponding to the highest number recorded in the previous step. C1 Clutch Backplate ID No.

Part Number

6221 6222 6223 6224 6225

29536221 or 29538521 29536222 or 29538522 29536223 or 29538523 29536224 or 29538524 29536225 or 29538525

64. Remove all J tools from the turbine shaft. 65. Align C1 clutch backplate (3) so that the beveled edge of the backplate is facing up.

1 2

66. Install the C1 clutch backplate onto turbine shaft (4).

3

67. Install retaining ring (2) onto turbine shaft (4). 68. Lift C1 clutch backplate (3) and install spiral retaining ring (1) into C1 clutch backplate (3).

4 5

CAUTION: Installing the thrust bearing assembly into the rear of the turbine shaft in the wrong direction— blue stripe not showing—could result in destruction of the transmission. R41

69. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from turbine shaft (3). 1

70. Install thrust bearing assembly (2) into turbine shaft (3). Make sure the blue stripe on the thrust bearing assembly is visible.

2 3

71. Center C1 clutch plates (4).

4

72. Install C1 drive hub (1) over C1 clutch plates (4). Make sure C1 drive hub (1) has seated on thrust bearing assembly (2).

R43

5–64

Copyright © 2003 General Motors Corp.

MODULE REBUILD CAUTION: Installing the thrust bearing assembly onto the rear of the C1 drive hub in the wrong direction— blue stripe not showing—could result in destruction of the transmission.

1

2

73. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from C1 drive hub (3). 74. Install thrust bearing assembly (2) onto rear of C1 drive hub (3). Make sure the blue stripe on the thrust bearing assembly is visible. 75. Align C2 drive hub (1) so that the small end is facing up. 76. Install C2 drive hub (1). 77. Starting with a C2 clutch reaction plate, alternately install seven C2 clutch reaction plates (2) and six C2 clutch friction plates (1) into the rotating clutch housing.

3

R43b

3

1

2

R44a

78. Align the tangs of bronze thrust washer (1) with the holes in C2 drive hub (2). 79. Install bronze thrust washer (1) onto C2 drive hub (2).

1

2

R45

Copyright © 2003 General Motors Corp.

5–65

1000/2000/2400 SERIES SERVICE MANUAL 80. Align P1 sun gear (3) so that the gear teeth of the sun gear face the concave face of P1 drive flange (2).

3 1

81. Install P1 sun gear (3) into P1 drive flange (2). Make sure the splines are engaged.

4

82. While holding the sun gear, align the double wide splines of P1 drive flange (2) with the double wide spaces on rotating clutch housing (4).

2

83. Install P1 sun gear (3) with P1 drive flange (2) into rotating clutch housing (4). 84. Install retaining ring (1) into rotating clutch housing (4). Make sure the retaining ring is seated all the way around the rotating clutch housing.

R46

5–11. MAIN HOUSING ASSEMBLY a. Disassembly of Selector Shaft and Detent Lever Tools Required • J 43911

Selector Shaft Seal Remover

NOTE: Do not remove the selector shaft unless replacing one or more of the following: • • • •

selector shaft selector shaft nut detent lever park pawl apply assembly 1. Position the transmission so that the valve body face of the main housing is facing up. 2. Remove screw J 43911-1 (2).

1

(3)

from

the

body

of

3. Screw the body of J 43911-1 into selector shaft seal (1). 4. Install screw (3) into the body of J 43911-1 (2). 5. Tighten screw (3) against shaft (4) until seal (1) becomes dislodged. 6. Remove selector J 43911-1 (2).

2

5–66

3

R67

Copyright © 2003 General Motors Corp.

shaft

seal

(1)

from

MODULE REBUILD 7. While holding the flats of selector shaft (1), loosen selector shaft nut (2) so that the nut slides freely on the selector shaft. 8. Remove detent lever (2) from the flats of the selector shaft.

2 1

3

R64

CAUTION: DO NOT mar the main housing surface around the spring pin when removing the spring pin. An unmarred surface is required to maintain the seal between the control valve assembly and the main housing.

1 2

9. Place a protective plate (2) on the main housing surface around spring pin (3).

3

10. Place a drill bit (1) into the spring pin to prevent cutting or collapsing the pin while removing the pin. 11. Remove spring pin (3) from the main housing. R64a

12. While holding the detent lever (3) and nut (4), carefully slide selector shaft (1) through the following. • selector shaft nut (4) • detent lever (3) • selector shaft seal hole (2)

13. Remove nut (4), detent lever (3), and park pawl apply assembly (5) (if present) from the main housing.

4

3 2

1

5

R65

Copyright © 2003 General Motors Corp.

5–67

1000/2000/2400 SERIES SERVICE MANUAL 14. If park pawl apply assembly (1) is present, do the following. • Rotate park pawl apply assembly (1) 180

degrees. • Remove the nib of park pawl apply assembly through the keyhole in detent lever (2).

1

2

b. Assembly of Selector Shaft and Detent Lever Tools Required R66a

• J 43909 • J 43766

Selector Shaft Seal Installer Selector Shaft Spring Pin Installer

1. Install a new selector shaft seal (1) onto J 43909 (2). 2. Using J 43909, drive selector shaft seal (1) into the main housing. 1

3. Make sure the selector shaft seal is seated in the bottom of the bore.

2

R67a

4. If the transmission has park pawl apply assembly (1), do the following. • Install

the nib of park pawl apply assembly (1) through the keyhole in detent lever (2). • Rotate the park pawl apply assembly 180 degrees.

1

2

R66b

5–68

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5. If present, place the roller end of park pawl apply assembly (5) into the main housing. 6. Align detent lever (3) so that: • The cockscomb of the detent lever is facing up. • The guide hole for the manual selector valve pin is facing forward. • The selector shaft hole in the detent lever is aligned with selector shaft seal (2). 7. Slide selector shaft (1) through the following components. • selector shaft seal (2) • detent lever (3) • selector shaft nut (4)

4

3 1

2

5

8. Install the selector shaft into the main housing. R65

9. Install detent lever (2) onto the flats of selector shaft (1). 10. Install selector shaft nut (3) onto selector shaft (1). 11. Install a crowsfoot with a torque wrench onto nut (3). 12. While holding the flats of selector shaft (1), tighten nut (3) to 24–34 N·m (18–25 ft lb).

2 1

3

R64

CAUTION: DO NOT mar the main housing surface when installing the spring pin. Use only gentle tapping on the J 43766 selector shaft spring pin installer tool. Heavy or continued hammering on the J 43766 will damage the main housing surface.

1

13. Install spring pin (2) into J 43766. 14. Using J 43766, drive spring pin (2) into the main housing.

2

15. Make sure the spring pin is installed to a height of 8.50–9.00 mm (0.335–0.354 inch). R64b

Copyright © 2003 General Motors Corp.

5–69

1000/2000/2400 SERIES SERVICE MANUAL c. Nameplate Replacement NOTE: When replacing a nameplate, keep the original nameplate. Stamp the information from the original nameplate onto the replacement nameplate.

M

CAUTION:

1 0 OD . 0 EL INDIANOFAP GE SE 0 S OL NE E 6 3 RIA IS, RA L IND XX L RIE MO IAN TO N RS DAT A, US 0 1 X X XO. S A CO RP – X X E . 1 0 X X X X X EFX X X – X X XCN X X 14 XXX – X 21– X X X X 16 XXX X –1 X 34– XXX X X X 7 X DIV

24

1

35 XX – X 37 XXX –X X XX X

DO NOT drill through the main housing when drilling out the nameplate rivets.

TID 39 – 50 XXX X X – X XX XXX X – XX XXX –X X XX X

2

R68

1. Using a 3⁄16 inch drill bit, drill through rivet (1). Remove rivet (1) and nameplate (2). 2. Place a new nameplate (2) and a new rivet (1) onto the main housing. 3. Using a pop rivet gun, install the rivet into the main housing. d. Main Housing Dowel Pin Replacement Tools Required • J 43780

1 2

Main Housing Dowel Pin Installer

NOTE: Do not replace the main housing dowel pin unless the dowel pin is damaged.

CAUTION: DO NOT mar the main housing surface when removing the dowel pin. An unmarred surface is required to maintain the seal between the rear cover assembly and the main housing. R69

1. Remove dowel pin (1) from the rear surface of the main housing. 2. Install a new dowel pin (1) into J 43780 (2).

CAUTION: DO NOT mar the main housing surface when installing the dowel pin. Use only gentle tapping on the J 43780 dowel pin installer tool. Heavy or continued hammering on the J 43780 will damage the main housing surface. 3. Using J 43780 (2), drive the dowel pin until seated. 4. Make sure the dowel pin is installed to a height of 20.80–21.20 mm (0.819–0.835 inch) above the main housing rear surface. 5–70

Copyright © 2003 General Motors Corp.

MODULE REBUILD e. Replacement of Fill Tube Plug 1. Remove fill tube plug (1).

1

2. Remove fill tube seal (2).

2

3. Install fill tube seal (2) into the main housing. 4. Align the tab on fill plug (1) with the tang on the main housing. NOTE: The fill plug should click into place. 5. Install fill plug (1) into fill tube seal (2) and the plug tab into the main housing tang. D5

f. Replacement of Vent Assembly 1

1. Pry off vent cap (1). 2. If vent (2) remains, gently pry the vent from the main housing.

2

3. Gently tap a new vent assembly into the main housing until the vent is seated.

D6

5–12. RING GEAR AND CLUTCH COMPONENT INSPECTIONS

1

a. C3 Clutch Component Inspection NOTE: • Make the measurements described below at three or more locations. • Replace any parts not meeting specifications. 1. Measure the thickness of each C3 clutch friction plate (1) (Dimension A). Minimum thickness is 2.375 mm (0.0935 inch). 2. Measure the oil groove depth of each C3 clutch friction plate (Dimension B). Minimum groove depth is 0.200 mm (0.0079 inch).

A

B

Copyright © 2003 General Motors Corp.

R71

5–71

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: Check the plates for coning on a level surface.

A

3. Measure the cone of each C3 clutch friction plate (1). Maximum cone is 0.225 mm (0.0089 inch).

1

R72

4. Measure the thickness of each C3 clutch reaction plate (1) (Dimension A). Minimum thickness is 2.440 mm (0.0961 inch).

1

A

R73

NOTE: Check the plates for coning on a level surface.

A

5. Measure the cone of each C3 clutch reaction plate (1) (Dimension A). Maximum cone is 0.400 mm (0.0157 inch).

1

R74

5–72

Copyright © 2003 General Motors Corp.

MODULE REBUILD 6. Measure the thickness of C3 spring plate (1) (Dimension A). Minimum thickness is 3.110 mm (0.1224 inch).

1

A

R145

7. Measure the cone of C3 spring plate (1) (Dimension A). Maximum cone is 0.400 mm (0.0157 inch).

A

1

R146

Copyright © 2003 General Motors Corp.

5–73

1000/2000/2400 SERIES SERVICE MANUAL 8. Measure the thickness of C3 clutch backplate (1) (Dimension C). Minimum thickness is 15.325 mm (0.6033 inch).

1

9. Measure the distance from the top of thrust plate (2) to the bottom of the C3 clutch plate inner rim (Dimension A). Measure the thickness of the C3 clutch plate inner rim (Dimension B). Calculate the thickness of the thrust plate (Dimension D) by subtracting Dimension B from Dimension A (Dimension D = Dimension A – Dimension B). Minimum thrust plate thickness is 3.000 mm (0.1181 inch).

2

A B

C

R85

NOTE: Check the plates for coning on a level surface. 10. Measure the cone of C3 clutch backplate (1). Replace backplate (1) if any cone is present.

5–74

Copyright © 2003 General Motors Corp.

MODULE REBUILD b. C3 Clutch Backplate Assembly Thrust Plate Replacement Tools Required • J 39354

Rivet Installer

CAUTION: Use care when drilling through the backplate rivets. Once the rivet has been drilled through, the drill bit may catch on the backplate causing damage to the drill bit and/or the backplate.

NOTE: Replace all three thrust plates if one thrust plate needs replacing. 1. Using a 9⁄64 inch drill bit, drill through the heads of six rivets (1). 2. Remove the rivets and three gear thrust plates (2). NOTE: Set the gap of the rivet installer to 4.45 mm (0.175 inch). If the rivet connection is too loose, use a smaller gap.

1 2

3

3. Using J 39354, install three new gear thrust plates (2) and six rivets (1) so that the rivets are flush or below the surface of the thrust plates. 4. Make sure rivets (1) and thrust plates (2) are not loose.

Copyright © 2003 General Motors Corp.

R87

5–75

1000/2000/2400 SERIES SERVICE MANUAL c. C4 Clutch Component Inspection 1

NOTE: • Measure as described below at three or more locations. • Check the plates for coning on a level surface. • Replace any parts not meeting specifications. 1. Measure the thickness of each C4 clutch friction plate (1) (Dimension A). Minimum thickness is 2.375 mm (0.0935 inch).

A

B R71

2. Measure the oil groove depth of each C4 clutch friction plate (1) (Dimension B). Minimum groove depth is 0.200 mm (0.0079 inch). 3. Measure the cone of each C4 clutch friction plate (1) (Dimension A). Maximum cone is 0.225 mm (0.0089 inch).

A

1

R72

4. Measure the thickness of each C4 clutch reaction plate (1) (Dimensions A). Minimum thickness is 2.440 mm (0.0961 inch).

1

A

R73

5–76

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5. Measure the cone of each C4 clutch reaction plate (1) (Dimension A). Maximum cone is 0.400 mm (0.0157 inch).

A

1

R74

6. Measure the thickness of C4 spring plate (1) (Dimension A). Minimum thickness is 3.110 mm (0.1224 inch).

1

A

R145

7. Measure the cone of C4 spring plate (1) (Dimension A). Maximum cone is 0.400 mm (0.0157 inch).

A

1

R146

Copyright © 2003 General Motors Corp.

5–77

1000/2000/2400 SERIES SERVICE MANUAL 8. Measure the thickness of the C4 clutch backplate (Dimensions A). Minimum thickness is 15.400 mm (0.6063 inch).

1

9. Measure the cone of the C4 clutch backplate. Replace backplate (1) if any cone is present.

A

V07716.00.00.eps

d. C5 Clutch Component Inspection 1

NOTE: • Measure as described below at three or more locations. • Check the plates for coning on a level surface. • Replace any parts not meeting specifications.

A

B V07802.00.00.eps

NOTE: Starting with S/N 631013648, C5 Clutch Friction Plates and the P3 Ring Gear have been redesigned. The former and current designs are interchangeable only if the current C5 Friction Plates are used with the current P3 Ring Gear. Do not mix current and former designs. The former design may be reused unless replacement is indicated by wear measurements or the design is no longer available. 1. Measure the thickness of each C5 clutch friction plate (1). Minimum thickness is 2.375 mm (0.0935 inch). 2. Measure the oil groove depth of each C5 clutch friction plate (1). Minimum groove depth is 0.200 mm (0.0079 inch).

5–78

Copyright © 2003 General Motors Corp.

MODULE REBUILD 3. Measure the cone of each C5 clutch friction plate (1). Maximum cone is 0.225 mm (0.0089 inch).

A

1

V07717.00.00.eps

4. Measure the thickness of each C5 clutch reaction plate (1). Minimum thickness is given in the following table. The clutch pack will contain five ID number 2 plates and an ID number 1, 2, or 3 selective plate. A clutch may contain six ID number 2 plates if build measurements require an ID number 2 plate as the selective plate. Part Number

Minimum Thickness

29536481

1.935 mm (0.0762 inch)

1

29536482

2.435 mm (0.0959 inch)

2

29536483

2.935 mm (0.1156 inch)

3

1

ID Number A

R81

5. Measure the cone of each C5 clutch reaction plate (1) (Dimension A). Maximum cone is 0.295 mm (0.0116 inch). A

1

R82

Copyright © 2003 General Motors Corp.

5–79

1000/2000/2400 SERIES SERVICE MANUAL 6. Measure the thickness of C5 clutch backplate (1) (Dimension A). Minimum thickness is 17.900 mm (0.7047 inch).

1

7. Measure the cone of C5 clutch backplate (1) (Dimension A). Replace backplate (1) if any cone is present.

A

R147

e. P1 Ring Gear Inspection 1

NOTE: Clutch plate movement can cause notching on the external splines of P1 ring gear. 1. Inspect the external splines of P1 planetary ring gear (1) for notching. Replace the ring gear if detectable notching has occurred.

V07803.00.00.eps

5–13. MAIN SHAFT INSPECTION NOTE: Replace the main shaft if it does not meet specifications.

A B 1

A

1. Inspect the main shaft pilots for damage. 2. Measure the main shaft pilots (Dimension A). Minimum pilot OD is 19.987 mm (0.7869 inch). 3. Inspect the main shaft journal contact area for damage. 4. Measure the main shaft journal contact area for the P2 planetary bushing (Dimension B). Minimum main-shaft journal diameter is 36.405 mm (1.4333 inch).

V07707.00.00.eps

5–80

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5–14. P1 PLANETARY MODULE

1

a. P1 Planetary Module Disassembly 1. Remove thrust washer (1) from P2 ring gear (4).

2

2. Remove retaining ring (2) from P2 ring gear (4).

3

3. Separate P1 planetary carrier assembly (3) from P2 ring gear (4). 4

V07708.00.00.eps

b. P1 Planetary Carrier Assembly Inspection 1. Check the end play between P1 planetary carrier (1) and thrust washer (2) at each pinion gear (3).

1

2. If the end play exceeds 1.010 mm (0.0040 inch), replace the P1 planetary carrier assembly.

2

3

V07705.00.00.eps

3. Inspect the bushing for wear or damage. 4. Measure the ID of the bushing. If the ID of the bushing exceeds 50.690 mm (1.9957 inch), replace the bushing.

A

1

V07706.00.00.eps

Copyright © 2003 General Motors Corp.

5–81

1000/2000/2400 SERIES SERVICE MANUAL c. P2 Planetary Ring Gear Inspection 1

A

NOTE: Clutch plate movement can cause notching on the external splines of P2 ring gear. 1. Inspect the external splines of P2 planetary ring gear (1) for notching. Replace the ring gear if detectable notching has occurred.

R90b

d. P1 Planetary Carrier Bushing Replacement Tools Required

1

• J 43781 • J 8092

P1 Bushing Remover/Installer Universal Driver

3

NOTE: The preferred method for removing/installing the P1 carrier bushing is to use J 43781 and a press. If a press is not available, use J 43781 and J 8092 universal driver.

2

4

1. Position P1 planetary carrier (3) on the press with the external splines facing up. R99a

2. If the bushing will be removed by hand, install the short end of J 43781 (2) onto J 8092 (1). 3. Using J 43781, press bushing (4) out of the carrier.

5–82

Copyright © 2003 General Motors Corp.

MODULE REBUILD 4. If the bushing will be installed by hand, install the long end of J 43781 (2) onto J 8092 (1).

1

5. Install a new bushing (3) onto J 43781 (2). 6. Using J 43781, press or drive the bushing into the carrier until J 43781 (2) seats.

3

2 4

R99

e. P1 Planetary Carrier Thrust Washer Inspection

1

NOTE: Replace the thrust washer if any of the following specifications are not met. 1. Measure the thickness of thrust washer (1) (Dimension A). 2. The minimum (0.059 inches).

thickness

is

1.49

A

mm

R60c

f. P1 Planetary Module Assembly 1. Position P2 ring gear (4) on the work table so that the tang holes are facing up. 2. Install P1 planetary carrier assembly (3) into P2 ring gear (4). Make sure the splines are engaged. 3. Install retaining ring (2) into the P2 ring gear so that the P1 planetary carrier assembly is retained. 4. Align the tangs of thrust washer (1) with the tang holes in the P2 ring gear.

1

2

3

4

5. Install the thrust washer onto the P2 ring gear. R89

Copyright © 2003 General Motors Corp.

5–83

1000/2000/2400 SERIES SERVICE MANUAL 5–15. P2 PLANETARY MODULE

1

a. P2 Planetary Module Disassembly 1. Remove retaining ring (1) from P3 ring gear (3).

2

2. Separate P2 planetary carrier assembly (2) from P3 ring gear (3).

3

V07804.00.00.eps

b. P2 Planetary Carrier Assembly Inspection 1. Check the end play between P2 planetary carrier (1) and thrust washer (2) at each pinion gear (3).

1 2

2. If the end play exceeds 1.060 mm (0.0417 inch), replace the P2 planetary carrier assembly.

3

V07703.00.00.eps

3. Inspect bushing (1) for wear and damage. A

4. Measure the ID of the bushing (Dimension A). If the bushing ID exceeds 36.575 mm (1.4400 inch), replace the bushing. 1

V07704.00.00.eps

5–84

Copyright © 2003 General Motors Corp.

MODULE REBUILD c. P3 Planetary Ring Gear Inspection 1

NOTE: Starting with S/N 631013648, C5 Clutch Friction Plates and the P3 Ring Gear have been redesigned. The former and current designs are interchangeable only if the current C5 Friction Plates are used with the current P3 Ring Gear. Do not mix current and former designs. The former design may be reused unless replacement is indicated by wear measurements or the design is no longer available.

NOTE: Clutch plate movement can cause notching on the external splines of P3 ring gear.

V07785.00.00.eps

1. Inspect the external splines of P3 planetary ring gear (1) for notching. Replace the ring gear if detectable notching has occurred. d. P2 Planetary Carrier Bushing Replacement 1

Tools Required

3

• J 43785

P2 Bushing Remover/Installer

• J 8092

Universal Driver

NOTE: The preferred method for removing/installing the P2 carrier bushing is to use J 43785 and a press. If a press is not available, use J 43785 and J 8092 universal driver.

2

4

1. Position P2 planetary carrier (3) on wooden blocks on the press with the external splines facing up. 2. If the bushing will be removed by hand, install the short end of J 43785 (2) onto J 8092 (1).

R102a

3. Using J 43785 (2), press or drive bushing (4) out of carrier (3). 4. Position P2 planetary carrier (4) on wooden blocks on the press with the external splines facing down.

Copyright © 2003 General Motors Corp.

5–85

1000/2000/2400 SERIES SERVICE MANUAL 5. If the bushing will be installed by hand, install the long end of J 43785 (2) into J 8092 (1).

1

6. Install a new bushing (3) onto J 43785 (2).

3

7. Using J 43785 (2), press or drive the bushing into the carrier until J 43785 (2) seats. 4 2

R102

e. P2 Planetary Module Assembly

1

1. Position P3 ring gear (3) on the work table so that the outer splines are facing down. 2. Install P2 planetary carrier assembly (2) into P3 ring gear. Make sure the splines are engaged.

2

3. Install retaining ring (1) into the P3 ring gear so that the P2 planetary carrier assembly is retained. 3

V07804.00.00.eps

5–16. P3 PLANETARY CARRIER ASSEMBLY

1

a. P3 Planetary Carrier Assembly Inspection

2 3

1. Check the end play between P3 planetary carrier (1) and thrust washer (2) at each pinion gear (3). 2. If the end play exceeds 1.010 mm (0.0040 inch), replace the P3 planetary carrier assembly.

V07714.00.00.eps

5–86

Copyright © 2003 General Motors Corp.

MODULE REBUILD 3. If the transmission has a parking pawl, do the following for each P3 carrier assembly tooth. • Place straight edge (3) against the side of

1

carrier assembly tooth (2). Measure the wear on the carrier assembly tooth (Dimension A). • If measurable wear exists, replace the P3 planetary carrier assembly.

2

3

A V07715.00.00.eps

b. P3 Planetary Carrier Bearing Race Replacement 4

Tools Required

1

• J 44528 P3 Carrier Bearing Race Remover • J 43797 P3 Carrier Bearing Race Installer

4

1. Position P3 planetary carrier (2) on the work table so that the rear of the carrier is facing up. 2. Install J 44528-1 (1) over the hub of the carrier and onto bearing race (3).

3

2

3. Tighten J 44528-1 screws (4) wrench tight.

R98

4. Place two wooden blocks (3) on the press. 1

5. Position carrier (4) so that J 44528-1 (2) spans the wooden blocks and the front of the carrier is facing down. 6. Install J 44528-2 (1) into the carrier.

2

WARNING! Pressing the P3 planetary carrier from the bearing race causes the P3 carrier to fall from the bearing race. Make sure the P3 carrier is safely caught when freed from the bearing race. An uncontrolled fall of the P3 carrier could cause personal injury and/or property damage.

3

4

R98a

Copyright © 2003 General Motors Corp.

5–87

1000/2000/2400 SERIES SERVICE MANUAL 7. Using J 44528-2 (1), press P3 planetary carrier (4) from J 44528-1 (2). 8. Remove the bearing race from J 44528-1. 9. Remove J 44528-2 (1) from the carrier. 10. Position P3 planetary carrier (3) on the press so that the rear of the carrier is facing up.

1

11. Install a new bearing race into J 43797 (1). 2

12. Using J 43797 (1), press bearing race (2) onto P3 planetary carrier (3) until J 43797 seats. 3

R98b

5–17. REAR COVER ASSEMBLY 1

a. Disassembly 1. Position rear cover (2) on the work table so that the rear of the cover is facing down. 2

2. Remove retaining ring (1).

R108

5–88

Copyright © 2003 General Motors Corp.

MODULE REBUILD 3. If the rear cover needle bearing assembly needs replacing and the transmission is not a 1000 Series™ 4WD, perform the following.

3

• Position rear cover (1) on the press so that

2

the rear of the cover is facing up. • Press output tone wheel (2) and needle bearing assembly (3) from the rear cover.

1

R108a

4. If the rear cover needle bearing assembly needs replacing and the transmission is a 1000 Series™ 4WD, perform the following.

1

• Position rear cover (1) on the work table so

that the rear of the cover is facing up. • Using a drift, tap needle bearing assembly (2) from the rear cover.

2

R108b

5. Position rear cover (1) on the work table so that the rear of the cover is facing down. 6. Gently pry C5 clutch piston (2) from rear cover (1).

2

1

R109

Copyright © 2003 General Motors Corp.

5–89

1000/2000/2400 SERIES SERVICE MANUAL 7. Remove sealrings (1) and (2) from C5 clutch piston (3).

1 2

3

R110

2

1

3

8. If tachograph plug (2) is present do the following. • Position the rear cover on the work table so

that the rear of the cover is facing up. • Remove tachograph plug (2). • Remove washer (3).

R105a

b. Rear Cover Retaining Ring Replacement 1

NOTE: DO NOT replace the retaining ring in the rear cover except for the following conditions. • The retaining ring is damaged 2

• The rear cover is replaced

1. Position rear cover (2) on the work table so that the rear of the cover is facing up. 2. Remove retaining ring (1). 3. Install a new retaining ring (1). 4. Make sure the retaining ring is seated. R108c

5–90

Copyright © 2003 General Motors Corp.

MODULE REBUILD c. Output Shaft Bushing Inspection (2WD Transmissions Only) 1. Inspect output shaft bushing (2) for wear and damage.

A 1

2. Measure the ID of bushing (2) (Dimension A). If the ID of the bushing exceeds 20.070 mm (0.7940 inch), replace the bushing.

2

3. Measure the OD of the bearing surface (Dimension B). If the OD of the bearing surface is less than 44.978 mm (1.7708 inch), replace the output shaft.

B

R111

d. Output Shaft Bushing Inspection (4WD Transmissions Only)

A

1. Inspect output shaft bushing (2) for wear and damage. 2. Measure the ID of bushing (2) (Dimension A). If the ID of the bushing exceeds 20.070 mm (0.7940 inch), replace the bushing. 3. Measure the OD of the bearing surface (Dimension B). If the OD of the bearing surface is less than 44.978 mm (1.7708 inch), replace the output shaft.

1 2

B

R111a

Copyright © 2003 General Motors Corp.

5–91

1000/2000/2400 SERIES SERVICE MANUAL e. Output Shaft Bushing Replacement Tools Required • J 44526 • J 43791

Output/Turbine Shaft Bushing Remover Output/Turbine Shaft Bushing Installer

CAUTION: Always use J 44526 when removing the output shaft bushing to help avoid damage to the output shaft. 1. Install J 44526-2 (8) into J 44526-1 (7).

1 2

2. Install J 44526-2 (8) and J 44526-1 (7) into bushing (9).

7 9

3

3. Install washer (6) and nut (5) onto J 44526-2 (8). 10

4 8

4. While holding the top of J 44526-2 (8) with a wrench, tighten nut (5) until J 44526-1 (7) engages bushing (9). 5. Install J 44526-3 (4) onto J 44526-2 (8). 6. Install bearing (3), washer (2), and nut (1) onto J 44526-2 (8).

5

7. While holding the top of J 44526-2 (8) with a wrench, tighten nut (1) until the bushing is dislodged.

6

R112

8. Remove the J tools. 9. Remove the bushing from the J tools. 10. Install a new bushing (2) onto J 43791 (1).

1

11. Using J 43791, drive the bushing into output shaft (3) until J 43791 (1) is seated. 2

12. Make sure the bushing is pressed flush to 0.25 mm (0.010 inch) below the output shaft surface.

3

R112a

5–92

Copyright © 2003 General Motors Corp.

MODULE REBUILD f. Assembly of Rear Cover 3

1. Position the rear cover so that the rear of the cover is facing down. 2. If present, install output tone wheel (2).

2

3. Gently tap needle bearing assembly (3) into the rear cover. 1

R108a

4. Install retaining ring (1). 1

2

R108

5. Install sealrings (1) and (2) onto C5 clutch piston (3). Lubricate the sealrings with petrolatum.

1 2

3

R110

Copyright © 2003 General Motors Corp.

5–93

1000/2000/2400 SERIES SERVICE MANUAL 6. Position the rear cover so that the rear of the cover is facing down. 7. Align the tang on C5 clutch piston (2) with the tang hole in rear cover (1).

2

8. Install C5 clutch piston (2) into rear cover (1). 1

R109

1

2

3

9. If tachograph plug (2) is present do the following. • Position rear cover (1) on the work table so

that the rear of the cover is facing up. • Install washer (3) onto tachograph plug (2). • Install tachograph plug (2) and washer (3) into rear cover (1). • Tighten the tachograph plug to 60–67 N·m (44–49 lb ft).

R105a

5–18. OUTPUT YOKE INSPECTION A

NOTE: • Measure as described below at three or more locations. • Replace the output yoke if it does not meet specifications. 1. Inspect output yoke (1) for damage. 2. Measure the OD of the output yoke oil seal surface. Minimum surface OD is 65.080 mm (2.5622 inch). R138

5–94

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5–19. CONTROL VALVE MODULE CAUTION: • Transmission damage may occur when control valve springs and other parts are mistakenly interchanged. Interchanging parts can be avoided by: — Tagging each part as the part is removed. — Using Valve Tray Set J 33163 to simplify correct valve body reassembly. • Protect the control valve assembly parts from damage by: — Handling all valves carefully. — Protecting the control valve assembly parts during removal, cleaning, inspection, and installation. — Keeping the parts in clean containers until the parts are installed. • When the valves are installed dry, the weight of the valves must be sufficient to move the valves through the valve bores. If the valves do not move freely, the transmission may be damaged. a. Disassembly of Control Valve Assembly Tools Required • J 33163

Valve Tray Set

1. Position the control valve assembly on the work table so that the main valve body assembly is facing up. 2. Remove the six bolts (1) and one bolt (2) retaining the reverse signal tube and pressure switch assembly to the main valve body.

1 1 2

1 1

1

1

1

V08125.00.00

Copyright © 2003 General Motors Corp.

5–95

1000/2000/2400 SERIES SERVICE MANUAL 3. Remove reverse signal tube (2) from main valve body (3).

2

4. Remove pressure switch assembly (1) from main valve body (3). 1

3

R114

5. Remove two bolts (1) retaining modulated main valve body (2) to valve body (3).

1

6. Remove modulated main valve body (2). 2

3

V08126.00.00 (R116).eps

V08176.00.00

7. Remove F trim solenoid retainer (1). 5 1

8. Remove F trim solenoid (7), sleeve (4), valve (3), and spring (2).

2

9. Remove O-rings (5) and (6) from F trim solenoid (7). 3

4 5 6 7 V08126.00.00

5–96

Copyright © 2003 General Motors Corp.

MODULE REBUILD 10. Remove D ON/OFF shift solenoid retainer (1). 5

11. Remove D ON/OFF shift solenoid (4).

1

12. Remove O-rings (2) and (3) from D ON/OFF shift solenoid (4).

2

3

4

V08127.00.00

13. Remove E ON/OFF shift solenoid retainer (1). 5

14. Remove E ON/OFF shift solenoid (4).

1

15. Remove O-rings (2) and (3) from E ON/OFF shift solenoid (4).

2

3

4

V08128.00.00

16. Remove three bolts (1) that retain A/B solenoid bracket (2) to main valve body (3).

1

3

2

V08129.00.00

Copyright © 2003 General Motors Corp.

5–97

1000/2000/2400 SERIES SERVICE MANUAL 17. Remove A/B solenoid bracket (1), two accumulator springs (2), and two accumulator plugs (3).

1 3

3

2

2

18. Remove A trim solenoid (15), valve (13), spring (12) if present, valve (11), and spring (10).

16

19. Remove B trim solenoid (9), valve (7), valve (6), and spring (5). 20. Remove O-ring (14) from A trim solenoid (15). 4

21. Remove O-ring (8) from B trim solenoid (9). 5

6 7

10

8

11 12

13

14

9

15

V08130.00.00

CAUTION: 2 1

4

Do not damage the solenoid(s) when turning over the control valve assembly. 22. Position the control valve assembly on the work table so that shift valve body (1) is facing up. 23. Remove C ON/OFF shift solenoid retainer (2).

3

5

24. Remove C ON/OFF shift solenoid (5). 25. Remove O-rings (3) and (4) from C ON/OFF shift solenoid (5).

V08131.00.00

5–98

Copyright © 2003 General Motors Corp.

MODULE REBUILD 26. Position the control valve assembly on the work table so that the main valve body is facing up. 1

1

27. Remove fourteen bolts (1) retaining the shift valve body and the main valve body together.

1

28. Position the control valve assembly on the work table so that the assembly is on edge (sideways). 29. Reinstall four bolts (1) so that the bolts are partially threaded into the shift valve body and protrude from the main valve body.

1 1

1 1 1 1

1 1

1 1

1

30. Gently tap the bolts until the assembly separates. V08132.00.00

31. Position the control valve assembly on the work table so that shift valve body (1) is facing up.

1

32. Separate shift valve body assembly (1), separator plate (2), and main valve body assembly (4). 2

3

4

3 3

V08135.00.00

b. Disassembly of Shift Valve Body 1

Tools Required • J 33163

Valve Tray Set

• J 43773

Valve Spring Compressor

1. Using J 43773 (2), compress the C shift spring until retaining clip (1) is loose. Remove the clip.

3

2

R130

Copyright © 2003 General Motors Corp.

5–99

1000/2000/2400 SERIES SERVICE MANUAL 2. Remove spring (2) and C shift valve (1).

1

2

R131

3. Using J 43773 (2), compress the E shift spring until retaining clip (1) is loose. Remove the clip.

1

2

R132

4. Remove plug (3), spring (2), and E shift valve (1).

1 2

3 R133

5–100

Copyright © 2003 General Motors Corp.

MODULE REBUILD 5. Using J 43773 (2), compress the D shift valve spring until retaining clip (1) is loose. Remove the clip.

1

2

R134

6. Remove plug (3), spring (2), and D shift valve (1).

1 2

3 R135

7. Using J 43773 (2), compress the control main valve spring until retaining clip (1) is loose. Remove the clip.

1

2

R136

Copyright © 2003 General Motors Corp.

5–101

1000/2000/2400 SERIES SERVICE MANUAL 8. Remove spring (2) and control main valve (1).

1

2

R137

9. Remove solenoid screen (1).

1

A

V08137.00.00

c. Disassembly of Modulated Main Valve Body

1

1. Remove G ON/OFF solenoid (4) retainer. 2 3

2. Remove G ON/OFF solenoid (3) from modulated main valve body (1). 3. Remove two O-rings (2) from the G ON/OFF solenoid.

4

5–102

V08177.00.00

Copyright © 2003 General Motors Corp.

MODULE REBUILD d. A/B Solenoid Bracket Inspection 1. Measure the angle between the surfaces of A/B solenoid bracket (1) (Angle A).

1

2. Adjust the bracket surfaces until the angle between the surfaces is approximately 82.84 degrees.

A

R148

e. Assembly of Shift Valve Body Tools Required • J 33163

Valve Tray Set

• J 43773

Valve Spring Compressor

1. Install solenoid screen (1). 2. Make sure the screen is installed to a depth of 0.50–1.00 mm (0.020–0.039 inch) (Dimension A) below the shift valve body surface as shown.

1

A

V08137.00.00

3. Install control main valve (1) and spring (2).

1

2

R137

Copyright © 2003 General Motors Corp.

5–103

1000/2000/2400 SERIES SERVICE MANUAL 4. Compress the spring with J 43773 (2). 5. Install retaining clip (1). Make sure the retaining clip is below the valve body surface.

1

2

R136

6. Install D shift valve (1), spring (2), and plug (3).

1 2

3 R135

7. Compress the spring with J 43773 (2). 8. Install retaining clip (1). Make sure the retaining clip is below the valve body surface.

1

2

R134

5–104

Copyright © 2003 General Motors Corp.

MODULE REBUILD 9. Install E shift valve (1), spring (2), and plug (3).

1 2

3 R133

10. Compress the spring with J 43773 (2). 11. Install retaining clip (1). Make sure the retaining clip is below the valve body surface.

1

2

R132

12. Install C shift valve (1) and spring (2).

1

2

R131

Copyright © 2003 General Motors Corp.

5–105

1000/2000/2400 SERIES SERVICE MANUAL 13. Compress the spring with J 43773 (2). 1

14. Install retaining clip (1). Make sure the retaining clip is below the valve body surface.

3

2

R130

f. Disassembly of the Main Valve Body 1

Tools Required 3

• J 33163

Valve Tray Set

• J 43773

Valve Spring Compressor

1. Using J 43773 (2), compress the control relief spring until retaining clip (1) is loose. Remove the clip.

2 R126

2. Remove spring (2) and control relief valve (1).

1 2

R127

5–106

Copyright © 2003 General Motors Corp.

MODULE REBUILD 3. Using J 43773 (2), compress the exhaust backfill spring until retaining clip (1) is loose. Remove the clip.

1

2

R128

4. Remove spring (2) and exhaust backfill valve (1).

1

2

R129

Copyright © 2003 General Motors Corp.

5–107

1000/2000/2400 SERIES SERVICE MANUAL g. Dowel Pin Replacement Tools Required • J 43779

Dowel Pin Installer

CAUTION: DO NOT mar the main valve body surface when installing the dowel pin(s). Use only gentle tapping on dowel pin installer tool J 43779. Heavy or continued hammering on J 43779 will damage the main housing surface. NOTE: The main valve body has five dowel pins that can be replaced. Do not replace a dowel pin unless the dowel pin is damaged. Use the following procedure to replace a dowel pin. 1. Remove the dowel pin from the main valve body. 1

2. Place a new dowel pin into J 43779 (3).

1

3. Install J 43779 with the dowel pin into the dowel pin hole. 4. Gently tap J 43779 until J 43779 touches the main valve body surface. 5. Make sure the dowel pin is installed to a height of 10.7–11.3 mm (0.42–0.44 inch) above the main valve body surface.

1 1

2 3 R125

5–108

Copyright © 2003 General Motors Corp.

MODULE REBUILD h. Assembly of the Main Valve Body Tools Required • J 33163

Valve Tray Set

• J 43773

Valve Spring Compressor

1. Install exhaust backfill valve (1) and spring (2).

1

2

R129

2. Compress the spring with J 43773 (2). 1

3. Install retaining clip (1). Make sure the retaining clip is below the valve body surface.

2

R128

4. Install control relief valve (1) and spring (2).

1 2

R127

Copyright © 2003 General Motors Corp.

5–109

1000/2000/2400 SERIES SERVICE MANUAL 5. Compress the spring with J 43773 (2). 1

6. Install retaining clip (1). Make sure the retaining clip is below the valve body surface. 3

2 R126

i. Assembly of Control Valve Assembly 1

Tools Required • J 33163

Valve Tray Set

1. Position main valve body assembly (4) on the work table so that the worm-track side is facing up. 2

2. Align separator plate (2) with main valve body dowel pins (3). 3. Install the separator plate.

3

4. Align shift valve body assembly (1) with main valve body dowel pins (3). 5. Install the shift valve body assembly onto the separator plate.

4

3 3

V08135.00.00

6. Position the control valve assembly on the work table so that the main valve body is facing up.

1

1 1

1

7. Install fourteen bolts (1) retaining the valve bodies together. Tighten the bolts to 10–13 N·m (7–10 lb ft).

1

1 1 1 1 1

1

1 1

1

V08132.00.00

5–110

Copyright © 2003 General Motors Corp.

MODULE REBUILD 8. Position the control valve assembly on the work table so that the shift valve body is facing up. 2 1

NOTE: • O-ring (4) is slightly larger than O-ring (3). • ON/OFF shift solenoid (5) has P/N 29536833 printed on the solenoid. 9. Install solenoid O-ring (4) onto C ON/OFF shift solenoid (5).

4

3

5

10. Install solenoid O-ring (3) onto C ON/OFF shift solenoid (5). 11. Align C ON/OFF shift solenoid (5) so that the electrical connector points away from the nearest dowel pin and is parallel to the separator plate.

V08131.00.00

12. Push the solenoid into the valve body until the solenoid seats. 13. Install solenoid retainer (2).

Copyright © 2003 General Motors Corp.

5–111

1000/2000/2400 SERIES SERVICE MANUAL CAUTION: Do not damage the solenoid(s) when turning over the control valve assembly.

1 3

3

2

2

14. Position the control valve assembly on the work table so that main valve body (16) is facing up.

16

NOTE: A trim solenoid (15) has P/N 29533074 printed on the solenoid.

4 5

6 7

10

8

11 12

13

14

9

15. Install solenoid O-ring (14) onto A trim solenoid (15). NOTE: The B trim solenoid (9) has P/N 29533075 printed on the solenoid.

15

V08130.00.00

16. Install solenoid O-ring (8) onto B trim solenoid (9). 17. Install spring (10), A trim valve (11), spring (12) if present, and trim gain valve (13). 18. Install spring (5), B trim valve (6), and trim gain valve (7). 19. Install A trim solenoid (15) so that the electrical connector faces up. 20. Install B trim solenoid (9) so that the electrical connector faces up. 21. Align two accumulator plugs (3) so that their spring bores are facing up. 22. Install two accumulator plugs two accumulator springs (2).

(3)

and

23. Push the A and B trim solenoids into their bores until the solenoids seat. 24. Align A/B solenoid bracket (1) with main valve body dowel pin (4). 25. Install A/B solenoid bracket (1) so that the A and B trim solenoids and the accumulator plugs and springs are retained in the valve body.

5–112

Copyright © 2003 General Motors Corp.

MODULE REBUILD 26. Install three bolts (1) through A/B solenoid bracket (2). Tighten the bolts to 10–13 N·m (7–10 lb ft).

1

3

2

V08129.00.00

NOTE: • The solenoid O-rings are brown in color. O-ring (3) is slightly larger than O-ring (2). • ON/OFF shift solenoid (4) has P/N 29536833 printed on the solenoid.

5 1

27. Install solenoid O-ring (3) onto E ON/OFF shift solenoid (4). 28. Install solenoid O-ring (2) onto E ON/OFF shift solenoid (4). 2

3

29. Install E ON/OFF shift solenoid (4) so that the solenoid electrical connector faces up.

4

30. Install solenoid retainer (1).

V08128.00.00

NOTE: • The solenoid O-rings are brown in color. O-ring (3) is slightly larger than O-ring (2). • ON/OFF shift solenoid (4) has P/N 29536833 printed on the solenoid.

5 1

31. Install solenoid O-ring (3) onto D ON/OFF shift solenoid (4). 32. Install solenoid O-ring (2) onto D ON/OFF shift solenoid (4). 2

33. Install D ON/OFF shift solenoid (4) so that the solenoid electrical connector faces up. 34. Install solenoid retainer (1).

3

4

V08127.00.00

Copyright © 2003 General Motors Corp.

5–113

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: The solenoid O-rings are brown in color. O-ring (6) is slightly larger than O-ring (5).

5 1

2

35. Install solenoid O-ring (6) onto F trim solenoid (7).

3

36. Install solenoid O-ring (5) onto F trim solenoid (7). 37. Install F trim spring (2).

4 5

38. Install F trim valve (3). 6

39. Install F trim sleeve (4).

7 V08126.00.00

40. Align F trim solenoid (7) so that the electrical connector faces up. 41. Push the solenoid into the valve body until the solenoid seats. 42. Install solenoid retainer (1). 43. Align the bolt holes and alignment tab of pressure switch assembly (1) with the pressure switch assembly holes in main valve body (3).

2

44. Install pressure switch assembly (1) onto main valve body (3).

1

45. Install reverse signal tube (2) into the main valve body. 3

R114

5–114

Copyright © 2003 General Motors Corp.

MODULE REBUILD

NOTE: Seven bolts retain the reverse signal tube and the pressure switch assembly. • One bolt (2) is slightly longer than the other six

bolts (1). • The pressure switch assembly is retained by five

bolts (1) and bolt (2). • The reverse signal tube is retained by one bolt (1) and bolt (2). 46. Install six bolts (1) and one bolt (2) retaining the reverse signal tube and pressure switch assembly to the main valve body.

1 1 2

1 1

1

1

1 R114a

47. Tighten the bolts (1) and (2) to 10–13 N·m (7–10 lb ft). j. Assembly of Modulated Main Valve Body

1

1. Install two O-rings (2) onto G ON/OFF solenoid (3).

2

2. Install G ON/OFF solenoid (3) into its bore in modulated main valve body (1).

3

3. Install solenoid retainer (4) into the valve body.

4

4. Align modulated main valve body (2) with its bolt holes in main valve body (3).

V08177.00.00

1

2

NOTE: The modulated main valve body retaining bolts, M6 x 1.0 x 65, are slightly longer and gold colored. 5. Install two bolts (1) retaining modulated main valve body (2) to main valve body (3).

3

6. Tighten bolts to 10–13 N·m (7–10 lb ft) V08126.00.00 (R116).eps

V08176.00.00

Copyright © 2003 General Motors Corp.

5–115

1000/2000/2400 SERIES SERVICE MANUAL NOTES

5–116

Copyright © 2003 General Motors Corp..

SECTION 6 — TRANSMISSION ASSEMBLY 6–1.

C3 CLUTCH INSTALLATION

Tools Required

1

• J 24204-2

Bar and Stud Assembly

• J 44530

C3/C4 Piston Spring Compressor

1. Position the main housing so that the front of the main housing is facing up. NOTE: Do not reuse the old C3 clutch piston assembly. Install a new C3 clutch piston assembly. 2. Apply petrolatum to the ID and OD of new C3 clutch piston assembly (1).

D39

3. Align new C3 clutch piston assembly (1) with the main housing so that the seal is facing down and the 1.016 mm (0.040 inch) lubrication/cooling orifice positioned at the top of the main housing. 4. Install the C3 clutch piston assembly. Gently tap the piston until the piston seats.

NOTE: • The spring assemblies can be reused. If required, squeeze the spring assembly tabs with pliers to make sure the spring assemblies are retained to the spring plate. • The piston return spring assemblies should snap into place.

1 1

2

5. Install three piston return spring assemblies (1) onto spring plate (2).

1 D38

Copyright © 2003 General Motors Corp.

6–1

1000/2000/2400 SERIES SERVICE MANUAL

3

1 2

6. Align spring plate (4) and piston return spring assemblies (3) so that the spring assemblies face up. 7. Install spring plate (4) into the main housing. 8. Starting with a C3 clutch friction plate, alternately install four C3 clutch friction plates (1) and three C3 clutch reaction plates (2) into the main housing.

4

D37

9. Align C3 clutch backplate assembly (1) with gear thrust plates (2) down.

1

10. Install C3 clutch backplate assembly (1) into the main housing.

2

D37a

CAUTION:

1

DO NOT install special tools (J tools) onto the gear thrust plate rivets of the C3 clutch backplate assembly. The special tools could damage the gear thrust plate rivets.

2 3 4 5

D36

6–2

11. Install J 24204-2 (1) and J 44530 (2) into the main housing. Make sure J 44530 does not touch gear thrust plate rivets (3) on the C3 clutch backplate assembly. 12. Compress C3 piston return spring assemblies (5) until the retaining ring groove is visible. 13. Install retaining ring (4). Make sure the retaining ring is seated. 14. Remove J 24204-2 and J 44530.

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–2.

P1 PLANETARY MODULE AND C4 CLUTCH INSTALLATION 1

Tools Required • J 24204-2

Bar and Stud Assembly

• J 44530

C3/C4 Piston Spring Compressor

1. Position the main housing so that the rear of the main housing is facing up. NOTE: Do not reuse the old C4 clutch piston assembly. Install a new C4 clutch piston assembly. D35a

2. Apply petrolatum to the ID and OD of new C4 clutch piston assembly (1). 3. Align C4 clutch piston assembly (1) so that the seal is facing down and the 1.016 mm (0.040 inch) lubrication/cooling orifice positioned at the top of the main housing. 4. Install C4 clutch piston assembly (1). Gently tap the piston until the piston seats.

5. Align P1 ring gear (1) so that the outside splines are facing down. 6. Install P1 ring gear (1). Rotate the ring gear until the C3 friction plates are engaged.

1

7. Make sure P1 ring gear (1) is seated against the thrust plates of the C3 clutch backplate assembly.

D35

Copyright © 2003 General Motors Corp.

6–3

1000/2000/2400 SERIES SERVICE MANUAL 8. Install P1 planetary module (2). Rotate the module until the module drops into place.

1

CAUTION: Installing the thrust bearing incorrectly could destroy the transmission.

2

9. Align thrust bearing (1) so that the blue stripe on the thrust bearing is facing away from P1 planetary module (2). 10. Install thrust bearing (1) onto P1 planetary module (2).

D31a

NOTE:

1

• The 1

spring assemblies can be reused. If necessary, squeeze the spring assembly tabs with pliers to make sure the spring assemblies are retained to the spring plate. • The piston return spring assemblies should snap into place.

2

11. Install three piston return spring assemblies (1) onto C4 spring plate (2).

1 D34

12. Align spring plate (4) and piston return spring assemblies (3) with the spring assemblies up. 13. Install spring plate (4) into the main housing.

3 1 4

2

14. Starting with a C4 clutch friction plate, alternately install five C4 clutch friction plates (1) and four C4 clutch reaction plates (2).

D33

6–4

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 15. Install C4 clutch backplate (1). 1

CAUTION: • DO NOT install special tools (J tools) onto the gear thrust plate rivets of the C3 clutch backplate assembly. The special tools could damage the gear thrust plate rivets. • DO NOT damage the P1 planetary carrier bushing when installing J 24204-2 into the main housing. The threaded rod of J 24204-2 must pass through but not touch the bushing.

D33a

1. Install J 24204-2 (1) and J 44530 (2) into the main housing. Make sure J 24204-2 does not touch gear thrust plate rivets (6) on the C3 clutch backplate assembly. 2. Compress piston return spring assemblies (5) until the retaining ring groove is visible. NOTE: The spiral retaining ring must be installed so that the spring leaves lay on top of each other. The leaves must not cross over themselves.

1 2 3 4 5

6 6

3. Install spiral retaining ring (4). 4. Install retaining ring (3). D32a

CAUTION: DO NOT damage the P1 planetary carrier bushing when removing J 24204-2 from the main housing. The threaded rod of J 24204-2 must pass through but not touch the bushing. 5. Remove J 24204-2 and J 44530 from the main housing.

Copyright © 2003 General Motors Corp.

6–5

1000/2000/2400 SERIES SERVICE MANUAL 6–3. 1

C5 CLUTCH REACTION PLATE SELECTION

Tools Required • J 24204-2 Bar and Stud Assembly • J 44530 C3/C4 Piston Spring Compressor

2

NOTE: The C5 clutch backplate installs in either direction. The plate may have no grooves, one side grooved, or both sides grooved.

3

1. Install C5 clutch backplate (3).

V07805.00.00.eps

NOTE: The C5 clutch pack uses a single selective reaction plate. The C5 clutch pack is stacked out of order to allow determining the required reaction plate part number. When properly stacked, the top plate is a reaction plate and the next two plates are friction plates. The selective reaction plate is not stacked. Reaction plates have an ID number stamped on a tang. The ID number that does not match the other ID numbers is the selective reaction plate. 2. Starting with a C5 clutch friction plate, alternately install the remaining five C5 clutch friction plates (2) and four C5 clutch reaction plates (1). 3. Install a C5 clutch friction plate (2). 4. Install a C5 clutch reaction plate (1).

CAUTION: 1 2

3 4

V07806.00.00.eps

• DO NOT install special tools (J tools) onto the gear thrust plate rivets of the C3 clutch backplate assembly. The special tools could damage the gear thrust plate rivets. • DO NOT damage the P1 planetary carrier bushing when installing J 24204-2 into the main housing. The threaded rod of the J 24204-2 must pass through but not touch the bushing. 5. Install J 24204-2 (3) and J 44530 (1) into the main housing. Make sure J 24204-2 does not touch gear thrust plate rivets (4) on the C3 clutch backplate assembly. NOTE: The C5 clutch plates need to be compressed enough to remove the coning from the plates. Hand tightening the wing nut of J 24204-2 should be sufficient to remove the coning. 6. Using the J 24204-2 wing nut, compress the C5 clutch plates until hand tight.

6–6

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 7. Place a 1 inch (25 mm) gauge bar (2) on the rear surface of the main housing at a location near J 44530. 8. Measure the distance from the top of the gauge bar to the top of C5 clutch stack (3) (Dimension A). 9. Subtract dimension B, the width of the gauge bar, from dimension A. Dimension C is the result of the subtraction. 10. Select a C5 clutch reaction plate using Dimension C and the table below. Dimension C

1

B

2

A

C

3

Part ID Number Number

35.37–35.86 mm (1.393–1.412 in.) 29536481 35.87–36.36 mm (1.412–1.431 in.) 29536482 36.37–37.27 mm (1.432–1.467 in.) 29536483

1 2 3

V07807.00.00.eps

CAUTION: 1

DO NOT damage the P1 planetary carrier bushing when removing J 24204-2 from the main housing. The threaded rod of J 24204-2 must pass through but not touch the bushing.

2

11. Remove J 24204-2 (3) and J 44530 (1).

3 4

V07806.00.00.eps

12. Remove six C5 clutch friction plates (2) and five C5 clutch reaction plates (1).

1

2

A30b

Copyright © 2003 General Motors Corp.

6–7

1000/2000/2400 SERIES SERVICE MANUAL 6–4.

1

P2 PLANETARY MODULE AND MAIN SHAFT INSTALLATION

Tools Required • J 44587

2

Main Shaft Holder

1. Install P2 planetary module (2). Rotate the module until the module drops into place.

CAUTION: Installing the thrust bearing incorrectly could destroy the transmission. 2. Align thrust bearing assembly (1) so that the blue stripe on the thrust bearing assembly is facing towards P2 planetary module (2).

V07808.00.00.eps

3. Install thrust bearing assembly (1) onto P2 planetary module (2).

4. Align J 44587 (1) with the PTO access as follows. • The tongue of J 44587 is facing toward the

PTO access. • The bolts holes of J 45587 are aligned with the two front bolt holes of the PTO access.

CAUTION: Transmission damage may occur if special tool J 44587 is not left in place until after the torque converter housing is installed. 1

5. Install J 44587 (1) onto the PTO access. 2

V07722.00.00.eps

6–8

6. Install two bolts (2) into J 45587 (1) and tighten the bolts.

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 7. Install P2 sun gear (3) and sun gear spacer (2) onto main shaft (4). 8. As a unit, install main shaft (4), P2 sun gear (3), and sun gear spacer (2) into P2 planetary carrier (5).

2 4

1 3

9. Align P3 sun gear (1) so that the flat side of the sun gear is facing the sun gear spacer. 10. Install P3 sun gear (1) onto main shaft (4). Make sure P2 sun gear (3) and spacer (2) splines are engaged.

5

V07720.00.00.eps A29b

CAUTION: Installing the thrust bearing incorrectly could destroy the transmission. 11. Align thrust bearing assembly (1) so that the blue stripe on the thrust bearing assembly is facing away from P3 sun gear (2)

1 2

12. Install thrust bearing assembly (1) into P3 sun gear (2).

V07721.00.00.eps

6–5.

C5 CLUTCH INSTALLATION

1. Starting with a C5 clutch friction plate, alternately install six C5 clutch friction plates (2) and five C5 clutch reaction plates (3). 2. Install selected C5 clutch reaction plate (1).

1

2 3

V07809.00.00.eps

Copyright © 2003 General Motors Corp.

6–9

1000/2000/2400 SERIES SERVICE MANUAL 6–6.

1

PARK PAWL INSTALLATION

1. If the transmission has a park pawl, install apply assembly guide (3).

2 3

2. Align the tang in C5 piston return spring assembly (1) with the notch in the main housing. 3. Install C5 piston return spring assembly (1). 4. Install pawl support pin (2) into the main housing.

D27

5. For transmissions with park pawls, do the following. 1

• Install pawl return spring (2) onto park

2

4

3

pawl (1). • Align the park pawl, pawl return spring toward the rear, with support pin (3). • Install park pawl (1) onto pawl support pin (3). • Connect pawl return spring (2) to the main housing.

D26

6–10

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–7.

OUTPUT SHAFT AND P3 PLANETARY CARRIER ASSEMBLY INSTALLATION

1 2

1. Install output shaft (2) into P3 planetary carrier assembly (1). 2. While holding output shaft (2), place P3 planetary carrier assembly (1) into the top of P3 ring gear (3). 3. Move/rotate the output shaft until the carrier assembly drops into P3 ring gear (3). 4. Gently drop the output shaft onto main shaft (4). 5. Rotate the carrier assembly until the carrier assembly seats.

3 4

D25a

6–8.

REAR COVER ASSEMBLY INSTALLATION

1

1. Install a new rear cover gasket (2) onto main housing (3). 2

2. Align the rear cover module with main housing dowel pin (4) and park pawl pin (5). Install the rear cover module.

5

3. If present, turn the output tone wheel through the output speed sensor hole. Make sure the output shaft turns with the tone wheel.

3

4

D24

Copyright © 2003 General Motors Corp.

6–11

1000/2000/2400 SERIES SERVICE MANUAL

1

4. If a park brake cable bracket is present, do the following.

3

2

3 2

CAUTION: 4

4 4 4 3

4

3

4

4

4

4

D24d

The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid installing torque converter housing bolts into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to avoid main housing damage.

CAUTION: Some transmissions have park brake cable brackets installed on their rear covers. • Use bolts 40 mm (1.6 inch) long to install a bracket 5 mm (0.2 inch) or less thick. • Use bolts 45 mm (1.8 inch) long to install a bracket thicker than 5 mm (0.2 inch). Never install a 45 mm (1.8 inch) bolt into the rear cover without at least a 5 mm thick park brake cable bracket. Damage to the transmission may result. • Hand install four rear cover bolts (3). • Evenly draw down rear cover bolts (3) until • • • •

6–12

the rear cover seats on the main housing. Install bracket (1) onto the rear cover. Install three bolts (2). Install nine bolts (4). Tighten the rear cover bolts (2), (3), and (4) to 51–61 N·m (38–45 lb ft).

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 5. If a park brake cable bracket is not present, do the following.

1

2

1 2

CAUTION: The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid installing torque converter housing bolts into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to avoid main housing damage. • Hand install four rear cover bolts (1).

2

2 2

2 2 1

2

1

2

2

2

2

D24e

• Evenly draw down rear cover bolts (1) until

the rear cover seats on the main housing. • Install twelve bolts (2). • Tighten the rear cover bolts (1) and (2) to 51–61 N·m (38–45 lb ft).

Copyright © 2003 General Motors Corp.

6–13

1000/2000/2400 SERIES SERVICE MANUAL 6–9.

CONTROL VALVE ASSEMBLY INSTALLATION

1

1. Position the main housing so that the valve body face of the main housing is facing up.

2

NOTE: Install a lint-free cloth into the park pawl apply assembly guide hole to prevent the selector valve pin from falling into the transmission. 2. Install a lint-free cloth (1) in the park pawl apply assembly guide hole in main housing (2). V08025.01.00

3. Align selector valve pin (3) with manual selector valve (2). 4. Rotate the selector valve pin until the pin can be installed into the manual selector valve. 5. Install selector valve pin (3) into manual selector valve (2). 6. Install the manual selector valve into shift valve body (1).

1 2

3 V08124.00.00

CAUTION: Do not drop the main selector valve when removing or installing the control valve assembly. The main selector valve can be easily damaged.

1 2

7. Align the control valve assembly with the main housing while installing selector valve pin (3) into detent lever (1).

3

D23a

6–14

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 8. Align two control valve assembly dowel pins (1) with the dowel pin holes in the main housing.

1

2

9. Install control valve assembly (2) onto the main housing.

V08123.00.00

10. Remove lint free cloth (1) from the park pawl apply assembly guide hole. 1 2

V08026.01.00

11. Install 11 control valve assembly bolts (1). Tighten the bolts to 10–13 N·m (7–10 lb ft). 2 1 2 1

1 1 1

1

1

1 1 1

1 1 1

V08121.00.00

Copyright © 2003 General Motors Corp.

6–15

1000/2000/2400 SERIES SERVICE MANUAL

1

12. Install detent spring assembly (2) onto main valve body (4). Make sure detent spring assembly (2) roller rests on detent lever (3).

1 2

4

13. Install 2 detent spring assembly bolts (1). Tighten the bolts to 10–13 N·m (7–10 lb ft).

3

V08120.00.00

6–10. WIRING HARNESS ASSEMBLY INSTALLATION 2

Tools Required

0 (R116).eps

• J 44247

Wiring Harness Connector Installer

1. Install the internal wiring harness connector by hand into the main housing. 2. Using J 44247 (2), install the connector of internal wiring harness (1) into the main housing. The four tabs on the wiring harness connector snap into place. 3. Make sure the wiring harness connector is securely in place. 1 V08139.01.00

1 2 11

10

9

4 8

6–16

6 7

3

5 V07821.01.00

4. Remove ON/OFF shift solenoid retainers (1). 5. Install internal wiring harness (2) onto main valve body (10). 6. Install ON/OFF shift solenoid retainers (1) over the wiring harness tabs. 7. Connect internal wiring harness (2) to the following components as shown. • Pressure switch assembly (9) • C ON/OFF shift solenoid (7) • F trim solenoid (3) • D ON/OFF shift solenoid (4) • E ON/OFF shift solenoid (5) • B trim solenoid (6) • A trim solenoid (8) • G ON/OFF modulated main solenoid (11)

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 8. Install connector shipping cover (1) into the wiring harness connector.

1 V07819.02.00

6–11. OIL PAN AND SUCTION FILTER INSTALLATION

7

1 2

CAUTION:

3

If a shallow pan and filter were removed, reinstall a shallow pan and filter. If a deep pan and filter were removed, reinstall a deep pan and filter. Transmission damage can occur if the correct oil pan and filter are not installed.

4

5

1. Install suction filter seal (6) onto suction filter (5).

6

2. Align the neck of suction filter (5) with the filter hole in the main housing. 3. Install filter (5). Make sure the filter is seated.

V07773.01.00

4. Install a new oil pan gasket (4) onto the main housing. 5. Install oil pan (3) onto the main housing. 6. Install twelve oil pan bolts (7). Tighten the bolts to 24–29 N·m (18–21 lb ft). 7. Install drain plug seal (2) onto drain plug (1). 8. Install drain plug (1). Tighten the plug to 30–40 N·m (22–30 lb ft).

Copyright © 2003 General Motors Corp.

6–17

1000/2000/2400 SERIES SERVICE MANUAL 6–12. ROTATING CLUTCH ASSEMBLY INSTALLATION Tools Required • J 44587

Main Shaft Holder

1. Position the main housing so that the front of the main housing is facing up. 1

2. Remove two bolts (2) from J 44587 (1). 3. Remove J 44587 from the PTO access.

2

V08028.00.00

4. Apply petrolatum to thrust bearing (1).

CAUTION: Installing the thrust bearing incorrectly could destroy the transmission.

1

5. Align thrust bearing (1) so that the blue stripe on the thrust bearing is facing towards the P1 planetary carrier assembly. 6. Install thrust bearing (1) into the P1 planetary carrier assembly.

V07725.00.00.eps

7. Install rotating clutch assembly (1). Rotate the clutch assembly until the module seats. 8. Make sure one of the following is visible through the turbine speed sensor hole in the main housing:

1

• The teeth of the PTO gear • The teeth of the turbine tone wheel

2

D17a

6–18

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–13. CONVERTER HOUSING/FRONT SUPPORT MODULE INSTALLATION WARNING! The 1000/2000/2400 Series converter housing/ front support module dry weights are approximately 27 kg (60 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the converter housing/front support module. • Get help when lifting the converter housing/ front support module. Assistance from a hoist or another person may be required. • Make sure lifting equipment can properly support the converter housing/front support module.

1

2 3

5

NOTE: Separator Plate Gasket (2) has been redesigned. The former and current designs are interchangeable. The former design may be reused unless replacement is necessary or the design is no longer available.

4

A12

1. Install a new main housing/separator plate gasket (3) onto the main housing. 2. Install two M10 x 1.5 guide bolts (5) into main housing (4). 3. Attach a sling to converter housing (1). 4. Attach a hoist to the sling. Align converter housing (1) with guide bolts (5). 5. Apply petrolatum to the three sealrings on the rear of the front support. 6. Lower converter housing/front support module (1) over turbine shaft (2) and onto main housing (4).

CAUTION: Transmission damage may occur if the torque converter housing is forced into position. If tapping does not cause the torque converter housing to drop into position, the P3 sun gear and/or P3 sun gear spacer or a sealring may be misaligned. 7. Tap the converter housing until the converter housing seats on the main housing. Remove the sling. Copyright © 2003 General Motors Corp.

6–19

1000/2000/2400 SERIES SERVICE MANUAL CAUTION: The bolts used to install the torque converter housing and rear cover to the main housing are similar in size and color. The rear cover bolts are shorter than the torque converter housing bolts. Installing torque converter housing bolts into the rear cover may damage the main housing. To help avoid installing torque converter housing bolts into the rear cover and vice versa, store the bolts separately. These bolts must be installed into their correct locations to avoid main housing damage. 8. Remove two guide bolts (5) from the main housing. 9. For SAE No. 2 or No. 3 converter housings, do the following. • Install fifteen bolts (1).

1

1

1

1

• Install five bolts (2).

1

• Tighten the bolts (1 and 2) to 51–61 N·m

1

1

(38–45 lb ft). 1

1 1 1

1

2

1

2 2

1

2

2

1

D10

10. For direct mount torque converter housings, do the following. 1

• Install eighteen bolts (1).

1

• Install one bolt (2).

1

1

• Install one bolts (3). 1

1 1

1 1

1

(38–45 lb ft).

1 1

1

• Tighten the bolts (1, 2, and 3) to 51–61 N·m

1 1

1

1 2 1 3 D10a

6–20

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–14. REAR COVER SELECTIVE SPACER INSTALLATION (2WD TRANSMISSIONS ONLY)

2

1

1. Position the main housing so that the rear of the main housing is facing up. 2. Measure the distance (Dimension A) from the rear face of rear cover (1) to the rear face of output tone wheel (2).

A

A24bi

3. Measure the distance from the rear face of rear cover module (3) to the rear face of retaining ring (4) (Dimension B).

1 2

4. Calculate Dimension C by subtracting Dimension B from Dimension A (Dimension C = Dimension A – Dimension B). 5. Select the appropriate selective spacer (1) from the following table based on the Dimension C.

Dimension C

Part Number

Thickness

3 4

B

# of Holes

1.0081–1.184 mm (0.0397-0.0466 in.)

29536850 0.245-0.295 mm (0.0096-0.0116 in.)

0

1.185-1.414 mm (0.0467-0.0557 in.)

29536851 0.475-0.525 mm (0.0187-0.0207 in.)

1

1.415-1.644 mm (0.0557-0.0647 in.)

29536852 0.705-0.755 mm (0.0278-0.0297 in.)

2

1.645-1.874 mm (0.0648-0.0738 in.)

29536853 0.935-0.985 in) (0.0368-0.0388 in.)

3

1.875-2.104 mm (0.0738-0.0828 in.)

29536854 1.165-1.215 mm (0.0459-0.0478 in.)

4

2.105-2.334 mm (0.0829-0.0919 in.)

29536855 1.395-1.445 mm (0.0549-0.0569 in.)

5

2.335-2.5015 mm (0.0919-0.0988 in.)

29536856 1.625-1.675 mm (0.0640-0.0659 in.)

6

A24c

6. Install selective spacer (1) onto output shaft (2).

Copyright © 2003 General Motors Corp.

6–21

1000/2000/2400 SERIES SERVICE MANUAL

2

6–15. REAR COVER SELECTIVE SPACER INSTALLATION (4WD TRANSMISSIONS ONLY)

1

1. Position the main housing so that the rear of the main housing is facing up. A

2. Measure the distance (Dimension A) from the rear face of rear cover (1) to the rear face of bearing spacer (2).

D40

3. Measure the distance from the rear face of rear cover module (3) to the rear face of retaining ring (4) (Dimension B).

1 2

3

4 B

4. Calculate Dimension C by subtracting Dimension B from Dimension A (Dimension C = Dimension A – Dimension B). 5. Select the appropriate selective spacer (1) from the following table based on Dimension C.

Dimension C

D41

Part Number

Thickness

# of Holes

1.0081–1.184 mm (0.0397-0.0466 in.)

29536850 0.245-0.295 mm (0.0096-0.0116 in.)

0

1.185-1.414 mm (0.0467-0.0557 in.)

29536851 0.475-0.525 mm (0.0187-0.0207 in.)

1

1.415-1.644 mm (0.0557-0.0647 in.)

29536852 0.705-0.755 mm (0.0278-0.0297 in.)

2

1.645-1.874 mm (0.0648-0.0738 in.)

29536853 0.935-0.985 in) (0.0368-0.0388 in.)

3

1.875-2.104 mm (0.0738-0.0828 in.)

29536854 1.165-1.215 mm (0.0459-0.0478 in.)

4

2.105-2.334 mm (0.0829-0.0919 in.)

29536855 1.395-1.445 mm (0.0549-0.0569 in.)

5

2.335-2.5015 mm (0.0919-0.0988 in.)

29536856 1.625-1.675 mm (0.0640-0.0659 in.)

6

6. Install selective spacer (1) onto output shaft (2).

6–22

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–16. TRANSMISSION END PLAY CHECK

1

Tools Required

2

• J 24446

Rear Bearing Installer

• J 5959

Dial Indicator Set

1. Using J 24446 (1), install ball bearing (2) until the bearing seats.

A24e

2. Align retaining ring (1) so that the beveled edge is facing up.

1

3. Install retaining ring (1).

A24f

4. Position the main housing so that the front is facing up. Assemble the following tools and install them onto the torque converter housing as shown. • J 5959-1 (2) • J 5959-2 (3) • J 5959-3 (1) • J 5959-7 (4)

1

2

4 3

5. Zero dial indicator (2). 6. Lift the rear of the rotating clutch housing with a screwdriver through the PTO hole in the main housing. Note the dial indicator reading (end play). The end play must be 0.279–1.549 mm (0.0110–0.0610 inch).

Copyright © 2003 General Motors Corp.

A24g

6–23

1000/2000/2400 SERIES SERVICE MANUAL 7. If the end play is not within the specification, a different selective spacer must be installed. Perform the following. • Remove the following tools from the

transmission. — J 5959-1 (2) — J 5959-2 (3) — J 5959-3 (1) — J 5959-7 (4) • Remove the retaining ring and ball bearing

assembly per Paragraph 4–13, Rear Ball Bearing Removal. • Return to Paragraph 6–14, Rear Cover Selective Spacer Installation. • Repeat the end play check procedures in Paragraph 6–16.

6–17. TORQUE CONVERTER INSTALLATION 1

WARNING! The 1000/2000/2400 Series torque converter dry weights are approximately 29 kg (63 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the torque converter. • Get help when lifting the torque converter. Assistance from a hoist or another person may be required. • Make sure lifting equipment can properly support the torque converter.

2

D9b

1. Position the transmission so that the converter housing is facing up. 2. Attach a sling to torque converter (1). Attach a hoist to the sling. 3. Lower torque converter (1) over the turbine shaft and the ground sleeve and into the main pump assembly. Make sure the torque converter is seated in the main pump assembly. 4. Remove the sling.

6–24

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY WARNING! The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage. NEVER tilt the converter end down unless a torque converter retaining device is installed. NOTE: The torque converter may not be seated if the shipping brackets cannot be installed. A correctly installed torque converter will lift when the shipping bracket bolts are tightened. 5. If used, install two shipping brackets (2) and four bolts (1). 1

1 2

2

1 1

D9

Copyright © 2003 General Motors Corp.

6–25

1000/2000/2400 SERIES SERVICE MANUAL 6. If used, install shipping bracket (3), two bolts (1), two nuts (4), and bolt (2).

1

2

3

1

4

4

D9a

6–18. NSBU SWITCH INSTALLATION (IF PRESENT) Tools Required • J 41364-A NSBU Switch Adjusting Tool (if

reusing the NSBU switch) 1. Place selector shaft (1) in the N (Neutral) position as follows.

20.9° 1

• Using a wrench on selector shaft flats (1),

rotate the shaft to its fullest clockwise position. • Rotate the selector shaft counter-clockwise two detents.

1 2 P

OD R N

D

23.2° 34.3° 45.5° 56.2° 67.0° 77.8° R63d

6–26

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 2. If a new NSBU switch is being installed, do the following. • Align the flats on the hub of NSBU

switch (1) with the flats of selector shaft (3). • While maintaining the correct NSBU switch-to-selector-shaft alignment, install the NSBU switch onto the selector shaft and onto the main case. • Install front splash shield (4) over the selector shaft so that the larger diameter seals against the NSBU switch body. • Install two bolts (2). Tighten the bolts to 24–29 N·m (18–21 lb ft).

1 3 2

4 2

V07746.02.00

3. If the NSBU switch is being reused, do the following. • Align the flats on the hub of NSBU switch • •

•

•

• •

(1) with the flats of the selector shaft. Install the NSBU switch onto the selector shaft. Position special tool J 41364-A (2) over the selector shaft so that the two tabs on the tool engage two slots on the NSBU switch near the selector shaft. Rotate the NSBU switch (1) and J 41364-A until the tab at the other end of tool (2) engages the slot at the top of the NSBU switch. While holding J 41364-A (2) to NSBU switch (1), tighten the bolts to 24–29 N·m (18–21 lb ft) Remove J 41364-A from the NSBU switch. Install the front splash shield over the selector shaft so that the large diameter seals against the NSBU switch body.

1

Copyright © 2003 General Motors Corp.

2

V08088.01.00

6–27

1000/2000/2400 SERIES SERVICE MANUAL

NOTE: The shift selector lever and shift lever nut may not be present.

6

4. Align selector lever (1) with selector shaft (2). If the lever is punched, the punched side should face the main case. 5. Install the lever onto the selector shaft until the lever is fully seated on the shaft shoulder. 6. Hand install selector lever nut (3) onto the selector shaft.

®

6

5

4

3

CAUTION:

2 1 V08086.01.00

To avoid internal damage to the transmission: • Do not use a power impact wrench to torque the shift lever nut. • Hold the selector lever while torquing the shift lever nut. 7. While holding the selector lever, tighten the selector lever nut to 20–27 N·m (15–20 lb ft).

6–28

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–19. REAR SEAL INSTALLATION (2WD TRANSMISSIONS ONLY) Tools Required • J 43782 • J 43783

1

Output Shaft Seal Installer Output Shaft Seal Installer

2

NOTE: • For transmissions without a parking brake provision, install the oil seal using J 43782. • For transmissions with a parking brake provision, install the oil seal using J 43783. 1. Using J 43782 or J 43783 (1), install the oil seal (2). 2. Check the installation of the oil seal as follows. • For transmissions without a parking brake provision, make sure the rear output seal is installed to 4.55–5.35 mm (0.179–0.211 inch) below the rear face of the rear cover. • For transmissions with a parking brake provision, make sure the rear output seal is installed to 31.10–31.90 mm (1.224–1.256 inch) below the rear face of the rear cover.

A24i

6–20. OUTPUT NUT INSTALLATION (1000 SERIES™ 4WD TRANSMISSIONS ONLY) Tools Required • J 43769

Spanner Nut Wrench—4WD 20.9° 1

NOTE: The fullest clockwise position of the selector shaft is P (Park), which engages the park pawl.

1

1. Using a wrench on selector shaft flats (1), rotate the shaft to its fullest clockwise position.

2 P

OD R N

D

23.2° 34.3° 45.5° 56.2° 67.0° 77.8° R63d

Copyright © 2003 General Motors Corp.

6–29

1000/2000/2400 SERIES SERVICE MANUAL 2. Make sure the park pawl is engaged. 3. Install J 43769 (1) onto output nut (2). 1

4. Using J 43769 (1), install a new output nut (2) onto output shaft (3).

2

5. Tighten output nut (2) to 54–68 N·m (40–50 lb ft).

3

A24j

NOTE: The N (Neutral) position of the selector shaft is two detents counter-clockwise from the fullest clockwise position.

20.9° 1

6. Rotate the selector shaft counter-clockwise two detents. 7. Make sure the park pawl is disengaged.

1 2 P

OD R N

D

23.2° 34.3° 45.5° 56.2° 67.0° 77.8° R63d

6–30

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–21. VENT INSTALLATION 1. Install vent (1) by hand. 2. Gently tap on vent (1) until seated.

1

V07744.00.00

6–22. INPUT SPEED SENSOR INSTALLATION

1

1. Install sensor O-ring (3) onto speed sensor (2).

2 3

2. Apply petrolatum to O-ring (3). 3. Install speed sensor (2) into the converter housing. 4

4. Install speed sensor bolt (1) into the converter housing. Tighten the bolt to 10–13 N·m (7–10 lb ft). 5. If present, install sensor shipping cover (4) onto the speed sensor.

D4b

Copyright © 2003 General Motors Corp.

6–31

1000/2000/2400 SERIES SERVICE MANUAL

1

6–23. TURBINE SPEED SENSOR INSTALLATION

2

1. Install sensor O-ring (3) onto speed sensor (2).

3

2. Apply petrolatum to O-ring (3). 3. Install speed sensor (2) into the main housing. 4. Install speed sensor bolt (1) into the main housing. Tighten the bolt to 10–13 N·m (7–10 lb ft).

4

5. If present, install sensor shipping cover (4) onto the speed sensor.

D4a

6–24. OUTPUT SPEED SENSOR INSTALLATION (2WD TRANSMISSIONS ONLY)

1 2 3

1. Install sensor O-ring (3) onto speed sensor (2). 2. Apply petrolatum to O-ring (3). 3. Install speed sensor (2) into the rear cover. 4. Install speed sensor bolt (1) into the rear cover. Tighten the bolt to 10–13 N·m (7–10 lb ft). 5. If present, install sensor shipping cover (4) onto the speed sensor.

4

6–32

D4

Copyright © 2003 General Motors Corp.

TRANSMISSION ASSEMBLY 6–25. REMOVAL OF TRANSMISSION FROM REPAIR STAND

1

Tools Required

2

• J 44723

Transmission/Stand Adapter Plate

• J 29109

Repair Stand

WARNING! The 1000/2000/2400 Series transmission dry weights are approximately 150 kg (330 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, or moving the transmission. • Get help when lifting the transmission. Assistance from a hoist or another person may be required. • Make sure lifting equipment can properly support the transmission.

V08141.01.00

1. Attach a sling to the transmission. 2. Attach a hoist to the sling. Put moderate lift tension on the hoist. 3. Disconnect and remove transmission (2) from adapter plate J 44723 (1). 4. Place the transmission on the work table with the oil pan facing down. NOTE: PTO Cover Gasket (2) has been redesigned. The former and current designs are interchangeable. The former design may be reused unless replacement is necessary or the design is no longer available. DO NOT use a PTO cover gasket to mount a PTO.

1

5. If present, install two PTO cover gaskets (1).

3

1 2

6. If present, install two PTO covers (2). 7. If present, install twelve PTO cover bolts (3). Tighten the bolts to 40–45 N·m (29–33 lb ft).

2

3

8. If present, install the PTO(s) per the PTO manufacturer’s instructions.

Copyright © 2003 General Motors Corp.

V07702.02.00

6–33

1000/2000/2400 SERIES SERVICE MANUAL NOTES

6–34

Copyright © 2003 General Motors Corp.

SECTION 7 — WEAR LIMITS AND SPRING DATA 7–1.

WEAR LIMITS DATA

meet the load height specifications according to Table 7–2, Spring Data.

a. Maximum Variations. Wear limits information in this Section are the maximum wear at which components are expected to function satisfactorily. Table 7–1 lists the Wear Limits Data. b. Cleaning and Inspection. Parts must be clean to permit effective inspection for wear or damage. Refer to Section 3.

b. Inspection. Inspection criteria (load vs. height) and identification characteristics of the springs are presented in Table 7–2. The Spring Data are keyed to the exploded views (Foldouts 5 through 20) in the back of this manual. NOTE:

7–2.

SPRING DATA

a. Spring Replacement. Replace springs if there are signs of overheating, wear due to rubbing adjacent parts, or permanent set. Discard springs which do not

When more than one spring part number is listed for the same location, refer to the latest edition of Parts Catalog PC3062EN to determine which spring is used in your specific assembly number.

Table 7–1. Wear Limits Data Description TORQUE CONVERTER MODULE

Wear Limit mm (inches)

Maximum Torque Converter End Play — Used

1.015

0.0400

Maximum Torque Converter End Play — New

0.762

0.0300

Minimum OD

58.250

2.2933

Minimum Distance Between Flats

51.816

2.0400

43.080

1.6960

Bushing, Maximum ID The pump bushing must have a complete burnt-orange color Teflon® coating. If any portion of the Teflon® coating is worn and bronze material is visible, replace the pump.

58.458

2.3015

Gear Cavity, Maximum Depth

24.940

0.9819

109.191

4.2989

Driven Gear, Max. Diametric Clearance w/ Pump Body

0.204

0.0080

Driven Gear, Maximum Tooth Clearance w/ Crescent

0.455

0.0179

108.987

4.2908

Wear Plate, Minimum Thickness

2.950

0.1161

Gear-to-Wear Plate, Maximum Side Clearance

0.064

0.0025

Drive Gear, Maximum Distance Between Flats

52.165

2.0537

0.066

0.0026

Converter Pump Hub:

Cover Pilot, Minimum OD FRONT SUPPORT AND OIL PUMP MODULE Charging Pump:

Gear Cavity, Maximum ID

Driven Gear, Minimum OD

Drive Gear, Side Clearance

Copyright © 2003 General Motors Corp.

7–1

1000/2000/2400 SERIES SERVICE MANUAL Table 7–1. Wear Limits Data (cont’d) Description Front Support and Ground Sleeve: Ground Sleeve, Maximum ID at Turbine Shaft Sealring Bore Ground Sleeve, Maximum Spline Wear Ground Sleeve Bushing, Maximum ID

Wear Limit mm (inches) 45.450

1.7894

No visible wear allowable 33.820

1.3315

1.49

0.059

Bushing, Maximum ID

78.170

3.0776

Rotating Seal Bore, Maximum ID

74.050

2.9154

Maximum Cone

0.255

0.0100

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.200

0.0079

Minimum Thickness

2.135

0.0841

0.000

0.0000

Part # 29536221

11.840

0.4661

Part # 29536222

12.280

0.4835

Part # 29536223

12.730

0.5012

Part # 29536224

13.180

0.5189

Part # 29536225

13.630

0.5366

Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.240

0.0094

Minimum Thickness

2.135

0.0841

20.117

0.7920

2.59

0.102

Thrust Washer ROTATING CLUTCH MODULE Rotating Clutch Housing:

C1 Friction Plates:

C1 Steel Reaction Plate:

C1 Backplate: Maximum Cone Minimum Thickness (Selective)

C2 Friction Plates:

C2 Steel Reaction Plate:

Turbine Shaft Bushing, Maximum ID Thrust Washer

7–2

Copyright © 2003 General Motors Corp.

WEAR LIMITS AND SPRING DATA Table 7–1. Wear Limits Data (cont’d) Description MAIN HOUSING MODULE

Wear Limit mm (inches)

C3/C4 Friction Plate: Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.400

0.0157

Minimum Thickness

2.440

0.0961

Maximum Cone

0.400

0.0157

Minimum Thickness

3.110

0.1224

0.000

0.0000

15.325

0.6033

3.000

0.1181

0.000

0.0000

15.400

0.6063

Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

0.295

0.0116

Part # 29536481

1.935

0.0762

Part # 29536482

2.435

0.0959

Part # 29536483

2.935

0.1156

0.000

0.0000

17.900

0.7047

P1 Ring Gear, Maximum Spline Wear (Notching)

0.100

0.0040

Main Housing Clutch Plate, Spline Wear (Notching)

1.150

0.0450

C3/C4 Steel Reaction Plate:

C3/C4 Spring Plate:

C3 Backplate: Maximum Cone Minimum Thickness Thrust Plate Inner Rim, Minimum Thickness C4 Backplate: Maximum Cone Minimum Thickness C5 Friction Plate:

C5 Steel Reaction Plate: Maximum Cone Minimum Thickness (Selective)

C5 Backplate: Maximum Cone Minimum Thickness

Copyright © 2003 General Motors Corp.

7–3

1000/2000/2400 SERIES SERVICE MANUAL Table 7–1. Wear Limits Data (cont’d) Description

Wear Limit mm (inches)

PLANETARY GEAR MODULE P1 Carrier Assembly: Pinion Gear, Maximum End Play

1.010

0.0400

50.690

1.9957

Thrust Washer, Minimum Thickness

1.490

0.0590

P2 Ring Gear, Maximum Spline Wear (Notching)

0.100

0.0040

1.060

0.0417

36.575

1.4400

0.100

0.0040

Pilot, Minimum OD (Turbine Shaft and Output Shaft)

19.987

0.7869

Journal, Minimum OD (P2 Carrier Bushing)

36.405

1.4333

Output Shaft Bushing (2WD and 4WD), Maximum ID

20.070

0.7940

Output Shaft (2WD and 4WD), Minimum Bearing Surface OD

44.978

1.7708

Pinion Gear, Maximum End Play

1.010

0.0400

Parking Pawl Gear Wear

0.000

0.0000

65.080

2.5622

Bushing, Maximum ID

P2 Carrier Assembly: Pinion Gear, Maximum End Play Bushing, Maximum ID P3 Ring Gear, Maximum Spline Wear (Notching) Main Shaft:

REAR COVER MODULE

P3 Carrier Assembly:

OUTPUT YOKE Output Seal Surface, Minimum OD

7–4

Copyright © 2003 General Motors Corp.

14, 6

3

19B, 19C

19C

Exhaust Backfill

Control Main/Control Relief

C1 Return Spring Assembly

C2 Return Spring Assembly

Clutch Backfill

Lube Reg/Converter Flow

Converter Relief

Main Pressure Regulator

Spring C3/C4 Return Spring Assembly

Copyright © 2003 General Motors Corp.

4, 8, 11

5

4

19B

16A

16A

Park Pawl Return

C5 Return Spring Assembly

C, D, and E Shift

A Trim

* Individual Springs ** For the complete Spring Assembly

13

19C

11, 17, 28 A, B, and F Trim

25

10

19C

16

7, 14

9

10

11

9

19

22

9

9

Ref. 12, 4

Foldout 6, 13

29531147

29531134

29531176

29537230

29536313

29531161

29541153

29536198

29536104

29531026

29540523

29541296

29531017

Part No. 29531046

No Code

No Code

No Code

No Code

No Code

Orange Stripe

No Code

No Code

No Code

No Code

Light Blue

No Code

No Code

Color Code No code

6

7.8*

11.55

7.21

7.44

11.35

11.85

7.99*

5.77*

8.75

6.79

12.18

11.87

No. Coils 8.78*

0.75 (0.030)

1.702* (0.0670)

1.00 (0.039)

1.30 (0.051)

0.76 (0.030)

0.90 (0.035)

1.50 (0.059)

1.295* (0.0510)

1.143* (0.0450)

0.64 (0.025)

1.60 (0.063)

1.42 (0.056)

2.77 (0.109)

Wire Dia. mm (in.) 1.588* (0.0625)

Table 7–2. Spring Data

8.70 (0.343)

13.5* (0.531)

11.00 (0.433)

15.20 (0.598)

9.80 (0.386)

12.60 (0.496)

14.00 (0.551)

9.17* (0.361)

10.05* (0.396)

9.65 (0.380)

16.10 (0.634)

13.46 (0.529)

22.61 (0.890)

Spring OD mm (in.) 12.00* (0.472)

29.55 (1.161)

31.40** (1.236)

29.29 (1.153)

23.25 (0.915)

20.15 (0.793)

22.54 (0.887)

40.62 (1.599)

19.49** (0.767)

19.60** (0.772)

29.93 (1.178)

31.43 (1.237)

44.85 (1.766)

73.74 (2.903)

Approx. Free Length mm (in.) 31.89** (1.256)

41.75 (1.644)

21.60** (0.850)

14.26 (0.561)

13.37 (0.526)

9.44 (0.372)

16.16 (0.636)

22.11 (0.870)

15.62** (0.615)

15.90** (0.626)

11.20 (0.44)

17.05 (0.671)

22.84 (0.899)

41.50 (1.634)

mm (in.) 24.81** (0.977)

11.3–14.9 (2.5–3.3)

1454.6–1620.2** (327.0–364.2)

14.61–16.59 (3.28–3.73)

18.69–21.35 (4.20–4.80)

8.14– 9.70 (1.83–2.18)

2.537–3.003 (0.570–0.675)

45.86–50.68 (10.31–11.39)

941.2–1126.4** (211.6–253.2)

652.5–770.9** (146.7–173.3)

5.59–6.59 (1.26–1.48)

54.23–73.89 (12.19–16.61)

45.10–55.44 (10.14–12.46)

231.56–255.94 (52.06–57.54)

N (lb) min. 162.00–187.60** (36.42–42.17)

Length Under Load

WEAR LIMITS AND SPRING DATA

7–5

1000/2000/2400 SERIES SERVICE MANUAL NOTES

7–6

Copyright © 2003 General Motors Corp.

SECTION 8 — CUSTOMER SERVICE 8–1.

OWNER ASSISTANCE

The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission Division (ATD), its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world eager to meet your parts and service needs with: • Expert service by trained personnel • Emergency service 24 hours a day in many

areas • Complete parts support • Sales teams to help determine your transmission requirements • Product information and literature Refer to the Worldwide Sales and Service Directory (SA2229EN) or the Allison transmission web site www.allisontransmission.com for a current listing of Allison Transmission authorized distributor and service dealers. This directory is available from SGI, Inc. Normally, any situation that arises in connection with the sale, operation, or service of your transmission will be handled by the distributor or dealer in your area. (Check the Allison transmission web site www.allisontransmission.com or a telephone directory for the Allison Transmission service outlet nearest you.) We recognize, however, that despite the best intentions of all concerned, misunderstandings may occur. To further assure your complete satisfaction, we have developed the following three-step procedure to be followed in the event you have a problem that has not been handled satisfactorily. Step One — Discuss the problem with a member of management from the distributorship or dealership. Complaints are frequently the result of a breakdown in communication and can be quickly resolved by a member of management. If you have already discussed the problem with the Sales or Service Manager, contact the General Manager. All ATD dealers are associated with an ATD distributor. If the problem originates with a dealer, explain the matter to a management member of the distributorship with whom the dealer has his service agreement. The dealer will provide his ATD distributor’s name, address, and telephone number on request.

Step Two — If your problem cannot be resolved readily at the distributor level without additional assistance, contact the Allison Transmission Regional Office responsible for your local distributor. You will be assisted by a member of the Regional Service Manager’s staff, depending on the nature of your problem. For prompt assistance, please have the following information available: • Name and location of authorized distributor or

dealer • Type and make of equipment • Transmission model number, serial number,

and assembly number — if equipped with electronic controls, also provide the ECU assembly number • Transmission delivery date and accumulated

miles and/or hours of operation • Nature of problem • Chronological summary of unit’s history

Step Three — If you contacted a regional office and you are still not satisfied, present the entire matter to the Home Office by writing to the following address or calling the phone number below: Manager, Warranty Administration — PF9 Allison Transmission P. O. Box 894 Indianapolis, IN 46206-0894 Phone: 1-800-524-2303 The inclusion of all pertinent information will assist the Home Office in expediting the matter. If an additional review by the Home Office of all the facts involved indicates that some further action can be taken, the Regional Office will be advised. When contacting the Regional or Home Office, please keep in mind that ultimately your problem will likely be resolved at the distributorship or dealership utilizing their facilities, equipment, and personnel. Therefore, it is suggested that the above steps be followed in sequence when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.

Copyright © 2003 General Motors Corp.

8–1

1000/2000/2400 SERIES SERVICE MANUAL 8–2.

SERVICE LITERATURE (Table 8–1)

Additional service literature is available. This service literature provides fully illustrated instructions for the operation, maintenance, service, overhaul, and parts support for your transmission. To ensure that you get maximum performance and service life from your unit, you may order publications from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995

Table 8–1. 1000/2000/2400 Series Literature Automatic Transmission Fluid Technician’s Guide

GN2055EN

*Mechanic’s Tips

MT3190EN

*In-Chassis Maintenance

JA3664EN

*Operator’s Manual—1000/2000/2400 Series OM3063EN *Operator’s Manual—2000MH Series

OM3364EN

Parts Catalog

PC3062EN

Parts Catalog CD-ROM

CD3062EN

Principles of Operation

PO3065EN

Retail Literature Catalog

GN2798EN

Service Manual

SM3191EN

Electronic Troubleshooting Manual

TS3192EN

Worldwide Sales and Service Directory

SA2229EN

*Also available on The Internet at www.allisontransmission.com

8–2

Copyright © 2003 General Motors Corp.

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 1 Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 1

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 1

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Foldout 1

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Torque converter assembly Converter housing Turbine shaft Input speed sensor Main pump assembly Front support assembly Rotating clutch assembly Turbine speed sensor PTO gear C1 clutch C2 clutch C3 clutch P1 planetary Main shaft P2 planetary C4 clutch P3 planetary C5 clutch Main housing Rear cover Output shaft Output speed sensor Output yoke Oil pan Shift valve body assembly Suction filter Main control valve assembly Tone wheel Control main filter

Copyright © 2003 General Motors Corp.

SM3191_Foldout 01-b.fm Page 1 Friday, January 30, 2004 9:29 AM

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Foldout 2

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Torque converter assembly Converter housing Turbine shaft Input speed sensor Main pump assembly Front support assembly Rotating clutch assembly Turbine speed sensor PTO gear C1 clutch C2 clutch C3 clutch P1 planetary Main shaft P2 planetary C4 clutch P3 planetary C5 clutch Main housing Rear cover Output shaft Output speed sensor Oil pan Shift valve body assembly Suction filter Main control valve assembly Tone wheel Control main filter Cooler manifold

Copyright © 2003 General Motors Corp.

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Copyright © 2003 General Motors Corp.

Foldout 3

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 3

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Foldout 3

— — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Torque converter assembly Converter housing Turbine shaft Input speed sensor Main pump assembly Front support assembly Rotating clutch assembly Turbine speed sensor PTO gear C1 clutch C2 clutch C3 clutch P1 planetary Main shaft P2 planetary C4 clutch P3 planetary C5 clutch Main housing Rear cover Output shaft Output speed sensor Oil pan Shift valve body assembly Suction filter Main control valve assembly Tone wheel Control main filter Cooler manifold

Copyright © 2003 General Motors Corp.

SM3191_Foldout 03-b.fm Page 1 Friday, January 30, 2004 9:28 AM

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Copyright © 2003 General Motors Corp.

Foldout 4

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 4

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Foldout 4

— — — — — — — — — — — — — — — — — — — — — — — — — — —

Torque converter assembly Converter housing Turbine shaft Input speed sensor Main pump assembly Front support assembly Rotating clutch assembly Turbine speed sensor PTO gear C1 clutch C2 clutch C3 clutch P1 planetary Main shaft P2 planetary C4 clutch P3 planetary C5 clutch Main housing Rear cover Output shaft Oil pan Shift valve body assembly Suction filter Main control valve assembly Tone wheel Control main filter

Copyright © 2003 General Motors Corp.

SM3191_Foldout 04-b.fm Page 1 Friday, January 30, 2004 9:29 AM

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Legend For Foldout 5A,B Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 5A,B

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 5A,B

A

B

1 — Torque Converter Assembly 2 — Converter Housing — SAE No. 3, with integral cooler ports 3 — Shipping Plug (2), A 4 — O-ring (2) 5 — Pressure Tap Plug, B 6 — O-ring 7 — Control Main Filter 8 — Control Main Magnet 9 — Filter Attachment Tube, C 10 — Bolt, M10 x 1.5 x 50 Flange Head (15), D 11 — Bolt, M10 x 1.5 x 70 Flange Head (15), D 12 — Sensor Shipping Cover 13 — Bolt, M6 x 1.0 x 13 Flange Head, B 14 — Input Speed Sensor 15 — Speed Sensor O-ring 16 — Bolt, M10 x 1.5 x 25 Flange Head (4), E 17 — Shipping Bracket (2) 18 — Hydraulic Connector Assembly (2), F Torque A B C D E F

N·m

lb ft

2.5–3.5 10–13 25–35 51–61 20–34 20–30

2–3 7–10 18–26 38–45 15–25 15–20

1 — Torque Converter Assembly 2 — Converter Housing — SAE No. 2, with manifold 3 — Bolt, M10 x 1.5 x 50 Flange Head (15), D 4 — Bolt, M10 x 1.5 x 70 Flange Head (5), D 5 — Sensor Shipping Cover 6 — Bolt, M6 x 1.0 x 13 Flange Head, B 7 — Input Speed Sensor 8 — Speed Sensor O-ring 9 — Bolt, M10 x 1.5 x 35 Flange Head (2), E 10 — Bolt, M10 x 1.5 x 25 Flange Head, E 11 — Shipping Bracket 12 — Nut, M10 x 1.5 (2), E 13 — Converter Housing/Manifold Plate Gasket 14 — Cooler Manifold Channel Plate 15 — Converter Housing/Manifold Plate Gasket 16 — Cooler Manifold 17 — Bolt, M8 x 1.25 x 30 Flange Head (8), G 18 — Plug (2), A 19 — O-ring (2) 20 — Pressure Tap Plug, B 21 — O-ring 22 — Bolt, M8 x 1.25 x 40 Flange Head (4), G 23 — Control Main Filter 24 — Control Main Magnet 25 — Filter Attachment Tube, C 26 — Elbow Adapter, 90 Degree, 11⁄ 16 x 13⁄ 16 (2) — Lock Nut, F — Fitting, F Torque A B C D E F G

Foldout 5A,B

Copyright © 2003 General Motors Corp.

N·m

lb ft

2.5–3.5 10–13 25–35 51–61 20–34 20–30 24–29

2–3 7–10 18–26 38–45 15–25 15–20 18–21

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25

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V06327

V06326

Foldout 5A. SAE No. 3 Torque Converter Housing With Integral Cooling Ports

Foldout 5B. SAE No. 2 Torque Converter Housing With Manifold

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 5C,D Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 5C,D

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 5C,D

C

D

1 — Torque Converter Assembly 2 — Converter Housing — SAE No. 3, with manifold 3 — Bolt, M10 x 1.5 x 50 Flange Head (15), D 4 — Bolt, M10 x 1.5 x 70 Flange Head (15), D 5 — Sensor Shipping Cover 6 — Bolt, M6 x 1.0 x 13 Flange Head, B 7 — Input Speed Sensor 8 — Speed Sensor O-ring 9 — Bolt, M10 x 1.5 x 25 Flange Head (4), E 10 — Shipping Bracket (2) 11 — Converter Housing/Manifold Plate Gasket 12 — Cooler Manifold Channel Plate 13 — Converter Housing/Manifold Plate Gasket 14 — Cooler Manifold 15 — Bolt, M8 x 1.25 x 30 Flange Head (8) 16 — Plug (2), A 17 — O-ring (2) 18 — Pressure Tap Plug, B 19 — O-ring 20 — Bolt, M8 x 1.25 x 40 Flange Head (4), G 21 — Control Main Filter 22 — Control Main Magnet 23 — Filter Attachment Tube, C 24 — Elbow Adapter, 90 Degree, 11⁄ 16 x 13⁄ 16 (2) — Lock Nut, F — Fitting, F Torque A B C D E F G

Foldout 5C,D

N·m

lb ft

2.5–3.5 10–13 25–35 51–61 20–34 20–30 24–29

2–3 7–10 18–26 38–45 15–25 15–20 18–21

1 — Torque Converter Assembly 2 — Converter Housing — Direct Mount 3 — Pressure Tap Plug, A 4 — O-ring 5 — Control Main Filter 6 — Control Main Magnet 7 — Filter Attachment Tube, B 8 — Bolt, M10 x 1.5 x 50 Flange Head (18), C 9 — Bolt, M10 x 1.5 x 70 Flange Head (1), C 10 — Sensor Shipping Cover 11 — Bolt, M6 x 1.0 x 13 Flange Head, B 12 — Input Speed Sensor 13 — Speed Sensor O-ring 14 — Bolt, M10 x 1.5 x 35 Flange Head (2), D 15 — Bolt, M10 x 1.5 x 25 Flange Head (2), D 16 — Nut, M10 x 1.5 (2), D 17 — Shipping Bracket 18 — Bolt, M10 x 1.5 x 110 Flange Head, C 19 — Hydraulic Connector Assembly (2), E 20 — Bolt Access Cover Torque A B C D E

Copyright © 2003 General Motors Corp.

N·m

lb ft

10–13 25–35 51–61 20–34 20–30

7–10 18–26 38–45 15–25 15–20

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Foldout 5C. SAE No. 3 Torque Converter Housing With Manifold

Foldout 5D. Direct Mount — Torque Converter Housing

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 6, 6A Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 6, 6A

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 6, 6A

6 1 2 3 4 5 6 7 8 9 10 11 12 13 14

— — — — — — — — — — — — — —

6,A

Converter Housing/Front Support Module Main Housing/Separator Plate Gasket Rotating Clutch Assembly Thrust Bearing Assembly, T3 Internal Retaining Ring C3 Clutch Backplate Assembly C3 Clutch Backplate Gear Thrust Plate (3) Rivet (6) C3 Clutch Friction Plate (4) C3 Clutch Reaction Plate (3) C3 Piston Return Spring Assembly (3) C3 Spring Plate C3 Clutch Piston Assembly (Bonded Seals)

Foldout 6, 6A

1 2 3 4 5 6

— — — — — —

Converter Housing/Front Support Module Bolt, M10 x 1.5 x 50 Flange Head (10), A Seal Converter Housing Converter Housing/Separator Plate Gasket Front Support Module

Torque A

Copyright © 2003 General Motors Corp.

N·m

lb ft

51–61

38–45

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Foldout 6. Converter Housing/Front Support Module, Rotating Clutch Housing, and C3 Clutch Components

Foldout 6A. Converter Housing/Front Support Module Components

SM3191_Foldout 07.fm Page 1 Friday, January 30, 2004 9:24 AM

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Torque A

Front Support Module Main Pump Assembly Converter/Main Case Separator Plate Butt Joint Sealring (End) Butt Joint Sealring (Middle) Front Support Assembly Bolt, M8 x 1.25 x 55 Flange Head (5), A Thrust Washer, W1 PEEK Butt Joint Sealring (3) N·m

lb ft

24–29

18–21

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Foldout 7. Front Support Module Components

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Main Pump Assembly O-ring Oil Seal Assembly Main Pump Bushing Main Pump Body Pump Driven Gear Pump Drive Gear Dowel Pin (2) Main Pump Wear Plate

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Foldout 8. Main Pump Assembly Components

SM3191_Foldout 09.fm Page 1 Friday, January 30, 2004 9:23 AM

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Front Support Assembly Needle Bearing Front Support Bushing, 33.8 mm (1.33 inch) ID Ground Sleeve Converter Flow Valve Converter Flow Valve Spring Converter Flow Valve Stop Converter Flow Stop Retainer Pin Converter Relief Valve Converter Relief Valve Spring Retaining Clip Lube Regulator Valve Lube Regulator Valve Spring O-Ring Lube Regulator Stop Lube Regulator Retainer Pin C1 Clutch Backfill Valve C1 Clutch Backfill Valve Spring Retaining Clip Main Regulator Valve Main Regulator Valve Spring Main Regulator Valve Stop Main Regulator Valve Retainer Pin

3 6 4

7 1

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Foldout 9. Front Support Assembly Components

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Rotating Clutch Assembly Butt Joint Sealring (2) Turbine Shaft Bushing, 20 mm (0.8 inch) ID Rotating Clutch Housing Assembly PTO Gear Turbine Tone Wheel Rotating Clutch Bushing Rotating Clutch Housing O-ring External Retaining Ring Piston ID Sealring C2 Piston OD Sealring C2 Balance Piston OD Sealring C2 Clutch Piston C2 Piston Return Spring Assembly Ball C1 Piston Housing External Retaining Ring C2 Balance Piston Internal Retaining Ring C1 Piston ID Sealring C1 Piston OD Sealring C1 Clutch Piston C1 Piston Return Spring Assembly

26 27 28 29 30 31

32 33 34 35 36 37 38 39 40 41 42 43

— — — — — —

— — — — — — — — — — — —

External Retaining Ring C1 Balance Piston Internal Retaining Ring C1 Clutch Reaction Plate (6) C1 Clutch Friction Plate (6) C1 Clutch Backplate — Selective ID Thickness 6221 6.44–6.64 mm (0.254–0.261 inch) 6222 6.88–7.08 mm (0.271–0.279 inch) 6223 7.33–7.53 mm (0.289–0.296 inch) 6224 7.78–7.98 mm (0.306–0.314 inch) 6225 8.23–8.43 mm (0.324–0.332 inch) External Retaining Ring Internal Spiral Retaining Ring Thrust Bearing Assembly, T1 C1 Drive Hub Thrust Bearing Assembly, T2 C2 Clutch Reaction Plate (7) C2 Clutch Friction Plate (6) C2 Drive Hub Thrust Washer, W2 P1 Sun Gear P1 Drive Flange Internal Retaining Ring

2 3 1 5

6

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32

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Foldout 10. Rotating Clutch Assembly Components

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

— — — — — — — — — — — — — — — — —

Fill Tube Plug (2) Fill Tube Seal (2) Deep Pan Suction Filter Suction Filter Seal Shallow Pan Suction Filter (use with shallow pan only) Suction Filter Seal Oil Pan Gasket Oil Pan Assembly Magnet Deep Sump Oil Pan Oil Pan Assembly Magnet Shallow Sump Oil Pan Drain Plug Assembly Drain Plug, A Drain Plug Seal Bolt, M8 x 1.25 x 20 Flange Head (12), B

2

6

4

5

3

7

11 8

9

Torque A B

N·m

lb ft

30–40 24–29

22–30 18–21

13

10

15 16

12

14

15 16

17 V06323.04.00

Foldout 11. Oil Pan and Suction Filter Components

14

SM3191_Foldout 12.fm Page 1 Friday, January 30, 2004 9:24 AM

F OLDOUT 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Main Housing Dowel Pin Vent Assembly Vent Cap Vent Rivet Nameplate Bolt, M6 x 1.0 x 13, A Sensor Shipping Cover Turbine Speed Sensor Speed Sensor O-ring PTO Cover Gasket (2) PTO Cover (2) Bolt, M10 x 1.5 x 20 Flange Head, Coated (12), B Neutral Start/Backup (NSBU) Switch Shift Lever Nut, C Bolt, M8 x 1.25 x 20 NSBU Switch (2), D Front Splash Shield Selector Shaft Selector Shaft Seal Selector Valve Pin Detent Lever Park Pawl Apply Assembly Spring Pin Selector Shaft Nut, M10 x 1.50 Flange, E Connector Shipping Cover Control Valve Assembly Bolt, M6 x 1.0 x 50 Flange Head (15), A Detent Spring Assembly Bolt, M6 x 1.0 x 12 Flange Head (2), A Internal Wiring Harness

13

4 1

N·m

lb ft

10–13 40–45 20–27 24–29 24–34

7–10 30–33 15–20 18–21 18–25

3

5 6

8

10 11 7

2 9

12

13 26

14

20 21 19

25

15

23

22

17

24

18 27

17 16 31

28 30

Torque A B C D E

14

12

Foldout 12. Main Housing Components

29

V06324.03.00

SM3191_Foldout 13.fm Page 1 Friday, January 30, 2004 9:25 AM

F OLDOUT 13

1 2 3 4 5 6 7 8 9 10 11 12 13

— — — — — — — — — — — — —

C4 Clutch Piston Assembly (Bonded Seals) P1 Ring Gear C4 Spring Plate C4 Piston Return Spring Assembly (3) C4 Clutch Friction Plate (5) C4 Clutch Reaction Plate (4) C4 Clutch Backplate Internal Retaining Ring Internal Retaining Ring C5 Clutch Backplate C5 Clutch Friction Plate (6) C5 Clutch Reaction Plate (5) C5 Clutch Reaction Plate — Selective P/N 29536481

ID No. 1

29536482

2

29536483

3

Thickness 1.935–2.065 mm (0.0762–0.0813 inch) 2.435–2.565 mm (0.0959–0.1010 inch) 2.935–3.065 mm (0.1156–0.1207 inch)

1

2

3 4 5 6

10 7 11 12 8 9

13

V06320.01.01

Foldout 13. C4 and C5 Clutch Components

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 14 Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 14

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 14

A 1 2 3 4 5 6 7 8 9

— — — — — — — — —

P1 Planetary Module Thrust Bearing Assembly, T4 P2 Planetary Module Thrust Bearing Assembly, T5 Main Shaft P2 Sun Gear Sun Gear Spacer P3 Sun Gear Thrust Bearing Assembly, T6

Foldout 14

B 1 2 3 4 5

— — — — —

P1 Planetary Module Thrust Washer, W4 PEEK Internal Retaining Ring P1 Planetary Carrier Assembly P2 Planetary Ring Gear

C 1 2 3 4

— — — —

P2 Planetary Module Internal Retaining Ring P2 Planetary Carrier Assembly P3 Planetary Ring Gear

Copyright © 2003 General Motors Corp.

SM3191_Foldout 14-b.fm Page 1 Friday, January 30, 2004 9:17 AM

F OLDOUT 14

1 1 1

2

2

3

2

3 3

4

4

5

4

5 6 7

V06576.02.00

V06575.02.02

8 9

V06574.01.01

Foldout 14A. P1 Planetary Module, P2 Planetary Module, and Main Shaft Components

Foldout 14B. P2 Planetary Module Components

Foldout 14C. P3 Planetary Module

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 15 Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 15

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 15

B

A 1 2 3 4 5 6 7 8

— — — — — — — —

P1 Planetary Carrier Assembly Bushing, 53.0 mm (2.09 inch) ID P1 Planetary Carrier P1 Spindle (4) P1 Thrust Washer (4) P1 Roller Bearing Assembly (8) P1 Pinion Gear (4) P1 Thrust Washer (4)

Foldout 15

1 2 3 4 5 6 7 8

— — — — — — — —

P2 Planetary Carrier Assembly P2 Planetary Carrier Bushing, 36.0 mm (1.42 inch) ID P2 Thrust Washer (4) P2 Roller Bearing Assembly (4) P2 Pinion Gear (4) P2 Thrust Washer (4) P2 Spindle (4)

Copyright © 2003 General Motors Corp.

SM3191_Foldout 15-b.fm Page 1 Friday, January 30, 2004 9:18 AM

F OLDOUT 15

1 1 2 3 4

2 3

5 6

4 5 7 6 8

7 8

V06577.01.01

Foldout 15A. P1 Planetary Carrier Assembly Components

V06578.01.01

Foldout 15B. P2 Planetary Carrier Assembly Components

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 16 Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 16

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 16

A 1 2 3 4 5 6 7 8 9

— — — — — — — — —

B

Apply Assembly Guide Pawl Support Pin Park Pawl Pawl Return Spring C5 Piston Return Spring Assembly Bushing, 20 mm (0.8 inch) ID Output Shaft, 2WD Output Shaft, 4WD P3 Planetary Carrier Assembly

1 2 3 4 5 6 7 8 9 10 11

— — — — — — — — — — —

Rear Cover Gasket Rear Cover Assembly, 10 x 3 Rear Cover Assembly, Non-Park Brake Adapter Housing Assembly, T-Case Rear Cover Assembly, 9 x 3 Bolt, M10 x 1.5 x 40 Flange Head (16), A Oil Seal Assembly Rear Shipping Cover Rear Shipping Cover, 2WD Output Nut, 4WD Rear Shipping Cover

Torque A

Foldout 16

Copyright © 2003 General Motors Corp.

N·m

lb ft

51–61

38–45

SM3191_Foldout 16-b.fm Page 1 Friday, January 30, 2004 9:19 AM

F OLDOUT 16

2 6

7 8

3 6

1 2 3

7

4

9

1 5 4 6

6

7

10 11

9

5

8

6

7 8 V06335.01.01

V06337.01.01

Foldout 16A. P3 Planetary Assembly, Output Shaft, C5 Piston Return Assembly, and Park Pawl Components

Foldout 16B. Rear Cover Assemblies

SM3191_Foldout 17.fm Page 1 Friday, January 30, 2004 9:17 AM

F OLDOUT 17

1 2 3 4 5 6 7 8

— — — — — — — —

P3 Planetary Carrier Assembly P3 Planetary Carrier P3 Thrust Washer (4) P3 Roller Bearing Assembly (8) P3 Pinion Gear (4) P3 Thrust Washer (4) P3 Planetary Spindle (4) Bearing Race

1

2

8

3 7

4 5 6

V06336.02.02

Foldout 17. P3 Planetary Carrier Assembly

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 18A,B Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 18A,B

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 18A,B

A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

— — — — — — — — — — — — — — —

B

Rear Cover Assembly, 10 x 3 C5 Clutch Piston C5 Piston OD Sealring C5 Piston ID Sealring Internal Retaining Ring Needle Bearing Assembly Output Tone Wheel, 6T Rear Cover, 10 x 3 Tachograph Plug, M18 x 1.5, A Washer Bolt, M6 x 1.0 x 13, B Sensor Shipping Cover Output Speed Sensor Speed Sensor O-ring Spacer — Selective

1 2 3 4 5 6 7 8 9 10 11 12 13

Thickness

# of Holes

P/N

0.245–0.295 mm (0.0096–0.0116 inch) 0.475–0.525 mm (0.0187–0.0207 inch) 0.705–0.755 mm (0.0278–0.0297 inch) 0.935–0.985 mm (0.0368–0.0388 inch) 1.165–1.215 mm (0.0459–0.0478 inch) 1.395–1.445 mm (0.0549–0.0569 inch) 1.625–1.675 mm (0.0640–0.0659 inch)

0

29536850

1

29536851

2

29536852

3

29536853

4

29536854

5

29536855

6

29536856

16 — External Retaining Ring 17 — Ball Bearing Assembly 18 — Internal Retaining Ring Torque A B

Foldout 18A,B

N·m

lb ft

60–67 10–13

44–49 7–10

— — — — — — — — — — — — —

Rear Cover Assembly, Non-Park Brake C5 Clutch Piston C5 Piston OD Sealring C5 Piston ID Sealring Internal Retaining Ring Needle Bearing Assembly Output Tone Wheel, 6T Rear Cover, Non-Park Brake Bolt, M6 x 1.0 x 13, A Sensor Shipping Cover Output Speed Sensor Speed Sensor O-ring Spacer — Selective Thickness

# of Holes

P/N

0.245–0.295 mm (0.0096–0.0116 inch) 0.475–0.525 mm (0.0187–0.0207 inch) 0.705–0.755 mm (0.0278–0.0297 inch) 0.935–0.985 mm (0.0368–0.0388 inch) 1.165–1.215 mm (0.0459–0.0478 inch) 1.395–1.445 mm (0.0549–0.0569 inch) 1.625–1.675 mm (0.0640–0.0659 inch)

0

29536850

1

29536851

2

29536852

3

29536853

4

29536854

5

29536855

6

29536856

14 — External Retaining Ring 15 — Ball Bearing Assembly 16 — Internal Retaining Ring Torque A

Copyright © 2003 General Motors Corp.

N·m

lb ft

10–13

7–10

SM3191_Foldout 18AB-b.fm Page 1 Friday, January 30, 2004 9:15 AM

F OLDOUT 18A,B

2

2

3

3

1

1 4

4 5

5

11 6

13 14

7

9 6

11 12

7

8

8

10

12 15

13 16 14

17

15

18

16 10

9

V06579

V06580.01.01

Foldout 18A. Rear Cover Assembly Components, 10 x 3

Foldout 18B. Rear Cover Assembly Components, Non-Park Brake

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 18C,D Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 18C,D

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 18C,D

C 1 2 3 4 5 6 7 8 9

10 11 12 13

— — — — — — — — —

— — — —

D

Adapter Housing Assembly, T-Case C5 Clutch Piston C5 Piston OD Sealring C5 Piston ID Sealring Internal Retaining Ring Needle Bearing Assembly Bearing Spacer, 4WD Adapter Housing, T-Case Spacer—Selective Thickness

# of Holes

P/N

0.245–0.295 mm (0.0096–0.0116 inch) 0.475–0.525 mm (0.0187–0.0207 inch) 0.705–0.755 mm (0.0278–0.0297 inch) 0.935–0.985 mm (0.0368–0.0388 inch) 1.165–1.215 mm (0.0459–0.0478 inch) 1.395–1.445 mm (0.0549–0.0569 inch) 1.625–1.675 mm (0.0640–0.0659 inch)

0

29536850

1

29536851

2

29536852

3

29536853

4

29536854

5

29536855

6

29536856

1 2 3 4 5 6 7 8 9 10 11 12 13

— — — — — — — — — — — — —

External Retaining Ring Ball Bearing Assembly Internal Retaining Ring Output Nut, A

Torque A

N·m

lb ft

58–64

40–50

Rear Cover Assembly, 9 x 3 C5 Clutch Piston C5 Piston OD Sealring C5 Piston ID Sealring Internal Retaining Ring Needle Bearing Assembly Output Tone Wheel, 6T Rear Cover, 9 x 3 Bolt, M6 x 1.0 x 13, A Sensor Shipping Cover Output Speed Sensor Speed Sensor O-ring Spacer—Selective Thickness

# of Holes

P/N

0.245–0.295 mm (0.0096–0.0116 inch) 0.475–0.525 mm (0.0187–0.0207 inch) 0.705–0.755 mm (0.0278–0.0297 inch) 0.935–0.985 mm (0.0368–0.0388 inch) 1.165–1.215 mm (0.0459–0.0478 inch) 1.395–1.445 mm (0.0549–0.0569 inch) 1.625–1.675 mm (0.0640–0.0659 inch)

0

29536850

1

29536851

2

29536852

3

29536853

4

29536854

5

29536855

6

29536856

14 — External Retaining Ring 15 — Ball Bearing Assembly 16 — Internal Retaining Ring Torque A

Foldout 18C,D

Copyright © 2003 General Motors Corp.

N·m

lb ft

10–13

7–10

SM3191_Foldout 18CD-b.fm Page 1 Friday, January 30, 2004 9:16 AM

F OLDOUT 18C,D

2 2 3 3

1

1 4

4

9

5 5

11 12

6 6

7 7

8 10

8

13 9

14 15

10

16

11 12

17 13

V06582.01.00 V06581.01.00

Foldout 18C. Rear Cover Assembly Components, Transfer Case

Foldout 18D. Rear Cover Assembly Components, 9 x 3

1000/2000/2400 SERIES SERVICE MANUAL

Legend For Foldout 19A,B Is On The Opposite Side Of This Page.

Copyright © 2003 General Motors Corp.

Foldout 19A,B

1000/2000/2400 SERIES SERVICE MANUAL Legend For Foldout 19A, B

A

B

1 2 3 4 5 6 7 8

— — — — — — — —

Control Valve Assembly Shift Valve Body Assembly Separator Plate Main Valve Body Assembly Bolt, M6 x 1.0 x 50 Flange Head (23), A Reverse Signal Tube Bolt, M6 x 1.0 x 65 Flange Head, A Pressure Switch Assembly

9 10 11 12

— — — —

Modulated Main Valve Body G ON/OFF Solenoid Bolt, M6 x 1.0 x 50 (4), A Bolt, M6 x 1.0 x 65 (2), A

Torque A

Foldout 19A,B

N·m

lb ft

10–13

7–10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

— — — — — — — — — — — — — — — — — — — — — — —

Shift Valve Body Assembly Retaining Clip D Shift Plug Shift Spring D Shift Valve Retaining Clip E Shift Plug Shift Spring E Shift Valve Retaining Clip Shift Spring C Shift Valve Retaining Clip Control Main Spring Control Main Valve Shift Valve Body ON/OFF Shift Solenoid Retainer Solenoid Screen C ON/OFF Shift Solenoid Solenoid O-ring Solenoid O-ring Manual Selector Valve

Copyright © 2003 General Motors Corp.

SM3191_Foldout 19AB-b.fm Page 1 Friday, January 30, 2004 9:15 AM

F OLDOUT 19A,B

1

2 1

10 6 7 2

13

11

3

12

14 15

8

3

9

4 5

16

17

4

20 21

8 5

22

19

18

9 6 7 10 12

11

V06583.02.00 V06325.02.00

Foldout 19A. Control Valve Assembly Components

Foldout 19B. Shift Valve Body Assembly Components

SM3191_Foldout 20.fm Page 1 Friday, January 30, 2004 9:11 AM

F OLDOUT 20

7

4 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

— — — — — — — — — — — — — — — — — — — — —

Torque A B C

Breather Adapter 90 Degree Elbow, 1⁄ 8 Pipe x 1⁄ 4 Hose Hose Clamp Vent Hose, 1⁄ 4 ID x 27.56 inch Hose Clamp Park Brake Lever Park Brake Cable Bracket Parking Brake Assembly Flat Washer (4) Bolt, M16 x 2.00 Grade 10.9 (4), C Bolt, 1⁄ 2-13 Grade 8, Patchlock (4), B End Yoke Assembly Companion Flange Assembly End Yoke Assembly Flanged End Yoke Assembly Yoke Assembly, 2⁄ 3 Round 1410 Flange Brake Drum, 9 x 3 Nut, 3⁄ 8-24 Nut, 3⁄ 8-24 Directional Prevailing Torque Tension Bolt, 1⁄ 2-20 Flange Head, A Sealing Washer N·m

lb ft

108–136 110–132 228–266

80–100 81–97 168–196

2 6 1

11 5 8

12 9 10

16 17

13

19

18

14 15

V06573

Foldout 20. Vent Hose and Yokes/Flanges

SM3191_Foldout 21.fm Page 1 Friday, January 30, 2004 9:12 AM

F OLDOUT 21 HYDRAULIC SCHEMATIC – NEUTRAL / PARK

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

Foldout 21. 1000/2000/2400 Series Hydraulic Schematic — Neutral/Park

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION A TRIM SIGNAL REVERSE SIGNAL C5 A TRIM PRESSURE V06914.03.00

SM3191_Foldout 22.fm Page 1 Friday, January 30, 2004 9:12 AM

F OLDOUT 22 HYDRAULIC SCHEMATIC – 1st RANGE

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C5 A TRIM PRESSURE V06915.03.00

Foldout 22. 1000/2000/2400 Series Hydraulic Schematic — First Range

SM3191_Foldout 23.fm Page 1 Friday, January 30, 2004 9:11 AM

F OLDOUT 23 HYDRAULIC SCHEMATIC – 2nd RANGE

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION B TRIM SIGNAL REVERSE SIGNAL C1 C4 B TRIM PRESSURE V06916.03.00

Foldout 23. 1000/2000/2400 Series Hydraulic Schematic — Second Range

SM3191_Foldout 24.fm Page 1 Friday, January 30, 2004 9:10 AM

F OLDOUT 24 HYDRAULIC SCHEMATIC – 3rd RANGE

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C3 A TRIM PRESSURE V06917.03.00

Foldout 24. 1000/2000/2400 Series Hydraulic Schematic — Third Range

SM3191_Foldout 25.fm Page 1 Friday, January 30, 2004 9:12 AM

F OLDOUT 25 HYDRAULIC SCHEMATIC – 4th RANGE

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION B TRIM SIGNAL REVERSE SIGNAL C1 C2 B TRIM PRESSURE V06918.03.00

Foldout 25. 1000/2000/2400 Series Hydraulic Schematic — Fourth Range

SM3191_Foldout 26.fm Page 1 Friday, January 30, 2004 9:11 AM

F OLDOUT 26 HYDRAULIC SCHEMATIC – 5th RANGE

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

OVERAGE

C Shift Valve

TCC CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

Foldout 26. 1000/2000/2400 Series Hydraulic Schematic — Fifth Range

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION A TRIM SIGNAL B TRIM SIGNAL REVERSE SIGNAL C2 C3 A TRIM PRESSURE

V06919.03.00

SM3191_Foldout 27.fm Page 1 Friday, January 30, 2004 9:13 AM

F OLDOUT 27 HYDRAULIC SCHEMATIC – REVERSE – CLOSED THROTTLE (WITH NO4* SOFTWARE AND LATER) 1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Added–3rd Quarter 2003

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

*EFFECTIVE JANUARY 1, 2001

Foldout 27. 1000/2000/2400 Series Hydraulic Schematic — Reverse (With N04* Software and Later)

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL

SUCTION A TRIM SIGNAL B TRIM SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE V06874.03.00

SM3191_Foldout 28.fm Page 1 Friday, January 30, 2004 9:13 AM

F OLDOUT 28 HYDRAULIC SCHEMATIC – REVERSE (PRIOR TO, AND INCLUDING, NO4* SOFTWARE WITH THROTTLE APPLIED) 1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Added–3rd Quarter 2003 G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

*EFFECTIVE JANUARY 1, 2001

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL

Foldout 28. 1000/2000/2400 Series Hydraulic Schematic — Reverse Range (Prior To and Including N04* Software With Throttle Applied)

SUCTION A TRIM SIGNAL B TRIM SIGNAL REVERSE SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE

V04755.03.00

SM3191_Foldout 29.fm Page 1 Friday, January 30, 2004 9:10 AM

F OLDOUT 29 HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT REVERSE ("LIMP HOME")

G Solenoid Added–3rd Quarter 2003

1000 SERIES™, 2000 SERIES™, 2400 SERIES™ PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

*EFFECTIVE JANUARY 1, 2001

Foldout 29. 1000/2000/2400 Series Hydraulic Schematic — Default Reverse (“Limp Home”)

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL

SUCTION A TRIM SIGNAL B TRIM SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE V07739.03.00

SM3191_Foldout 30.fm Page 1 Friday, January 30, 2004 9:10 AM

F OLDOUT 30 HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT FORWARD (3rd RANGE "LIMP HOME") 1000 Series™, 2000 Series™, 2400 Series™ A Trim Accumulator Solenoid

B Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Added–3rd Quarter 2003

N/O

C On/Off Shift Solenoid

D On/Off Shift Solenoid

E On/Off Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Charging Pump CONV – IN TCC SIGNAL SUMP

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

LUBE

C5

PSE PSD

Exhaust Backfill Valve

Cooler

Converter Flow Valve

PSR

Blocked At Separator Plate For Modulated Main Pressure

Main Filter

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C3 A TRIM PRESSURE V07738.03.00

Foldout 30. 1000/2000/2400 Series Hydraulic Schematic — Default Forward (3rd Range “Limp Home”)

ts.pdf

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Transmission Troubleshooting Manual 1000 and 2000 Product Families Electronic Controls TS3192EN

Troubleshooting Manual

2003 APRIL REV. 1 2004 MAY TS3192EN

Allison Transmission ELECTRONIC CONTROLS 1000 and 2000 Product Families

Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46202-0894 www.allisontransmission.com

Printed in USA

Copyright © 2004 General Motors Corporation

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

FOREWORD — How to Use This Manual This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product Families transmissions. Service Manual SM3191EN, Mechanics Tips MT3190EN, and Parts Catalog PC3062EN may be used in conjunction with this manual. This manual includes: • Description of the electronic control system. • Description of the electronic control system components. • Description of diagnostic codes, system responses to faults, and troubleshooting. • Wire, terminal, and connector repair information.

Specific instructions for using many of the available or required service tools and equipment are not included in this manual. The service tool manufacturer will furnish instructions for using the tools or equipment. Additional information may be published from time to time in Service Information Letters (SIL) and will be included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date information concerning Allison Transmission products. This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by a new date on the title page and rear cover. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions — Truck, Tractor, etc. Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly locating information. NOTE:

Allison Transmission is providing service of wiring harnesses and wiring harness components as follows: • Repair parts for the internal wiring harness will be available through the Allison

Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained from the vehicle OEM or the OEM is responsible for warranty on these parts.

ii

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual. These warnings and cautions advise against using specific service procedures that can result in personal injury, equipment damage, or cause the equipment to become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service procedures used. Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the vehicle manufacturer and/or body builder before servicing the Allison transmission in that vehicle. Proper service and repair is important to the safe and reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. Some procedures require using specially designed tools. Use special tools when and in the manner recommended.

The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not to other vehicle systems which may interact with the transmission. Be sure to review and observe any vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison transmission is being serviced.

WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention:

WARNING!

Is used when an operating procedure, practice, etc., which, if not correctly followed, could result in injury or loss of life.

CAUTION:

Is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment.

NOTE:

Is used when an operating procedure, practice, etc., is essential to highlight.

Copyright© 2004 General Motors Corp.

iii

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

TRADEMARKS USED IN THIS MANUAL The following trademarks are the property of the companies indicated: • Adobe® Acrobat® Reader® are registered trademarks of Adobe Systems Incorporated. • Allison DOC™ For PC is a trademark of General Motors Corporation. • MagiKey™ is a trademark of Micro Processor Systems, Inc. • LPS® Cleaner is a registered trademark of LPS Laboratories. • Loctite® is a registered trademark of the Loctite Corporation. • Teflon® is a registered trademark of the DuPont Corporation. • Windows® 95, Windows® 98, Windows® XP, and Windows NT® are trademarks of Microsoft Corporation.

SERVICE LITERATURE This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. To ensure maximum performance and service life from you unit, you may order publications from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995 1000 and 2000 Product Families Service Literature

Publication Name Publication No. Automatic Transmission Fluid Technician’s Guide GN2055EN *Mechanic’s Tips MT3190EN *In-Chassis Maintenance JA3664EN *EVS Operator’s Manual OM3761EN *HS Operator’s Manual OM3757EN *RDS Operator’s Manual OM3759EN *MHS Operator’s Manual OM3364EN *PTS Operator’s Manual OM3758EN *BUS Operator’s Manual OM3765EN *1000, 2000, 2400 Operator’s Manual OM3063EN *Owner’s Manual (2000MH) OM3364EN *Parts Catalog PC3062EN Parts Catalog On CD-ROM CD3062EN Principles Of Operation PO3065EN Service Manual SM3191EN Electronic Troubleshooting Manual TS3192EN * Also Available On The Internet At www.allisontransmission.com

iv

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

TABLE OF CONTENTS Page Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INFORMATION Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Warnings, Cautions, and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv SECTION 1. GENERAL DESCRIPTION 1–1. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2. TRANSMISSION CONTROL MODULE (TCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Manual Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. NSBU Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4. THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Input (Engine) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Output Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6. CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 1–3 1–3 1–3 1–4 1–4 1–5 1–5 1–6 1–6 1–6 1–7 1–7 1–7 1–9

SECTION 2. DEFINITIONS AND ABBREVIATIONS 2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2. SCAN TOOL INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3. SCAN TOOL (Allison DOC™ For PC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5. RANGE INHIBIT RESPONSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–1 2–1 2–3 2–4 2–6

SECTION 3. BASIC KNOWLEDGE 3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . 3–5. BASIC TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6. TCM REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . . . . . . . . . . . . 3–8. RESETTING TCM AUTOSELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–1 3–1 3–1 3–2 3–3 3–6 3–7 3–7

Copyright© 2004 General Motors Corp.

v

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

TABLE OF CONTENTS (cont’d) Page SECTION 4. WIRE CHECK PROCEDURES 4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . 4–1 4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . 4–2 SECTION 5. DIAGNOSTIC TROUBLE CODES (DTC) 5–1. DTC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2. FAILURE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3. CODE READING AND DTC CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Clearing Active Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4. BEGINNING THE TROUBLESHOOTING PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Solenoid Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5. DIAGNOSTIC TROUBLE CODES (DTCs — Includes Index) . . . . . . . . . . . . . . . . . . . . . .

5–1 5–1 5–2 5–2 5–2 5–2 5–2 5–3 5–3 5–3 5–6

SECTION 6. INPUT AND OUTPUT FUNCTIONS 6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 A. Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 B. Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SECTION 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS. . . . . . . . . . 7–1 APPENDICES A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1 B.

MAIN PRESSURE CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1

C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1 D.

WIRE/CONNECTOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1

E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1 F.

THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1

G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . G–1 H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1 J.

WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1

K. RESISTANCE vs. TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1 L.

ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1

M. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–1 N. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1 P.

vi

FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 1—GENERAL DESCRIPTION 1–1.

TRANSMISSION

The 1000 and 2000 Product Families Electronic Controls system features closed-loop clutch control to provide superior shift quality over a wide range of operating conditions. The 1000 and 2000 Product Families configurations can be programmed to provide five forward speeds, neutral, and reverse. The fifth range has an overdrive gear ratio. The 1000 and 2000 Product Families incorporate a variety of standard and optional design features. Figure 1–1 is a block diagram of the basic system inputs and outputs.

PRESSURE SWITCH MANIFOLD NSBU SPEED SENSORS

SOLENOIDS (VBS, PWM, ON/OFF)

THROTTLE POSITION SENSOR

TCM

VEHICLE/ENGINE COMMUNICATION LINKS

TEMPERATURE SENSOR (SUMP/ENGINE)

INPUTS OUTPUTS V05726

Figure 1–1. Transmission Control Module Block Diagram Figure 1–2 shows the electronic control components. Electronic Controls consist of the following elements: • Remote 12V or 24V Sealed Transmission Control Module (TCM) • Throttle Position Sensor (TPS), electronic engine throttle data, or PWM signal • Speed Sensors — Input (Engine), Turbine, and Output • Control Valve Assembly (Electro-Hydraulic Valve Body) • NSBU Switch • Pressure Switch Manifold (PSM) • Wiring Harnesses NOTE:

All external harnesses are OEM-supplied.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION TRANSMISSION CONTROL MODULE (TCM)

VEHICLE (J1) HARNESS

“J1” CONNECTOR (GRAY)

J1939 CONNECTOR

TRANSMISSION (J2) HARNESS “J2” CONNECTOR (RED)

Bulkhead Connector (Optional)

VIW “X” CONNECTOR

NSBU SWITCH CONNECTORS

7-PIN (OEM-SUPPLIED) 12-PIN CONNECTOR (USED WITH NSBU P/N 29541852)

VIW “Y” CONNECTOR 4-PIN

THROTTLE POSITION SENSOR (TPS) CONNECTOR (OPTIONAL) OUTPUT SPEED SENSOR CONNECTOR

THROTTLE POSITION SENSOR (TPS)

TURBINE SPEED SENSOR CONNECTOR

ENGINE SPEED SENSOR CONNECTOR MAIN TRANSMISSION CONNECTOR

NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration. V06475.01.01 .

Figure 1–2. Electronic Control Components

1–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION 1–2.

TRANSMISSION CONTROL MODULE (TCM)

The electronic control of the transmission is performed by a microcomputer. The microcomputer is an independent controller and is referred to as a Transmission Control Module (TCM). TCMs are available in both 12V and 24V configurations to match the configuration of the vehicle electrical system. The TCM (Figure 1–3) receives and processes signals from various switches and sensors. The TCM determines shift sequences, shift timing, and clutch apply and release pressures. The TCM uses the information to control transmission solenoids and valves, supply system status, and provide diagnostic information.

V05728.01.01

Figure 1–3. Transmission Control Module (TCM)

1–3.

SHIFT SELECTOR

The vehicle is equipped with a lever-type shift selector (Figure 1–4). In addition to the lever assembly provided for the operator, other components associated with the shift selector are the manual selector valve in the main control valve body and an NSBU switch mounted on the selector shaft. Shift selector components (with the exception of the transmission selector shaft) are customer-supplied. A.

Shift Selector Range Positions The operator chooses the transmission range by moving the selector lever to the appropriate gate position (Figure 1–4). When properly adjusted, the shifter gates prevent inadvertent shifting between ranges and correspond to the internal transmission detent positions. A positive detent is provided in the transmission to maintain the selector shaft in the selected position.

SHIFT SELECTOR

P R N OD D 2 1

TOP VIEW V06476

Figure 1–4. Typical Lever-Type Shift Selector

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION The TCM shift calibration determines the available forward ranges for each selector position. Although specific installations vary, typical selector positions for the 1000 and 2000 Product Families are: P — Park. Parking pawl or parking brake is engaged, if available. This position is not available on all shift selectors. R — Reverse. N — Neutral. May be used when starting the engine and for stationary operations. The NSBU Switch disables the starter switch if a range other than N (Neutral) or P (Park) is selected before starting the vehicle. OD — Overdrive. The highest forward range used for normal driving. The transmission shifts to first range for starting, then automatically upshifts through the ranges (as operating conditions permit) until the highest range is attained. D, 2, 1 — Forward Range. The transmission shifts to first range for starting. The range selected on the shift selector is the highest range which will be attained during automatic shifting. B.

Manual Selector Valve The manual shift selector shaft is attached to the manual selector valve within the transmission main control valve body. The selector valve has three positions: Reverse, Neutral, and Forward. NOTE: For transmissions equipped with a Park position, the selector valve remains in the Neutral position when the selector is moved to Park. The Neutral and Reverse selector valve positions (refer to Appendix H—Hydraulic Schematics) exhaust the C1 and C2 rotating clutches. By exhausting C1 and C2 clutches, forward range is inhibited. This provides the capability for the operator to override the electronically commanded ranges if N (Neutral) is required.

C.

NSBU Switch The installation of a transmission-mounted neutral start/reverse signal switch is required. This switch, commonly called an “NSBU Switch” (Figure 1–5), mounts directly onto the transmission housing from the outside and detects the angular position of the shift selector shaft. This position is communicated to the TCM so that certain vehicle control functions can be coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to alert the TCM in the event of a single wire or switch failure. The neutral signal output of the NSBU switch is typically used as confirmation that the transmission is in N (Neutral) before the engine starter is engaged. The NSBU switch is interfaced to the starter circuit with weatherproof electrical connectors. The reverse signal provision may be used to activate vehicle back-up lights and/or reverse warning devices.

V05729.01.00

Figure 1–5. NSBU Switch

1–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION 1–4.

THROTTLE POSITION SENSOR

The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS (Figure 1–6) contains a pull actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and the other, inside a protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the TCM through the external harness. The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. A

B C

THROTTLE POSITION SENSOR (TPS)

V00628.01

Figure 1–6. Throttle Position Sensor

1–5.

SPEED SENSORS

There are three speed sensors available for use with 1000 and 2000 Product Families transmissions: the input (engine) speed sensor, the turbine speed sensor, and the output speed sensor (Figure 1–7). The speed sensors provide rpm information to the TCM. The speed ratios between the various sensors allow the TCM to determine the transmission operating range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in the best possible shift quality.

V04736

Figure 1–7. Typical Speed Sensor The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member (such as a gear tooth). Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The TCM calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION NOTE:

Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation. A.

Input (Engine) Speed Sensor The input speed sensor is externally mounted in the torque converter housing directed at the ribs protruding from the torque converter. The input speed sensor connector should be positioned at approximately four o’clock, as viewed from the left side of the transmission (Figure 1–8).

B.

Turbine Speed Sensor The turbine speed sensor is externally mounted in the main housing directed at the tone wheel or PTO drive gear attached to the rotating clutch module. The turbine speed sensor connector should be positioned at approximately three o’clock, as viewed from the left side of the transmission (Figure 1–8).

C.

Output Speed Sensor The output speed sensor is externally mounted in the rear cover and directed at the teeth of a tone wheel splined to and rotating with the output shaft. The output speed sensor connector should be positioned at approximately five o’clock, as viewed from the left side of the transmission (Figure 1–8). ENGINE SPEED SENSOR CONNECTOR ORIENTATION = 4 o'clock

TURBINE SPEED SENSOR CONNECTOR ORIENTATION = 3 o'clock

OUTPUT SPEED SENSOR CONNECTOR ORIENTATION = 5 o'clock

V06457

Figure 1–8. Speed Sensor Connector Orientation

1–6

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION 1–6.

CONTROL VALVE ASSEMBLY

The hydraulic control valve assembly (Figure 1–9) governs fluid flow to the clutches (including the torque converter clutch). Solenoids, actuated by the TCM, control valve movement. The control valve assembly consists of two components. The main valve body contains the trim valves, the TCC valve, the exhaust backfill valve, and the control main relief valve. The shift valve body contains the shift valves, the control main pressure valve, and the manual selector valve. The control valve assembly attaches to the bottom of the gearbox module and is enclosed by the oil pan. An internal wiring harness connects the solenoids and PSM to the main transmission connector and external wiring harness. A.

Modulated Main Pressure Modulated main pressure was added to the 1000 and 2000 Product Families in the second quarter of 2003. Starting with DEE software level, the TCM will autodetect if the hardware is present. Main pressure is reduced by utilizing an additional on/off solenoid (“G”) that is located in the control valve body assembly. The G solenoid body is bolted to the revised main valve body. Main pressure will be reduced under various conditions such as low throttle, low torque, low engine speeds, and low output speeds. The primary benefit of modulating main pressure is to increase cooler flow at low engine speeds.

C

E

A TRIM B TRIM

D

G

F

V07476.01.01

Figure 1–9. Control Valve Assembly

1–7.

WIRING HARNESSES A.

External Wiring Harness (Figure 1–10) The external wiring harness requirements are typically met through the use of two separate harnesses — one connecting the TCM to the transmission, throttle position sensor, NSBU switch, and speed sensors; another connecting the TCM to the Scan Tool (ST) and other vehicle interfaces. Each harness may be a single piece or may be divided into two segments joined by bulkhead connectors. All wiring harnesses and mating connectors are customer-supplied.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION NOTE:

Allison Transmission is providing for service of wiring harnesses and wiring harness components as follows: • Repair parts for the internal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained through the vehicle OEM. The OEM is responsible for warranty on these parts.

VEHICLE (J1) HARNESS

“J1” CONNECTOR (GRAY)

TRANSMISSION (J2) HARNESS

J1939 CONNECTOR

“J2” CONNECTOR (RED)

Bulkhead Connector (Optional)

VIW “X” CONNECTOR NSBU SWITCH CONNECTORS

7-PIN (OEM-SUPPLIED) 12-PIN CONNECTOR (USED WITH NSBU P/N 29541852)

VIW “Y” CONNECTOR

4-PIN

THROTTLE POSITION SENSOR (TPS) CONNECTOR (OPTIONAL) OUTPUT SPEED SENSOR CONNECTOR

THROTTLE POSITION SENSOR (TPS)

TURBINE SPEED SENSOR CONNECTOR

ENGINE SPEED SENSOR CONNECTOR

NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration.

MAIN TRANSMISSION CONNECTOR V06477.01.01

Figure 1–10. Typical External Wiring Harnesses

1–8

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION B.

Internal Wiring Harness (Figure 1–11) An internal wiring harness connects the shift solenoids, clutch trim solenoids, torque converter clutch solenoid, pressure switch manifold, and temperature sensor to the external harness leading to the TCM.

SOL C 13 mm EXTENSION PSM SOL G MAIN TRANSMISSION CONNECTOR SOL A SOL B SOL E SOL D SOL F

V05732.01.02

Figure 1–11. Typical Internal Wiring Harness

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION NOTES

1–10

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 2—DEFINITIONS AND ABBREVIATIONS 2–1.

CHECK TRANS LIGHT

The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, vehicle, and transmission. To do this, the TCM turns on the CHECK TRANS light on the instrument panel, which notifies the operator that a Diagnostic Trouble Code (DTC) has been stored. Each time the engine is started, the TCM will illuminate the CHECK TRANS light, then turn it off after a few seconds. This is a circuit check to verify that the lamp and wiring are in proper working order. Illumination of the CHECK TRANS light at any time after start-up indicates that the TCM has set a DTC. The Scan Tool is used to verify that the TCM has set a DTC (see Paragraph 2–5). While the CHECK TRANS light is on, upshifts and downshifts may be restricted and direction changes (D–R, R–D) may not occur. The torque converter clutch is inhibited when transmission shifting is restricted or during any critical transmission malfunction. The 1000 and 2000 Product Families transmissions DTCs are latching DTCs. When a failure condition is detected, the DTC set by the TCM remains active for the entire time the ignition is on. When the ignition is turned off and then on again, the transmission DTCs will reset and the TCM will recheck for the failure condition. If the failure condition is not present, the previously set DTC will remain in history; the CHECK TRANS light will turn off after the circuit check, and the transmission will function normally unless another failure occurs. This feature allows the vehicle to be driven to a service outlet.

2–2.

SCAN TOOL INHIBITS

The following inhibit information may be displayed on the Allison DOC™ For PC (Scan Tool), depending on the TCM software level. If TCM software does not support one of the inhibits listed below, a N/A will be shown in the information box. If an inhibit has occurred since the last DTC was cleared, the inhibit state will indicate ON and will stay ON until the next manual DTC clear with the Scan Tool. These inhibits do not turn OFF after a specified number ignition cycles. The range inhibit light will illuminate and/or an inhibited state will be shown on the Scan Tool when the transmission is inhibited to Neutral for the following reasons: • Low Main Pressure If the transmission pressure switches do not indicate transmission pressurized at start-up, shifts-torange may be inhibited and the range inhibit light will illuminate. The Scan Tool will indicate an active inhibit. Common causes are transmission low on fluid, transmission filter has just been changed, or pan has been removed and fluid recently drained. May produce P0701. • Transfer Case Neutral If the transfer case is shifted into neutral while the transmission is in drive or reverse at a speed above idle, the transmission will continue to command range until the output speed is reduced to a point where neutral range is commanded. The range inhibit light will illuminate and the Scan Tool will indicate an active inhibit. • Diagnostic Active This indicates that an active diagnostic code is set and that the CHECK TRANS light should be illuminated. In some failure modes, Reverse cannot and will not be commanded. If Reverse is selected during these failure modes a range inhibit light will illuminate in Reverse. During diagnostic responses, Neutral-to-Range Inhibits and Direction Change Inhibits continue to operate, but they may latch under certain conditions. In these cases, shutting down ignition and waiting for at least 5 seconds before re-starting will clear the inhibit condition. The Scan tool will indicate an active inhibit. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS • Auto Neutral for PTO Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when TCM detects that auto neutral function input is active. • Reverse Enable Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when no input is detected from dash or floor mounted reverse enable switch when selecting reverse range. The Scan Tool will indicate an active inhibit. This function is only used in European transit and tour buses applications. • Refuse Packer Step Switch Transmission operation is limited to only 1st range. Neutral-to-reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when input is detected from a step switch indicating that personnel is present on rear step platform. • Auxiliary Function Range Inhibit Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when input is detected from an auxiliary switch or device. This inhibit will remain active until the auxiliary switch input is shut off and range is reselected. • PTO Neutral Lockup The Scan Tool will show an inhibited state when Neutral Lockup is active and range shifts are being inhibited to neutral. When the selector is moved, lockup is released and the inhibit clears. • Engine Speed Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate if the Engine Speed is greater than a calibrated value (1400 rpm for medium duty non-emergency vehicles). The Scan Tool will indicate an active inhibit. • Output Speed Reverse-to-Drive, Drive-to-Reverse, and Neutral-to-Reverse shifts initiated above 300 rpm of output speed will be inhibited to neutral and the range inhibit light will illuminate. The Scan Tool will indicate an active inhibit. • Throttle Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts where throttle position is greater then 25 percent will be inhibited to neutral and the range inhibit light will illuminate. The Scan Tool will indicate an active inhibit. • NSBU Function or Alignment Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate when a NSBU failure or misalignment is detected. Common cause would be an error in the four-bit NSBU switch input signal that is sent to the TCM. The Scan Tool will indicate an active inhibit. • NSBU RPS Disagree Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate when the reverse pressure switch status is in the incorrect state when compared to the NSBU switch state. The Scan Tool will indicate an active inhibit. • MSV Mis-Alignment/Unable to detect ratio after shift to range If the range verification test fails to detect turbine speed pull-down or valid gear ratio when shifting to either forward or reverse range from neutral, the transmission will shift back to a neutral condition and the range inhibit light will illuminate. 2–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS Conditions that may cause this include: Attempts to shift the transmission from Neutral-to-Drive or Neutral-to-Reverse with the transfer case in neutral; transmission low on fluid; misadjustment in the NSBU or Selector Linkage; turbine or output speed sensor failure that may prevent the pull down test/ ratio test from passing; solenoid A or B hydraulically failures; and possibly failed range clutch (C1 or C5 for 1st, C3 or C5 for Reverse). The Scan Tool will indicate an active inhibit response. • Wheel Spin or Lock When the TCM detects that wheel lock or spin is occurring, the TCC is disengaged and a lock-to-range response is commanded for 6 seconds. The Scan Tool will indicate an active inhibit response.

2–3.

SCAN TOOL (Allison DOC™ For PC) (Figure 2–1)

The current Scan Tool (ST) is the PC Tool Software Allison DOC™ For PC, which is available through Kent-Moore Heavy-Duty Division. When installed on a Windows® PC, the Allison DOC™ For PC transmits and receives data to and from the TCM via the vehicle data communications link, processes the data, and displays appropriate information. Use Allison DOC™ For PC during installation checkout and troubleshooting. For more details on Allison DOC™ For PC features, see information in Appendix M.

V05490

Figure 2–1. Scan Tool

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS 2–4.

ABBREVIATIONS

A/N

Assembly Number

ABS

Anti-lock Brake System—OEM-provided means to detect and prevent wheel stoppage to enhance vehicle handling. Retarder and engine brakes will not apply when ABS is active.

Amp

Ampere—Unit of electrical current

CAN

Controller Area Network—A network for all SAE J1939 communications in a vehicle (engine, transmission, diagnostics, ABS, etc.)

CC

Calibration Compatibility—First two digits of the CIN

CIN

Calibration Identification Number—Used to identify transmission controls software level

CT

Closed Throttle

DNA

Does Not Adapt—Adaptive shift control is disabled.

DNS

DO NOT SHIFT—Refers to the DO NOT SHIFT diagnostic response during which the CHECK TRANS light is illuminated and the transmission will not shift and will not respond to the Shift Selector.

DTC

Diagnostic Trouble Code

DVOM

Digital volt/ohmmeter

ECM

Engine Controller Module—Available on electronically-controlled engines—provides some relevant data to TCM.

EMI

ElectroMagnetic Interference

GPI

General Purpose Input—Input signal to the TCM to request a special operating mode or condition.

GPO

General Purpose Output—Output signal from the TCM to control vehicle components (such as PTOs, backup lights, etc.) or allow a special operating mode or condition.

IPC

Instrument Panel Controller

J1939

High-speed vehicle serial data communications link.

LED

Light-Emitting Diode—Electronic device used for illumination.

LRTP

Low-Range Torque Protection—A feature limiting engine torque in lower ranges to protect the transmission from damage when a stall condition occurs.

NNC

Neutral No Clutches—Neutral commanded with no clutches applied.

NSBU Switch

Neutral Start Backup Switch

NVL

Neutral Very Low—The TCM has sensed turbine speed below 150 rpm. This is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. When attained, the C4 and C5 clutches are applied to lock the transmission output.

OBD II

On Board Diagnostics Second generation. EPA mandated specification for vehicle diagnostics.

OEM

Original Equipment Manufacturer—Maker of vehicle or equipment.

Ohm

Unit of electrical resistance.

PC

Personal Computer

PCCS

Production Calibration Configuration System

PCM

Powertrain Controller Module—Electronic device used on some vehicles.

PDM

Parallel Data Module

2–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS 2–4.

ABBREVIATIONS (cont’d)

PPC

Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is proportional to the current being supplied to the solenoid.

PROM

Programmable Read Only Memory

PSM

Pressure Switch Manifold—Part of transmission control system located inside the oil pan.

PTO

Power Takeoff

PWM Solenoid

Pulse Width Modulated Solenoid—Solenoids are controlled by pulse width modulation. Solenoid control of clutch pressures is based on the solenoid’s duty cycle. Duty cycle is determined by the ratio of solenoid’s on-time to off-time.

RFI

Radio Frequency Interference

RPR

Return to Previous Range—Diagnostic response in which the transmission is commanded to return to previously commanded range.

SEM

Shift Energy Management—Currently used on 2000MH Series. Allows the TCM to request torque reduction from the ECM during upshifts for increased clutch life.

SOL OFF

All SOLenoids OFF

ST

Scan Tool—Most current version is the Allison DOC™ For PC. Diagnostic tool used to interrogate the TCM for diagnostic information.

TBC

Truck Body Controller

TCC

Torque Converter Clutch

TCM

Transmission Control Module (also commonly referred to as the “computer”)

TFT

Transmission Fluid Temperature—Data provided by thermistor that is part of the PSM.

TPS

Throttle Position Sensor—Potentiometer for signaling the position of the engine fuel control lever.

V

Version—Abbreviation used in describing TCM software levels.

VBS

Variable Bleed Solenoid—Another name for Pressure Proportional to Current (PPC) solenoid. Solenoid control of clutch pressure is proportional to the current being supplied to the solenoid.

VDC

Volts Direct Current (DC)

VIW

Vehicle Interface Wiring—Interfaces TCM programmed input and output functions with the vehicle wiring.

Volt

Unit of electrical force

VOM

Volt/ohmmeter

WOT

Wide Open Throttle

∞

Infinity—Condition of a circuit with higher resistance than can be measured; effectively an open circuit.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS 2–5.

RANGE INHIBIT RESPONSES

The range inhibit feature is a function of the TCM logic. The TCM senses when certain input variables are exceeded and takes action to prevent transmission damage. The TCM inhibits neutral-to-range shifts and illuminates a light on the dash when the inhibit is active. Listed below are three variables that, when exceeded, cause inhibited shifts (with thresholds listed). • Engine speed above 1000 rpm • Throttle setting above 40 percent • Output speed above 225 rpm There are two levels of the special logic inhibits. • Self-clearing inhibit—This inhibit clears itself if one of the above conditions is not present after a calibrated time. This is three seconds in the case of medium-duty vehicles. If the shift inhibit is active, but not latched, the bulb will stay lit until self-cleared. • Latching inhibit — This inhibit latches when one of the conditions listed above is still present after a calibrated time. This is above three seconds for medium duty vehicles. To clear a latching inhibit, move the selector into any other position than the one originally selected.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 3—BASIC KNOWLEDGE 3–1.

BASIC KNOWLEDGE REQUIRED

To service 1000 and 2000 Product Families Electronic Controls, the technician must understand basic electrical concepts. Technicians need to know how to use a volt/ohmmeter (VOM) to make resistance and continuity checks. Most troubleshooting checks consist of checking resistance and continuity, and checking for shorts between wires and to ground. The technician should be able to use jumper wires and breakout harnesses and connectors. Technicians unsure of making the required checks should ask questions of experienced personnel or find instruction. The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to identified pressure ports used in the troubleshooting process. Pressure tap locations and pressure values are shown in Appendix B — Main Pressure Check Procedure. Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning and may not generate a DTC. A working knowledge of 1000 and 2000 Product Families Electronic Controls vehicle installation is necessary in troubleshooting installation-related problems. Refer to Section 7 for information concerning performance complaints (non-DTC) troubleshooting. A complete wiring schematic is shown in Appendix J. Refer to the 1000/2000 Product Family Tech Data for information concerning electronic controls installation and the Installation Checklist. Reliable transmission operation and performance depend upon a correctly installed transmission. For proper installation, review the Installation Checklist in the 1000/2000 Product Family Tech Data, available on the extranet under Engineering at www.allisontransmission.com. NOTE:

Allison Transmission is providing for service of wiring harnesses and wiring harness components as follows: • Repair parts for the internal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained through the vehicle OEM. The OEM is responsible for warranty on these parts.

3–2.

USING THE TROUBLESHOOTING MANUAL

Use this manual as an aid to troubleshooting the 1000 and 2000 Product Families Electronic Controls. Every possible problem and its solution cannot be encompassed by any manual. However, this manual does provide a starting point from which most problems can be resolved. Once a problem solution is discovered in the manual do not look further for other solutions. It is necessary to determine why a problem occurred. The root cause of a problem as well as the symptom must be corrected to ensure trouble free operation. For example, taping a wire that has been rubbing on a frame rail will not correct the problem unless the rubbing contact is eliminated.

3–3.

SYSTEM OVERVIEW

1000 and 2000 Product Families Electronic Control functions are controlled by the TCM. The TCM reads shift selector range selection, output speed, and throttle position to determine when to command a shift. When a shift occurs, the TCM monitors turbine speed, output speed, and throttle position to control the oncoming and off-going clutches during the shift. When the TCM detects an electrical fault, it logs a DTC indicating the faulty circuit and may alter the transmission operation to prevent or reduce damage. When the TCM detects a non-electrical problem while trying to make a shift, the TCM may try that shift a second or third time before setting a DTC. Once that shift has been retried, and a fault is still detected, the TCM sets a DTC and holds the transmission in a fail-to-range mode of operation. Copyright© 2004 General Motors Corp.

3–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE The 1000 and 2000 Product Families transmission utilizes “clutch to clutch” shift control to achieve range changes. In every case (except shifts to or from neutral), one clutch is exhausted and another applied to make a range shift. The “handoff” between exhausting and applying clutches is very precisely controlled by use of two “PPC” (Pressure Proportional to Current) solenoids. These solenoids are labeled A and B in the transmission, and are referred to as “trim” solenoids. For example, to make a 1–2 shift, A solenoid is used to trim pressure off C5 clutch, and B solenoid is used to trim pressure on C4 clutch. The TCM (transmission control module) modulates the current to both A and B solenoid, which translates to a proportional level of pressure to the clutch. In order to make a shift, the TCM uses software and calibration settings of several program parameters to determine the level of current sent to the respective trim solenoids. These parameters are referred to as “adaptive values.” With a new transmission and TCM calibration, the adaptive values are set to “base calibration” level. The transmission uses the base calibration to perform the first of each type of shift. However, once it has performed a shift, the TCM evaluates the actual shift and compares it to an “ideal” shift in the TCM’s memory. Based on that comparison, the TCM changes the settings of the adaptive values to a level that it believes will result in a shift closer to the “ideal” shift the next time it makes that type of shift. This is referred to as “adaptive shifting.” When the transmission/TCM calibration is new, the TCM is in “fast adaptive” mode. In other words, the TCM is allowed to make relatively large changes in the adaptive values after each shift. Once the TCM determines that a given shift is close to its ideal level it switches to “slow adaptive” mode. In slow adaptive the TCM still is evaluating shifts and changing adaptive values, but is only allowed to do so in smaller increments. When a shift switches from fast to slow adaptive mode, it is described as “converged”. The TCM is programmed to try to switch from fast to slow adaptive mode within approximately five shifts. It is important to understand that there are many different distinct shifts recognized by the TCM, and each of these shifts has its own adaptive values. For example, there are upshift and downshifts to and from each range, as well as unique adaptive values for several different throttle regions for each upshift and downshift. The point is, it may take a significant amount of time before most of the shifts converge from fast to slow adaptive, and thus it is not unusual to experience somewhat harsh or unpleasant shift quality until these shifts are converged. TCC engagement is accomplished by a separate PWM (pulse-width modulated) solenoid labeled “F” in the transmission. There are adaptive values for this as well, and thus it will also require some driving for TCC engagement to converge.

3–4.

IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

Before beginning the troubleshooting process, read and understand the following: • Allison recommended wire numbers (i.e. 212) are a combination of the first digit indicating the TCM connector number (i.e. J2) and the last two digits indicating the pin-out information (i.e. 12). • Shut off the engine and ignition before any harness connectors are disconnected or connected. • Remember to do the following when checking for shorts and opens: — Minimize movement of wiring harnesses when looking for shorts. Shorts involve wire-to-wire or wire-to-ground contacts and moving the harnesses may eliminate the problem. — Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle movements which occur during actual operation. • When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and not the wires extending from the connector. • Resistance checks involving the wiring between the TCM connectors and other components adds about one Ohm of resistance to the component resistance shown. • Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to maintain firm contact. 3–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE • Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, nonresidue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner® or LPS NoFlash Electro Contact Cleaner®.

CAUTION:

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.)

CAUTION:

Care should be taken when welding on a vehicle equipped with electronic controls. Refer to Appendix G, Paragraph 1–1.

• DTCs displayed after system power is turned on while a harness connector is disconnected can be ignored and cleared from memory. Refer to Section 5, DTCs, for the DTC clearing procedure.

3–5.

BASIC TROUBLESHOOTING INFORMATION 1.

Begin troubleshooting by checking the transmission fluid level and ignition voltage. Remember that some problems may be temperature related. Do troubleshooting, including the fluid level and ignition voltage checks, at the temperature level where the problem occurs.

NOTE:

Fluid level and igniton voltage MUST be checked before any troubleshooting is performed.

NOTE:

If you are experiencing harsh shifts, it is important to use the Scan Tool to check whether that particular shift is converged. If it is not, the TCM is still “learning” how to adapt that shift and simply needs to be driven further while performing more of that particular type of shift. If a particular shift is converged but still objectionable, it’s good troubleshooting practice to reset the adaptive values for that shift back to “base cal” level. This will automatically reset the TCM to fast adaptive mode. The vehicle should then be driven to allow the TCM to “re-learn” the shift. Many times this will correct the problem. It is possible to reset individual shifts without affecting the other shifts.

CAUTION:

2.

Whenever a transmission is overhauled, exchanged, or has undergone repairs, the Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS.” This will cause the TCM to erase previous adaptive information and begin to adapt in Fast Adaptive Mode from the base calibration. Failure to follow this procedure may cause premature failure of the overhauled, repaired, or replaced transmission.

If a transmission has been overhauled, exchanged, or repaired, use the Allison DOC™ For PC to “RESET TO UNADAPTED SHIFTS”. Accomplish the reset by doing the following: • Select the Shift Selector icon. • Select the Reset Adaptives icon. • Push the Reset All Adaptive Values button. At the “Are you sure you want to reset all adaptive parameters?” prompt, select “OK.” Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE 3.

Before using your Allison DOC™ For PC Scan Tool, check the following: • The desktop or laptop computer must meet the minimum system requirements (see Allison DOC™ For PC User Guide, GN3433EN): — Microsoft Windows® 95B, Windows® ME, Windows NT® 4.0 (SP6 or later), Windows® 2000 (SP1 or later), or Windows® XP — 60 MB free hard drive space (an additional 440 MB of disc space needed if training videos are stored on hard drive) — 64 MB of RAM — Intel® Pentium® II processor — Available serial port and parallel port — 1024 x 768 screen resolution — 256-color palette — Small fonts — A media player program (Windows Media Player® is provided on the Allison DOC™ For PC CD) — Adobe® Acrobat® Reader® (provided on the Allison DOC™ For PC CD)

NOTE:

Refer to the CD Readme.txt file for more information. • The proper driver (electronic file) is installed for the Computer Interface Module. • Power at the Deutsch 9-pin diagnostic connector (pin A is negative, pin B is positive). • The proper connections exist for communicating with Allison DOC™ For PC Scan Tool (Figure 3–1 and Figure 3–2). Presently there are two communication standards for Allison DOC™ For PC diagnostic software: J 1939 and J 1850. Both standards are supported by Allison DOC™ For PC (versions 2.0, 2.05, 3.0, and 3.1). The Deutsch 9-pin vehicle connector should always be used to establish communication for troubleshooting. If it is necessary to use the J 43890 T-Adapter Harness, the following conditions will occur: • • • • •

DTC U2105 CAN bus error sets. The CHECK TRANS light illuminates (beginning with M04 software, effective March 2000). The TCM freezes shift adapts. The TCM inhibits TCC engagement. Throttle information is defaulted; the TCM estimates throttle data from torque converter slip.

J 42660

RP1210A – COMPLIANT COMPUTER INTERFACE BOX (MPSI MAGIKEY™ SHOWN)

J 42660-90

Figure 3–1. Proper Allison DOC™ For PC Scan Tool Connections — J1939 3–4

Copyright© 2004 General Motors Corp.

V06528.00.02

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE

J 44652 DDL ADAPTER J 1850/OBD II HEAVY DUTY (GMC)

SPX J 1850 – VPW DIAGNOSTIC INTERFACE BOX

V06527.00.01

Figure 3–2. Proper Allison DOC™ For PC Scan Tool Connections — J1850

The J1850 Diagnostic Interface Box (J 44652) utilizes a serial port connection, rather than a parallel port, and is used only for off-board diagnostic communications. J1939 is still used for on-board communications such as throttle position; therefore it will necessary to use the J1939 T-Adapter Harness (J 43890) and MPSI MagiKey™ Interface Box (J 42660) to perform a recalibration (Figure 3–3).

VEHICLE TCM

J 43890

J 42660

J1 VEHICLE HARNESS

MPSI MAGIKEY™ INTERFACE BOX J 42660-90 V06526.00.01

Figure 3–3. Proper Allison DOC™ For PC Scan Tool Connections Using J1939 T-Adapter Harness (J 43890) Copyright© 2004 General Motors Corp.

3–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE 4.

Check DTCs by using the Scan Tool.

5.

When a problem exists but a DTC is not indicated, refer to the General Troubleshooting Section (Section 7) for a listing of various electrical and hydraulic problems, their causes, and remedies.

6.

If a DTC is found in the TCM memory, save all available DTC and failure record information before clearing the active indicator (refer to Section 5).

7.

When certain DTCs are active, a range selection into reverse or forward may not be possible. To determine if a failure is electrical or hydraulic, perform the following “limp home” test.

WARNING!

Never remove electronic control connectors while the engine is running. Always turn off the ignition, set parking brakes and chock the wheels. Failure to follow this procedure may result in unexpected vehicle movement.

Limp Home Test With the ignition in the OFF position (engine not running), the selector in N (Neutral) and the parking brake set, remove the wiring harness from the main transmission connector. When the engine is restarted, the transmission will default to a “limp home” capability. In this state, trim solenoid A (deenergized) allows C3 clutch to be applied. If the selector valve is moved to the reverse range position, main pressure will be routed to C5 clutch, allowing reverse operation. If the selector valve is moved to the drive range position, main pressure will be routed to C1 clutch, allowing third range operation. This allows a technician to use “limp home” capability to determine if a hydraulic or an electrical problem exists. If reverse and third ranges are available in “limp home,” an electrical failure may be indicated. If only one of the two ranges or neither was obtainable, this may indicate an internal hydraulic failure (failed clutch, stuck valve, or solenoid failure). The clutches that could possibly have an indicated failure in “limp home” are C1, C3, and C5. NOTE:

Removing the main transmission connector will induce several DTCs. Make sure all codes are cleared before proceeding with further troubleshooting. 8.

Test drive the vehicle to confirm a DTC or performance complaint. • If the DTC reappears, refer to the DTC section (Section 5) and the appropriate DTC table. The DTC section lists diagnostic codes and their description. Locate the appropriate troubleshooting table and follow the instructions. • If the DTC does not reappear and the test has passed, it may be an intermittent problem. Use the Scan Tool (Allison DOC™ For PC) and the DTC (Section 5). The DTC display procedure will identify possible causes of the problem. • Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a circuit problem is suspected.

NOTE:

3–6.

Information concerning specific items is contained in the appendices located in the back of this manual. The appendices are referred to throughout the manual.

TCM REPLACEMENT PROCEDURE • Using the Scan Tool, verify the current calibration information number (CIN) and record or print a report of the current customer modifiable constants (CMC) information for later reference. • Remove the J1 and J2 connectors from the suspect TCM; inspect the J1 and J2 connectors for damaged or bent pins.

3–6

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE • Replace TCM with a new or known good TCM from a similar vehicle. • If the replacement TCM corrects the original complaint, reinstall the original TCM to verify the complaint returns. If original complaint is confirmed, reinstall a new TCM. • If the complaint does not return, leave the original TCM installed. Disconnecting and reconnecting the TCM can often correct faulty wiring harness connections that may have been present. • Clear any DTCs that may be present and test drive the vehicle to confirm the repair. NOTE:

3–7.

All 1000 and 2000 Product Families TCMs are designed to be isolated from the vehicle chassis ground. Be sure that the TCM case is not contacting the vehicle frame or any other point that might provide a ground connection.

RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE Shift Energy Management (SEM) Autoselect feature was added to TCM software in the second quarter of 2002. Autoselect is deactivated following the first 20 engine starts where engine and transmission communication are present. If during the first 20 engine starts the TCM recognizes an engine to be on its list of certified engines, it will lock to the SEM active state. If the engine is not supported, the TCM will lock to a non-SEM state.

TCM Autoselect Certified Engines

CC Level 16 18 19 N/A

Software Level U02 U2A DEE N/A

Autoselect Functionality Implemented in TCM Software May 2002 July 2002 September 2002 Proposed first quarter 2004

Engine Type Supported Cummins ISB Cummins ISB02 Cummins ISBe (6-cylinder) Caterpillar C7

ISB engine software since December 2001 should support SEM, as well as most ISBe since October 2002. ISB02 ECM software started supporting SEM in July 2002. NOTE:

Most engine upgrades are same type/rating; under normal circumstances there should be no reason to reset the TCM Autoselect. However, there may be a small chance that transmission performance, shift quality, or codes may result from the use of different engine models within the same engine family or when a recalibration of engine software has taken place. If a vehicle receives upgraded engine hardware or software it may become necessary to reactivate the Autoselect feature to redetect the engines current SEM status.

NOTE:

3–8.

Once TCM Autoselect locks, the only way to reactivate is to perform the power-off data erase procedure described below.

RESETTING TCM AUTOSELECT Verify a new engine rating by checking the engine data tag. The engine must be compatible with the transmission rating. If the engine rating is not compatible, the vehicle must be returned to the OEM for engine recalibration. If the rating is correct for the transmission, perform the following steps. Copyright© 2004 General Motors Corp.

3–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE PCCS Load Station is used to reset Autoselect function, to do this it is necessary to clear all power-off data currently stored in the TCM. • Go to the Maintenance button and select “Erase Power-off Data” • After selecting “Erase Power-off data”, a message will indicate “PCCS is going to erase Power-off data”. Select “Yes”. Selecting “No” will abort the clearing of Power-off Data. • After clearing Power-off Data, there will be a prompt to cycle the ignition. The TCM is now reset to Autoselect and will start looking for supporting engine software. Drive the vehicle; confirm DTCs have not returned. NOTE:

Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the vehicle to allow shifts to converge. Autoselect reset function will be incorporated into the Allison DOC™ For PC service tool at a later date, along with an indication of the current SEM Autoselect status.

3–8

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 4—WIRE CHECK PROCEDURES 4–1.

CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197)

NOTE:

Please refer to Paragraph 3–5 to begin the troubleshooting process. 1.

Make sure all connectors are tightly connected and re-check the circuit.

2.

Disconnect and inspect all connectors.

3.

Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs, proceed with Step (4). The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.)

CAUTION:

4.

Review the wire numbering system described in Paragraph 3–4.

5.

If all connectors are clean and properly seated, determine which wires in the chassis harness are indicated by the DTC. For example, DTC P0748, indicates an open or a short-to-ground in the solenoid A circuit — wires 222 and 223. a. Check continuity of wires 222 and 223 by performing the following (Figure 4–1): (1) Disconnect the red (J2) connector from the TCM and disconnect the harness from the transmission main connector. At one end of the harness, using jumper wire kit J 39197 and connector probes in J 39775-CP, connect wire 222 and 223 to each other, being careful not to distort the terminals. Jumping the wires together creates a circuit between wires 222 and 223.

TRANSMISSION CONNECTOR WIRING HARNESS JUMPER

TCM “J2” CONNECTOR

0

+

–

VOLT/OHMMETER (VOM)

+

–

0 OHMS Circuit has continuity. Jumper from 222 or 223 to another wire produces a complete circuit. VOM reading is near zero Ohms.

OHMS Circuit does not have continuity due to a broken wire (open circuit). VOM reading is very high (infinite Ohms or OL – overlimit).

V06478

Figure 4–1. Checking Continuity (External Harness) Copyright© 2004 General Motors Corp.

4–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES (2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. Refer to OEM wiring harness repair procedure. b. If the continuity check is good (0–2 Ohms resistance), remove the jumpers. Check the harness for shorts between wires and shorts-to-ground by performing the following (refer to Figure 4–2): (1) At the TCM end of the harness, touch one VOM probe to one wire of the circuit being tested and touch the other probe to each terminal in the same connector, then touch the probe to chassis ground and to the transmission main housing. Do this for both wires in the circuit being tested. (2) If at any time the VOM shows zero to low resistance, or the meter’s continuity beeper sounds, there is a short between the two points being probed — wire-to-wire or wire-to-ground. Isolate and repair the short. TRANSMISSION CONNECTOR WIRING HARNESS TCM “J2” CONNECTOR Wires shorted together

Shorted to ground on metal frame rail

0

+

Ground to metal frame rail

0 VOLT/OHMMETER – (VOM)

– +

0 OHMS

0 OHMS

Two wires have frayed and are shorted together. Continuity beeper of VOM will sound, or reading will go to zero Ohms when these two wires are probed with the VOM.

Harness has been chafed and one or more wires are shorted-to-ground. VOM continuity beeper will sound, or reading will go to zero Ohms when meter is probing between this wire and chassis ground.

V05734

Figure 4–2. Short Between Wires and to Ground (External Harness)

4–2.

CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 1.

Disconnect the external wiring harness from the transmission.

2.

Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned.

CAUTION:

4–2

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.)

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES 3.

If the connectors are clean and properly seated, determine which wires in the harness to test. Use the diagnostic code system schematic to locate the wire terminals. For this example, DTC P0748 indicates an open or a short-to-ground in the solenoid “A” circuit — wires 222 and 223 (refer to Figure 4–3 and Figure 4–4). a. At the transmission connector, check the resistance of the A solenoid circuit. Resistance of a solenoid circuit should be 5.5–8 Ohms — covering a temperature range of –18°C to 149°C (0°F to 300°F). Refer to Solenoid Resistance vs. Temperature chart in Appendix K. No continuity in the circuit (infinite resistance) indicates an open in the internal harness, the feedthrough connector, or the solenoid coil. Replace the internal harness, replace the feedthrough connector, or replace the solenoid.

SOLENOID MAIN TRANSMISSION CONNECTOR

3.5

–

–

+

+

VOLT/OHMMETER (VOM)

5.5–8 OHMS AT NORMAL OPERATING TEMPERATURE* Circuit has continuity. * Refer to Appendix K

INFINITE (

) OHMS

Circuit does not have continuity due to a broken wire (open circuit). VOM reading is very high (infinite ohms or OL–overlimit). This could also be due to an open solenoid coil or bad connection. V05735

Figure 4–3. Checking Continuity (Internal Harness) b. If the resistance check is good, check the harness for shorts between wires and to ground by performing the following (refer to Figure 4–4): (1) At the transmission connector, touch one probe of the VOM to one wire of the circuit being tested and touch the other probe to each terminal in the connector and to chassis ground and the transmission main housing. Do this for both wires in the circuit being tested. (2) If the VOM shows zero to low resistance, or the continuity beeper sounds, there is a short between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J for splice locations. If the short is not a splice, then isolate and repair the short.

Copyright© 2004 General Motors Corp.

4–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES

Shorted to metal

MAIN TRANSMISSION CONNECTOR

SOLENOIDS Bare wires touching each other

0 0

– +

VOLT/OHMMETER (VOM)

– +

0 OHMS

Two wires have frayed and are shorted together. Continuity beeper of VOM will sound, or reading will go to zero Ohms when these two wires are probed with the VOM.

0 OHMS

Harness has been chafed and one or more wires are shorted to ground. VOM continuity beeper will sound or meter reading will go to zero Ohms when meter is probing between this wire and chassis ground.

V05736

Figure 4–4. Short Between Wires and to Ground (Internal Harness) NOTE:

4–4

When conducting circuit checks that include the external harness, add one (1) Ohm to the values shown. Speed sensor resistance is 2304–2815 Ohms at 20°C (68°F).

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 5—DIAGNOSTIC TROUBLE CODES (DTC) 5–1.

DTC MEMORY

Diagnostic Trouble Codes (DTCs) are logged in a list in TCM memory. The DTCs contained in the list have information recorded as shown in Table 5–1 (DTCs are examples). The TCM is capable of displaying all historical and active DTCs. Table 5–1. DTC List Code P0562 P0875 P0743 P1892

DTC Description System Voltage Low Transmission Pressure Switch Reverse Circuit Torque Converter Clutch PWM Solenoid Circuit Throttle Position Sensor PWM Signal High Input

Active Indicator Y N N N

CHECK TRANS Light Y N Y N

The following paragraphs define the different parts of the DTC list.

5–2.

A.

Code. The number assigned to a given fault condition in accordance with SAE J2012.

B.

DTC Description. Name assigned to a given fault condition in accordance with SAE J2012.

C.

Active Indicator. Indicates when a DTC is active. If a DTC is active, the Scan Tool displays Y (Yes). If DTC is not active, N (No) is displayed.

D.

CHECK TRANS Light. Indicates if CHECK TRANS Light/Malfunction Indicator Lamp (MIL) is illuminated.

FAILURE RECORDS

Failure records contain a snapshot of transmission data that is stored in the TCM when DTCs are logged. A limit of five failure records can be stored. When an additional DTC is logged, the new failure record pushes the oldest record from the TCM memory. Table 5–2 illustrates the failure record data stored in the TCM when a DTC is set. Table 5–2. Failure Record Data Data Description Gear Selected Gear Commanded Current Gear Previous Gear Ignition Voltage Trans Fluid Temperature (TFT) Trans Input Shaft Speed Trans Output Shaft Speed Turbine Speed Present Gear Ratio Normalized TPS Force Motor Solenoid A Actual Current Force Motor Solenoid B Actual Current Force Motor Solenoid A Pressure Force Motor Solenoid B Pressure TCC PWM Duty Cycle PSM C PSM D

Copyright© 2004 General Motors Corp.

5–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Table 5–2. Failure Record Data (cont’d) Data Description PSM E PSM R Shift Solenoid C Shift Solenoid D Shift Solenoid E Engine Run Time

5–3.

DTC READING AND DTC CLEARING

DTCs can be read and cleared by using the Allison DOC™ For PC scan tool. The use of Allison DOC™ For PC is described in the instruction manual furnished with each tool and briefly in Appendix M of this manual. A.

Clearing DTCs • DTCs will automatically clear after 40 code-free warm-up cycles. • DTCs can be manually cleared by the Allison DOC™ For PC.

B.

Clearing Active Indicators • A DTC’s active indicator can be cleared, which removes the DTC’s shift inhibitions while the DTC remains in the queue as inactive. • The active indicator clearing method is to power down (all active indicators are cleared at TCM power down).

CAUTION:

5–4.

BEGINNING THE TROUBLESHOOTING PROCESS A.

NOTE:

If an active indicator is cleared while the transmission is locked in a forward range or reverse (fail-to-range), the transmission will remain in the forward range or reverse after the clearing procedure is completed. N (Neutral) must be manually selected.

Starting Procedure Review Paragraph 3–5, “Basic Troubleshooting Information” and check fluid level and ignition voltage before any troubleshooting is performed. 1. Begin troubleshooting by reading Paragraph 3–5, checking the transmission fluid level and the TCM input voltage. Check for DTCs by using the Allison DOC™ For PC diagnostic tool. 2. When a problem exists, but a DTC is not indicated, refer to Section 7 — General Troubleshooting Performance Complaint for a listing of various electrical and hydraulic problems, their causes, and remedies. 3. If a DTC is found in the TCM memory, record all available DTC information and failure record data before clearing the DTC (refer to Paragraph 5–3). 4. Test drive the vehicle to confirm a DTC or performance complaint. • If the DTC reappears, refer to the DTC paragraph (Paragraph 5–5) and the appropriate DTC table. The DTC section lists DTCs and their description. Locate the appropriate troubleshooting table and follow the instructions. • If the DTC does not reappear, it may be an intermittent problem. Use the Allison DOC™ For PC and the DTC display procedure described in Section 5. Refer to the troubleshooting table for possible causes of the problem. • Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a circuit problem is suspected.

5–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) NOTE:

Information concerning specific items is contained in the appendices located in the back of this manual. The appendices are referred to throughout the manual. B.

Solenoid Locations Solenoid locations in the control module are as illustrated in Figure 5–1. Refer to Figure 5–1 as necessary when using the DTC schematics.

C

E

A TRIM B TRIM

D

G

F

V07476.01.01

Figure 5–1. Solenoid Locations C.

Wire/Terminal Numbering Scheme Allison Transmission recommended wire numbers (i.e. 212) consist of three digits, where the first digit indicates the TCM connector number (i.e. J2=2), and the last two digits indicate the pin-out information (i.e. 12).

D.

Available Diagnostic Adapters Figures 5–2 and 5–3 show the J 43799 and J 44722 Adapters that are available for use with the J 39700 Breakout Box.

Copyright© 2004 General Motors Corp.

5–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) J 43799 ADAPTER CABLE

J 39700 BREAKOUT BOX

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Detail of Magnetic Overlay for use with J 43799 Adapter Box

To Ground

A

D

A JP 43 T 7 E 9 R 9 C A B L

E

Existing J1 and J2 Harnesses

x) 0 70 Bo -39 ut h J ako wit re se l B (U ersa iv Un

“J2” CONNECTOR (RED) TRANSMISSION CONTROL MODULE (TCM) “J1” CONNECTOR (GRAY)

“J1” CONNECTOR (GRAY)

“J2” CONNECTOR (RED)

Figure 5–2. J 39700 Breakout Box And J 43799 Adapter 5–4

Copyright© 2004 General Motors Corp.

V06827.00.00

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) J 39700 BREAKOUT BOX

1000/2000/2400 SERIES ENGINE SPEED SENSOR

A

TURBINE SPEED SENSOR

B

DOUBLE CONNECTOR NSBU

4A

5

A

B

4B

4C

6

8

TM

OUTPUT SPEED SENSOR

A

B

4D SINGLE CONNECTOR NSBU

4

MAIN TRANSMISSION CONNECTOR

A

B

C

D

E

F

G

H

J

K

L

M

N

P

R

S

T

U

V

W

SPEED SENSORS PIN A + B 2500 Ω @ 68˚ F Shift selector pre-select ranges are calibration dependent.

NSBU SWITCH OPEN ON CLOSE/GROUNDED

OFF

5

1

3

4

1 2 4 5 1 2 3 5 N R PIN SWA P A OFF OFF ON ON OFF OFF ON A ON OFF OFF OFF OFF ON ON B D ON ON ON OFF OFF OFF OFF C C P OFF ON OFF ON OFF ON OFF G

- NSBU TERMINAL REFERENCE DOUBLE CONNECTOR NSBU USES ALPHA-NUMERIC. SINGLE CONNECTOR NSBU USES NUMERIC.

SOL SOL SOL SOL SOL SOL SOL

A B C D E F G

PIN M + L PIN N + P PIN A + C PIN B + C PIN W + C PIN J + S PIN J + R

PRESSURE SWITCH MANIFOLD OPEN OFF CLOSE/GROUNDED ON TCM

5-6 5-6 21 - 23 21 - 23 21 - 23 10 - 11 21 - 23

Ω @ 68˚ F Ω @ 68˚ F Ω @ 68˚ F Ω @ 68˚ F Ω @ 68˚ F Ω @ 68˚ F Ω @ 68˚ F

3 2 1 N PIN SWA R A B OFF ON ON OFF OFF ON ON OFF OFF OFF B C C P OFF OFF OFF ON OFF ON OFF ON ON OFF D B – Switch C Off in Rev. starting with software level NO4 or later.

4 — — — —

5 ON OFF ON OFF

SUMP TEMP PIN G + H 3088-3942 Ω @ 68˚ F

J-44722-A FORM 1B

Detail of Magnetic Overlay for use with J 44722-A Transmission Breakout Harness

To Existing Harness To Engine Speed Sensor

To Existing NSBU To 4-Pin Connector Harness

To Existing Harness

To Existing 12-Pin Single Harness

To Turbine Speed Sensor

J 46971 Harness for use with Single Connector NSBU Switch

To Existing Harness To Output Speed Sensor To Existing 4-Pin Harness To NSBU 4-Pin Connector

To Main Case Connector To Existing 32-Pin Harness

V06828.01.01

Figure 5–3. J 39700 Breakout Box And J 44722 Adapter Copyright© 2004 General Motors Corp.

5–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) 5–5.

DIAGNOSTIC TROUBLE CODES (DTCs) DTC LIST AND DESCRIPTION INDEX

DTC P0122 P0123 P0218 P0561 P0562 P0563 P0602 P0606 P0614 P0701 P0703

Description Pedal Position Sensor Circuit Low Voltage Pedal Position Sensor Circuit High Voltage Transmission Fluid Over Temperature Condition Unrealistic Variations In Vehicle System Voltage System Voltage Low System Voltage High TCM Not Programmed Controller Internal Performance—Not enabled for Pickups or med duty “04” Torque Control Data Mismatch—ECM/TCM Transmission Control System Performance Brake Switch Circuit Malfunction—GMT800 only Transmission Range Sensor Circuit (PNRDL input) P0705✝ Not production enabled/could be in development cals Transmission Range Sensor Circuit (Performance) P0706✝ Not production enabled/could be in development cals P0708 Transmission Range Sensor Circuit High Input Transmission Fluid Temperature Sensor Circuit P0710✝ Not production enabled/could be in development cals P0711 Transmission Fluid Temperature Sensor Circuit Performance P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature) P0716 Turbine Speed Sensor Circuit Performance P0717 Turbine Speed Sensor Circuit No Signal P0719 Brake Switch ABS Input Low P0721 Output Speed Sensor Circuit Performance P0722 Output Speed Sensor Circuit No Signal P0726 Engine Speed Input Circuit Performance P0727 Engine Speed Input Circuit No Signal P0731 Incorrect 1st Gear Ratio P0732 Incorrect 2nd Gear Ratio P0733 Incorrect 3rd Gear Ratio P0734 Incorrect 4th Gear Ratio P0735 Incorrect 5th Gear Ratio P0736 Incorrect Reverse Ratio P0741 Torque Converter Clutch System Stuck Off P0742 Torque Converter Clutch System Stuck On P0743 Torque Converter Clutch PWM Solenoid Circuit—Electrical (Previously P1860) P0746 Solenoid A Controlled Clutch Stuck Off (Previously P1720) P0747 Solenoid A Controlled Clutch Stuck On (Previously P1723) P0748 Pressure Control Solenoid A Electrical P0763 Shift Solenoid C Electrical

5–6

Copyright© 2004 General Motors Corp.

CHECK TRANS Light Yes Yes No Yes Yes Yes Yes Yes Yes No No

Page 5–16 5–20 5–24 5–27 5–31 5–34 5–37 5–38 5–39 5–41 5–43

N/A N/A Yes

5–46

N/A No No No Yes Yes N/A Yes Yes No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

5–50 5–54 5–58 5–62 5–65 5–69 5–71 5–75 5–79 5–82 5–85 5–88 5–91 5–94 5–97 5–100 5–104 5–107 5–110 5–115 5–118 5–121 5–126

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC LIST AND DESCRIPTION INDEX (cont’d) CHECK TRANS Light DTC Description P0768 Shift Solenoid D Electrical Yes P0773 Shift Solenoid E Electrical Yes P0776 Solenoid B Controlled Clutch Stuck Off (Previously P1721) Yes P0777 Solenoid B Controlled Clutch Stuck On (Previously P1724) Yes P0778 Pressure Control Solenoid B Electrical Yes P0840 Transmission Pressure Switch Solenoid C Circuit Yes P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open Yes P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed Yes P0843 Transmission Pressure Switch Solenoid C Circuit High Yes P0845 Transmission Pressure Switch Solenoid D Circuit Yes P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open Yes P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed Yes P0848 Transmission Pressure Switch Solenoid D Circuit High Yes P0870 Transmission Pressure Switch Solenoid E Circuit (Previously P1709) Yes P0871 Transmission Pressure Switch Solenoid E Circuit Stuck Open (Previously P1710) Yes P0872 Transmission Pressure Switch Solenoid E Circuit Stuck Closed (Previously P1711) Yes P0873 Transmission Pressure Switch Solenoid E Circuit High (Previously P1712) Yes P0875 Transmission Reverse Pressure Switch Circuit Malfunction (Previously P1713) Yes Transmission Reverse Pressure Switch Circuit Stuck Open (Previously P1714) P0876 Yes Not production enabled/could be in development cals Transmission Reverse Pressure Switch Circuit Stuck Closed (Previously P1715) P0877✝ N/A Not production enabled/could be in development cals Transmission Reverse Pressure Switch Circuit High (Previously P1716) P0878✝ N/A Not production enabled/could be in development cals P0880 TCM Supply Voltage (Previously P1760) No Pressure Control Solenoid Control Circuit P0960✝ N/A Not production enabled/could be in development cals P1688 Unmanaged Engine Torque Delivered To TCM Signal See Note P1709 See DTC P0870 P1710 See DTC P0871 P1711 See DTC P0872 P1712 See DTC P0873 P1713 See DTC P0875 P1714 See DTC P0876 P1715 See DTC P0877 P1716 See DTC P0878 P1720 See DTC P0746 P1721 See DTC P0776 P1723 See DTC P0747 P1724 See DTC P0777 P1760 See DTC P0880 P1779 Engine Torque Delivered To TCM Signal See Note Copyright© 2004 General Motors Corp.

Page 5–131 5–135 5–139 5–142 5–145 5–150 5–155 5–160 5–165 5–170 5–175 5–180 5–185 5–190 5–195 5–200 5–205 5–210 5–215

5–220

5–223 5–190 5–195 5–200 5–205 5–210 5–215

5–115 5–139 5–118 5–142 5–220 5–225

5–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC LIST AND DESCRIPTION INDEX (cont’d)

DTC Description P1860 See DTC P0743 P1891 Throttle Position Sensor Pulse Width Modulation (PWM) Signal Low Input P1892 Throttle Position Sensor Pulse Width Modulation (PWM) Signal High Input P2771 Four-Wheel Drive Switch Circuit (Previously P0836, P1875) P2773 Torque Control Request Ignored—ECM/TCM P2810 Solenoid G Electrical U0031 J1850 (Class 2) Serial Data Communication Link Low (Previously U1300) U0032 J1850 (Class 2) Serial Data Communication Link High (Previously U1301) U0073 CAN Bus Reset Counter Overrun (Previously U2104) U0100 CAN Bus ECM Error (Previously U2105) U1000 Class 2 Loss of Serial Data Communication U1016 J1850 (Class 2) Powertrain Controller State of Health Failure U1041 J1850 (Class 2) ABS Controller State of Health Failure U1064 J1850 (Class 2) TBC Controller State of Health Failure U1096 J1850 (Class 2) IPC Controller State of Health Failure U1300 See DTC U0031 U1301 See DTC U0032 U2104 See DTC U0073 U2105 See DTC U0100 * Enabled for MY2001 Non-OBD Vehicles. ✝ Call Technical Assistance Center (TAC) at 1-800-252-5283 for further information.

CHECK TRANS Light No No Yes Yes Yes No No Yes Yes No * No * No * No *

NOTE: Used with GM gasoline engine applications only—CHECK TRANS light will illuminate.

DTC REFERENCE TABLES Gear Ratio Table Range 1 2 3 4 5 R

1000 Product Family Gear Ratio 3.10:1 1.81:1 1.41:1 1.00:1 0.71:1 –4.49:1

2000 Product Family Gear Ratio 3.51:1 1.90:1 1.44:1 1.00:1 0.74:1 –5.09:1

Main Pressure Schedule Table (Used Prior To S/N 6310004116) Range Forward Converter Forward Lockup Reverse Neutral/Park

5–8

Main Pressure @ 600 rpm 800–1380 kPa (115–200 psi) — 800–1380 kPa (115–200 psi) 900–1655 kPa (130–240 psi)

Main Pressure @ 2100 rpm 1515–1795 kPa (220–260 psi) 1000–1170 kPa (145–170 psi) 1515–1795 kPa (220–260 psi) 1515–1795 kPa (220–260 psi)

Copyright© 2004 General Motors Corp.

Page 5–110 5–227 5–230 5–233 5–237 5–239 5–244 5–247 5–250 5–253 5–256 5–256 5–256 5–256 5–256 5–244 5–247 5–250 5–253

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Main Pressure Schedule Table (Used Starting With S/N 6310004116) Range Forward Converter

Main Pressure @ 600 rpm

Main Pressure @ 2100 rpm

700–1380 kPa (102–200 psi)

1515–1795 kPa (220–260 psi)

—

1000–1170 kPa (145–170 psi)

Reverse

700–1380 kPa (102–200 psi)

1515–1795 kPa (220–260 psi)

Neutral/Park

800–1655 kPa (116–240 psi)

1515–1795 kPa (220–260 psi)

Forward Lockup

Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid) Range Forward/Reverse Converter with G Solenoid Active (viewable in Allison DOC™)

590–720 kPa (85–105 psi)

Main Pressure @ 600 rpm

634–758 kPa (92–110 psi)

Main Pressure @ 2100 rpm

Forward Converter with G Solenoid Inactive

700–1380 kPa (101–200 psi)

1515–1795 kPa (220–260 psi)

Forward Lockup with G Solenoid Active*

—

510–627 kPa (74–91 psi)

Forward Lockup with G Solenoid Inactive*

—

1000–1170 kPa (145–170 psi)

Neutral/Park with G Solenoid Active

590–720 kPa (85–105 psi)

—

Neutral/Park

800–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi)

* Medium duty gasoline engines only.

NSBU Switch Table Selector Position

A

B

C

P

P

OFF

ON

ON

OFF

R

OFF

OFF

ON

ON

N

ON

OFF

ON

OFF

5

5

5

ON

OFF

OFF

ON

3

4

4

OFF

OFF

OFF

OFF

2

2

3

OFF

ON

OFF

ON

1

1

1

ON

ON

OFF

OFF

ON = Open Circuit OFF = Grounded Circuit The NSBU Switch has only four positions available in the forward ranges. Therefore, one range position will be omitted at the selector. This position may be 2nd, 3rd, 4th, or 5th range depending upon chosen calibration.

Copyright© 2004 General Motors Corp.

5–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Solenoid and Clutch Table — Software Levels Prior To N04 Trim Solenoids A B De-energized; Energized; C3 Applied C5 Applied

Logic

Clutch To Main

R

—

Garage Shift

R–N

—

De-energizing; C3 Trimming Off

Garage Shift

N–R

—

Steady State

N

Garage Shift

Range Status Steady State

Shift Solenoids C D E

TCC Sol F

ON

ON

ON

OFF

Energizing; C5 Applied

ON

ON

ON

OFF

Energizing; C3 Trimming On

Energizing; C5 Applied

ON

ON

ON

OFF

—

De-energized; C5 Applied

De-energized; Exhausted

ON

ON

ON

OFF

N–1

—

De-energizing; C5 Applied

Energizing; C1 Trimming On

ON

ON

ON

OFF

Garage Shift

1–N

—

De-energizing; C5 Applied

Energizing; C1 Trimming Off

ON

ON

ON

OFF

Steady State

1

C1

De-energized; C5 Applied

De-energized; C4 Exhausted

OFF

ON

OFF

OFF

Upshift

1–2

C1

Energizing; C5 Trimming Off

Energizing; C4 Trimming On

OFF

ON

OFF

OFF

Downshift

2–1

C1

Energizing; C5 Trimming On

Energizing; C4 Trimming Off

OFF

ON

OFF

OFF

2

C1

Energized; C3 Exhausted

Energized; C4 Applied

OFF

OFF

OFF

ON or OFF *

Upshift

2–3

C1

De-energizing; C3 Trimming On

De-energizing; C4 Trimming Off

OFF

OFF

OFF

ON

Downshift

3–2

C1

De-energizing; C3 Trimming Off

De-energizing; C4 Trimming On

OFF

OFF

OFF

ON

3

C1

De-energized; C3 Applied

De-energized; C2 Exhausted

ON

OFF

OFF

ON

Upshift

3–4

C1

Energizing; C3 Trimming Off

Energizing; C2 Trimming On

ON

OFF

OFF

ON

Downshift

4–3

C1

Energizing; C3 Trimming On

Energizing; C2 Trimming Off

ON

OFF

OFF

ON

4

C2

Energized; C3 Exhausted

Energized; C1 Applied

ON

OFF

ON

ON

Upshift

4–5

C2

De-energizing; C3 Trimming On

De-energizing; C1 Trimming Off

ON

OFF

ON

ON

Downshift

5–4

C2

De-energizing; C3 Trimming Off

De-energizing; C1 Trimming On

ON

OFF

ON

ON

5

C2

De-energized; C3 Applied

De-energized

OFF

OFF

ON

ON

Steady State

Steady State

Steady State

Steady State

* Depending upon output speed

5–10

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Solenoid and Clutch Table — Software Level N04 And Later Range Status Steady State with Throttle Steady State at Closed Throttle Garage Shift

Logic R R

ClutchTo Trim Solenoids Main A B De-energized; Energized; — C3 Applied C5 Applied De-energized; Energized; — C5 Applied C3 Applied

Shift Solenoids C D E ON ON ON OFF

ON

ON

TCC Sol F OFF OFF

De-energizing; Energizing; OFF ON ON OFF C3 Trimming Off C5 Applied Garage Shift Energizing; Energizing; N–R — OFF ON ON OFF C3 Trimming On C5 Applied Steady State De-energized; De-energized; N — ON ON ON OFF C5 Applied Exhausted Garage Shift De-energizing; Energizing; N–1 — ON ON ON OFF C5 Applied C1 Trimming On Garage Shift De-energizing; Energizing; 1–N — ON ON ON OFF C5 Applied C1 Trimming Off Steady State De-energized; De-energized; 1 C1 OFF ON OFF OFF C5 Applied C4 Exhausted Upshift Energizing; Energizing; 1–2 C1 OFF ON OFF OFF C5 Trimming Off C4 Trimming On Downshift Energizing; Energizing; 2–1 C1 OFF ON OFF OFF C5 Trimming On C4 Trimming Off Steady State Energized; Energized; 2 C1 OFF OFF OFF ON or OFF ** C3 Exhausted C4 Applied Upshift De-energizing; De-energizing; OFF OFF OFF ON 2–3 C1 C3 Trimming On C4 Trimming Off Downshift De-energizing; De-energizing; OFF OFF OFF ON 3–2 C1 C3 Trimming Off C4 Trimming On Steady State De-energized; De-energized; ON OFF OFF ON 3 C1 C3 Applied C2 Exhausted Upshift Energizing; Energizing; ON OFF OFF ON 3–4 C1 C3 Trimming Off C2 Trimming On Downshift Energizing; Energizing; ON OFF OFF ON 4–3 C1 C3 Trimming On C2 Trimming Off Steady State Energized; Energized; 4 C2 ON OFF ON ON C3 Exhausted C1 Applied Upshift De-energizing; De-energizing; ON OFF ON ON 4–5 C2 C3 Trimming On C1 Trimming Off Downshift De-energizing; De-energizing; 5–4 C2 ON OFF ON ON C3 Trimming Off C1 Trimming On Steady State De-energized; De-energized 5 C2 OFF OFF ON ON C3 Applied Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range: At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch. Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5. Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule. * Values are calibration dependent ** Depending upon output speed R–N

—

Copyright© 2004 General Motors Corp.

5–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Pressure Switch Status Table — Software Levels Prior To N04 Pressure Switch C (N/O) Switch Scan Tool Status Status Closed ON

Pressure Switch D (N/O) Switch Scan Tool Status Status Closed ON

Pressure Switch E (N/O) Switch Scan Tool Status Status Closed ON

N

Closed

ON

Closed

ON

Closed

ON

Open

OFF

1

Open

OFF

Closed

ON

Open

OFF

Open

OFF

2

Open

OFF

Open

OFF

Open

OFF

Open

OFF

3

Closed

ON

Open

OFF

Open

OFF

Open

OFF

4

Closed

ON

Open

OFF

Closed

ON

Open

OFF

Open OFF Open OFF N/O = Normally OpenN/C = Normally Closed

Closed

ON

Open

OFF

Range R

5

Pressure Switch R (N/C) Switch Scan Tool Status Status Closed ON

Pressure Switch Status Table — Software Level N04 And Later Pressure Switch C (N/O)

Pressure Switch D (N/O)

Pressure Switch E (N/O)

Pressure Switch R (N/C)

Range

Switch Status

Scan Tool Status

Switch Status

Scan Tool Status

Switch Status

Scan Tool Status

Switch Status

Scan Tool Status

R

Open

OFF*

Closed

ON

Closed

ON

Closed

ON

N

Closed

ON

Closed

ON

Closed

ON

Open

OFF

1

Open

OFF

Closed

ON

Open

OFF

Open

OFF

2

Open

OFF

Open

OFF

Open

OFF

Open

OFF

3

Closed

ON

Open

OFF

Open

OFF

Open

OFF

4

Closed

ON

Open

OFF

Closed

ON

Open

OFF

5

Open

OFF

Open

OFF

Closed

ON

Open

OFF

N/O = Normally OpenN/C = Normally Closed * C pressure switch reverts to the CLOSED/ON state with throttle applied in Reverse.

Solenoid Resistance vs. Temperature Table Sump Temperature

5–12

Solenoid A, B Resistance

Solenoid C, D, E, G Resistance

Solenoid F Resistance

(°C)

(°F)

(Ω)

(Ω)

(Ω)

0

32

4.5

20.0

9.5

20

68

5.5

22.0

10.5

40

104

6.5

24.5

11.5

80

176

7.5

27.0

12.5

120

248

8.5

29.5

13.5

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Speed Sensor Resistance vs. Temperature Table Temperature (°C)

Temperature ( F)

Minimum Resistance (Ω)

–25

–13

1929

2143

2358

0

32

2157

2397

2637

25

77

2340

2600

2860

50

122

2614

2904

3195

75

167

2842

3158

3474

100

212

3071

3412

3753

125

257

3299

3666

4032

150

302

3483

3870

4257

Nominal Resistance Maximum Resistance (Ω) (Ω)

Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table Temperature (°C)

Temperature (°F)

Minimum Resistance (Ω)

Nominal Resistance Maximum Resistance (Ω) (Ω)

–45

–49

128 565

141 951

155 338

–40

–40

95 826

100 735

105 644

–35

–31

68 952

72 315

75 679

–30

–22

50 153

52 480

54 807

–25

–13

36 854

38 478

40 103

–20

–4

27 345

28 488

29 631

–15

5

20 476

21 286

22 097

–10

14

15 467

16 045

16 624

–5

23

11 781

12 197

12 612

0

32

9045

9345

9646

5

41

6998

7219

7441

10

50

5458

5623

5787

15

59

4291

4413

4536

20

68

3398

3490

3582

25

77

2710

2779

2849

30

86

2173

2228

2282

35

95

1754

1797

1840

40

104

1424

1459

1493

45

113

1163

1191

1218

50

122

955.0

977.1

999.2

55

131

788.6

806.5

824.5

Copyright© 2004 General Motors Corp.

5–13

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table (cont’d) Temperature (°C)

Temperature (°F)

Minimum Resistance (Ω)

Nominal Resistance Maximum Resistance (Ω) (Ω)

60

140

654.7

669.3

683.9

65

149

546.3

558.3

570.2

70

158

458.1

467.9

477.8

75

167

385.9

394.1

402.2

80

176

326.6

333.3

340.1

85

185

277.5

283.2

288.9

90

194

236.5

241.6

246.7

95

203

202.4

206.9

211.5

100

212

173.8

177.9

182.0

105

221

149.8

153.6

157.3

110

230

129.7

133.0

136.4

115

239

112.6

115.6

118.7

120

248

98.17

100.88

103.6

125

257

85.87

88.29

90.71

130

266

75.35

77.52

79.69

135

275

66.34

68.27

70.21

140

284

58.58

60.31

62.04

145

293

51.88

53.42

54.97

150

302

46.08

47.46

48.84

155

311

41.04

42.27

43.50

160

320

36.65

37.74

38.84

TPS Table (Distance (mm) of Travel vs. Volts) mm 0

Volts 0

mm 12

Volts 1.317

mm 24

Volts 2.634

mm 36

Volts 3.951

1

0.110

13

1.427

25

2.744

37

4.061

2

0.220

14

1.537

26

2.854

38

4.171

3

0.329

15

1.646

27

2.964

39

4.281

4

0.439

16

1.756

28

3.073

40

4.390

5

0.549

17

1.866

29

3.183

41

4.500

6

0.659

18

1.976

30

3.293

42

4.610

7

0.768

19

2.085

31

3.403

43

4.720

8

0.878

20

2.195

32

3.512

44

4.829

9

0.988

21

2.305

33

3.622

45

4.939

10

1.098

22

2.415

34

3.732

46

5.049

11

1.207

23

2.524

35

3.842

5–14

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Clutch Test Failure Table Range — Clutches Applied

C1 Failure

C2 Failure

*Reverse / C3 and C5

C4 Failure

NT > 0 in 3rd and 5th

First / C1 and C5

NT > 0 in 1st and 4th

Second / C1 and C4

NT > 0 in 1st and 4th

Third / C1 and C3

NT > 0 in 1st and 4th

Fourth / C1 and C2

NT > 0 in 1st and 4th

Fifth / C 2 and C3

C3 Failure

C5 Failure NT > 0 in 1st only NT > 0 in 1st only

NT > 0 in 4th only NT > 0 in 3rd only NT > 0 in 4th and 5th NT > 0 in 4th and 5th

NT > 0 in 3rd and 5th

* CAUTION: Reverse is not attainable in clutch test mode. Do not stall transmission in Reverse or driveline damage may occur. NOTE: NT is transmission turbine speed observed during clutch test

Copyright© 2004 General Motors Corp.

5–15

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0122 Pedal Position Sensor Circuit Low Voltage J2 HARNESS CONNECTOR (RED) J2-9

TCM TPS CONNECTOR J2-19

J2-20

J2

C

B

J1

A

C

THROTTLE POSITION SENSOR (TPS)

219

J2-19

5V

J2-9

ANALOG INTERFACE

TCM B

A

209

220

J2-20

V06225.01.00

Circuit Description The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor (TPS) or a signal transmitted by the engine electronic controls. Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage. The TPS continuously sends the exact throttle position to the transmission TCM. The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor contacts of the TPS are connected to provide a regulated voltage signal input to the TCM. When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch) along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0123 Pedal Position Sensor Circuit High Voltage is not active.

5–16

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0122 sets when the TCM detects a throttle position sensor voltage less than 0.55V for 5 seconds. Action Taken When the DTC Sets • • • • •

DTC P0122 is stored in the TCM history. The TCM uses the default throttle value. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement. The CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

• •

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper adjustment of TPS. 3. This step tests for the proper ignition voltage. 4. This step tests for the proper reference voltage from TCM. 5. This step tests for dead spots in the TPS rheostat. 6. This step tests for a high or low resistance in the TPS internal circuit. 7. This step tests for a harness-wiring problem.

DTC P0122 Pedal Position Sensor Circuit Low Voltage Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

Refer to Appendix F to check for proper TPS adjustment. Is the TPS adjusted properly?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Adjust TPS to proper setting. Go to Step 11 5–17

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0122 Pedal Position Sensor Circuit Low Voltage Step 1. 3 2. 3. 4.

4

5

6

7

8

9

5–18

Action Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector from the TCM and install the J43799 adapter box. 3. Reconnect the J2 connector to the adapter box. With the engine OFF, turn the ignition to the ON position. 4. Using a DVOM, measure the voltage between pins 19 and 20. Is the voltage within the specified value?

Value(s) 9–18V (12V TCM); 18–32V (24V TCM)

Yes Go to Step 4

No Resolve voltage problem (Refer to DTC P0562 and P0563)

4.75–5.0V

Go to Step 5

Go to Step 10

1. With the engine OFF and the ignition in the ON position, monitor throttle percentage with the Scan Tool. 2. Slowly increase the throttle from Idle to the full throttle position. 3. Watch for a steady increase in throttle percentage. Was the throttle percentage steady and without interruptions? 1. Turn the ignition OFF. 2. Disconnect the TPS connector. 3. Using a DVOM, measure the resistance at pins A and C. Is resistance within the specified value? 1. Reconnect the TPS connector. 2. Disconnect J2 connector from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 19 and 20. Is resistance within the specified value? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

—

Go to Step 6

Go to Step 7

9,000–15,000 Ohms

Go to Step 7

Go to Step 9

9,000–15,000 Ohms

Go to Diagnostic Aids

Go to Step 8

—

Go to Step 10

—

—

Go to Step 11

—

Repair the vehicle wiring harness. Is the repair complete? Replace the throttle position sensor. Is the replacement complete?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0122 Pedal Position Sensor Circuit Low Voltage Step Action 10 NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

11

Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle under normal driving conditions. Did the DTC return?

Value(s) —

Yes Go to Step 11

No —

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

5–19

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0123 Pedal Position Sensor Circuit High Voltage

J2 HARNESS CONNECTOR (RED) J2-9

TCM TPS CONNECTOR J2-19

J2-20

J2

C

B

J1

A

C

THROTTLE POSITION SENSOR (TPS)

219

J2-19

5V

J2-9

ANALOG INTERFACE

TCM B

A

209

220

J2-20

V06225.01.00

Circuit Description The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor (TPS) or a signal transmitted by the engine electronic controls. Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage. The TPS continuously sends the exact throttle position to the transmission TCM. The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor contacts of the TPS are connected to provide a regulated voltage signal input to the TCM. When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch) along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0122 Throttle/Pedal Position Sensor/Switch A Circuit Low Input is not active.

5–20

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0123 sets when the TCM detects a throttle position sensor voltage greater than 4.75 for 5 seconds. Action Taken When the DTC Sets • • • • •

DTC P0123 is stored in the TCM history. The TCM uses the default throttle value. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement. The CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

• •

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper adjustment of TPS. 3. This step tests for the proper ignition voltage. 4. This step tests for the proper reference voltage from TCM. 5. This step tests for dead spots in the TPS rheostat. 6. This step tests for a high or low resistance in the TPS internal circuit. 7. This step tests for a harness-wiring problem.

DTC P0123 Pedal Position Sensor Circuit High Voltage Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

Refer to Appendix F to check for proper TPS adjustment. Is the TPS adjusted properly?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

—

Go to Step 3

Adjust TPS to proper setting. Go to Step 11

Copyright© 2004 General Motors Corp.

5–21

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0123 Pedal Position Sensor Circuit High Voltage Step 1. 3 2. 3. 4.

4

5

6

7

8

9

5–22

Action Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector from the TCM and install the J43799 adapter box. 3. Reconnect the J2 connector to the adapter box. With the engine OFF, turn the ignition to the ON position. 4. Using a DVOM, measure the voltage between pins 19 and 20. Is the voltage within the specified value?

Value(s) 9–18V (12V TCM); 18–32V (24V TCM)

Yes Go to Step 4

No Resolve voltage problem (Refer to DTC P0562 and P0563)

4.75–5.0V

Go to Step 5

Go to Step 10

1. With the engine OFF and the ignition in the ON position, monitor throttle percentage with the Scan Tool. 2. Slowly increase the throttle from Idle to the full throttle position. 3. Watch for a steady increase in throttle percentage. Was the throttle percentage steady and without interruptions? 1. Turn the ignition OFF. 2. Disconnect the TPS connector. 3. Using a DVOM, measure the resistance at pins A and C. Is resistance within the specified value? 1. Reconnect the TPS connector. 2. Disconnect J2 connector from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 19 and 20. Is resistance within the specified value? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

—

Go to Step 6

Go to Step 7

9,000–15,000 Ohms

Go to Step 7

Go to Step 9

9,000–15,000 Ohms

Go to Diagnostic Aids

Go to Step 8

—

Go to Step 10

—

—

Go to Step 11

—

Repair the vehicle wiring harness. Is the repair complete? Replace the throttle position sensor. Is the replacement complete?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0123 Pedal Position Sensor Circuit High Voltage Step Action 10 NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

11

Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle under normal driving conditions. Did the DTC return?

Value(s) —

Yes Go to Step 11

No —

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

5–23

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0218 Transmission Fluid Over Temperature Condition

N/C

V07737.01.00

Circuit Description The flow of transmission fluid starts in the transmission pan. Fluid is then drawn through the filter and internal passages into the oil pump assembly. The oil pump pressurizes the fluid into main-pressure that is regulated at the main-pressure regulator valve. From this point, fluid is directed to the F trim solenoid and to the control-main regulator and control-main relief valve into the control-main filter assembly and on to all solenoids for use as control pressure. Hot fluid leaving the torque converter is routed through the converter flow valve to cooler lines and into the cooler assembly. The transmission oil cooler is located in the radiator. The vehicle may be equipped with an auxiliary oil cooler. The cooled fluid is returned to the transmission through the return cooler line and to the transmission lube circuit. The automatic transmission fluid temperature (TFT) sensor, which is part of the PSM, is located in the oil pan. If the Transmission Control Module (TCM) detects a high TFT for an extended period of time, then DTC P0218 sets. 5–24

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Running the DTC •

DTCs P0711, P0712, P0713 are not active.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Engine speed is greater than 200 rpm for more than 5 seconds.

Conditions for Setting the DTC DTC P0218 sets when the TCM detects a transmission sump temperature greater than 126°C (252°F) for 10 seconds. Action Taken When the DTC Sets •

The TCM does not illuminate the CHECK TRANS light.

•

The TCM freezes shift adapts (DNA).

•

The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM stores this information as Failure Records.

•

DTC P0218 is stored in the TCM history.

•

The TCM defaults to “hot mode” shift schedule where 4th-range is held and TCC is inhibited to increase engine speed and improve cooler flow.

Conditions for Clearing the DTC/CHECK TRANS Light •

A Scan Tool may be used to clear the code from the TCM history.

•

The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

•

The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes test.

Diagnostic Aids •

Verify the customer’s driving habits, such as trailer towing, etc.

•

The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then stabilize.

•

DTC P0218 may set after DTC P0711 (not active) has set. Follow the diagnostic table for DTC P0711 before proceeding to the diagnostic for DTC P0218. Repairing the condition that set DTC P0711 will likely eliminate DTC P0218.

Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step inspects for air restriction and loss of transmission fluid flow, causing an extremely high TFT. 4. This step tests main-pressure. 5. This step inspects for a stuck torque converter stator.

DTC P0218 Transmission Fluid Over Temperature Condition Step Action Was the Beginning The Troubleshooting Process 1 (Paragraph 5–4A) performed?

Yes Go to Step 2

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) 5–25

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0218 Transmission Fluid Over Temperature Condition (cont’d) Step Action 1. Install the Scan Tool. 2 2. Turn ON the ignition, with the engine OFF. 3. Record the Failure Record data. 4. Clear the DTC. 5. Perform the A/T Fluid Checking Procedure (Appendix P). Was the A/T fluid level check performed? 1. Inspect the engine cooling system for the following 3 conditions: • Air flow restrictions • Air flow blockage • System fluid level and condition • Debris 2. Inspect the transmission cooling system for the following conditions: • Air flow restrictions • Air flow blockage • System fluid level and condition • Debris • Damaged cooler lines or hoses Did you find and correct the condition?

Yes Go to Step 3

No Go to A/T Fluid Checking Procedure. (Appendix P)

Go to Step 6

Go to Step 4

Perform the Main Pressure Check Procedure. Refer to Appendix B. Did you find and correct a pressure problem? Check for a possible torque converter stator malfunction. A stuck stator would be indicated by no cool-down in neutral after stalling the transmission. Refer to Section 7. Did you find and correct the condition? Perform the following procedure in order to verify your repair: 1. Clear the DTC. 2. Using the Scan Tool, monitor the transmission fluid temperature. 3. Operate the vehicle under the following conditions. 4. Turn ON the ignition, with the engine OFF. 5. The TFT must be less than 126°C (258°F) for at least 10 seconds. 6. Using the Scan tool, verify that the test to detect this code has run. Has the test run and passed?

Go to Step 6

Go to Step 5

Go to Step 6

Go to General Troubleshooting (Section 7)

Begin the diagnosis again. Go to Step 1

System OK

4

5

6

5–26

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0561 Unrealistic Variations in Vehicle System Voltage J1 HARNESS CONNECTOR (GRAY)

TCM

J1-4 J1-3 J1-2 J1-1

J1-5

J2 J1

102 104 103

10a 10a

101

IGN SWITCH

105

+

J1-2 J1-4

IGNITION POWER

J1-3

BATTERY POWER

J1-1

GND

J1-5

GND

TCM

—

12V/24V BATTERY V06215.01.00

Circuit Description The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in the J1 connector at the TCM. Battery direct voltage is supplied to pin 103 at the J1 connector. Conditions for Running the DTC • •

The test becomes enabled when the engine has been running above 400 rpm for at least 0.5 seconds. The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC P0561 sets when the TCM detects a large variation in ignition voltage or battery direct voltage. When an ignition or battery direct voltage variation of 4.0V or greater is detected for 0.5 seconds, a fault pending is reported. After 1.0 second of 4.0V or greater variation, a DTC is set with a failure response. Action Taken When the DTC Sets When DTC P0561 is active, the following conditions will occur: • • •

DTC P0561 is stored in the TCM history. Hydraulic default is commanded. Shift selector position and hydraulic state of logic valves determine the range attained. The CHECK TRANS light illuminates. Copyright© 2004 General Motors Corp.

5–27

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

You may have to drive the vehicle in order to experience a fault.

•

This DTC indicates a variation in ignition voltage or battery direct voltage. Common ignition circuit problems for this DTC are a fault in the feed wires to the TCM, a defective ignition switch, or a large vehicle accessory load on the ignition circuit. Battery direct voltage problems may be due to loose or corroded battery cables, a bad connection at the battery direct feed terminal (103), or an internal TCM failure due to a burnt trace.

•

A vehicle charging system failure may cause this DTC under certain circumstances.

•

This code may indicate that an internal voltage problem has occurred inside the TCM. The use of a substitute TCM would be a good way to diagnose this problem.

•

A defective vehicle battery may induce this DTC.

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for an active DTC after clearing. 3. This step tests for the proper battery direct input voltage. 4. This step tests for the proper ignition input voltage. 5. This step tests for shorts or open conditions at battery direct input circuit. 6. This step tests for shorts or open conditions at ignition input circuit.

DTC P0561 Unrealistic Variations in Vehicle System Voltage Step 1

5–28

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Value(s)

Copyright© 2004 General Motors Corp.

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0561 Unrealistic Variations in Vehicle System Voltage Step 2

1. 2. 3. 4. 5. 6.

Action Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start vehicle and test drive. Duplicate same operating conditions observed in failure records.

Value(s) —

Yes Go to Step 3

No Go to Step 4

11.5–12.5V

Go to Step 4

Go to Step 5

11.5–12.5V

Go to Diagnostic Aids

Go to Step 6

—

Go to Step 8

Go to Step 7

NOTE: This DTC indicates that a voltage variation exists in the ignition voltage or at the battery direct input. This variation is measured from min. and max. voltage values. If the voltage variation is present for a pre-determined amount of time, this DTC sets. 3

4

5

Did DTC P0561 return? 1. Turn the ignition OFF. 2. Disconnect TCM connector J1 (gray) at the TCM. 3. Install J 39700 Breakout Box and J 43799 Adapter box at the J1 connector. 4, Using a digital multimeter (DVOM), measure voltage at J1 connector pin 1 and pin 3. Is the voltage within the specified value? 1. Using a digital multimeter (DVOM), sequentially measure voltage at J1 connector pins 2 and 4 using J1 connector pins 1 or 5 as ground return. 2. Turn ON the ignition, with the engine OFF. Is the voltage within the specified value? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Inspect battery direct circuit 103 for one of the following conditions: • Intermittent open or short. • Loose or corroded connections at battery or connection points. • Defective battery. Was one of these conditions discovered and repaired?

Copyright© 2004 General Motors Corp.

5–29

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0561 Unrealistic Variations in Vehicle System Voltage Step 6

7

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Inspect the TCM ignition input circuit for one of the following conditions: • Intermittent open or short at ignition input circuits 101, 102, 103, or 104. • Loose or corroded connections at ignition switch or ignition relay assembly. • Defective ignition switch or relay. • Loading of ignition circuit by defective vehicle accessories. Was one of these conditions discovered and repaired? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 8

No Go to Step 7

—

Go to Step 8

—

—

Begin the diagnosis again. Go to Step 1

System OK

Replace the TCM. Is the replacement complete? 8

5–30

In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions shown in failure records. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0562 System Voltage Low J1 HARNESS CONNECTOR (GRAY)

TCM

J1-4 J1-3 J1-2 J1-1

J1-5

J2 J1

102 104 103

10a 10a

101

IGN SWITCH

105

+

J1-2 J1-4

IGNITION POWER

J1-3

BATTERY POWER

J1-1

GND

J1-5

GND

TCM

—

12V/24V BATTERY V06215.01.00

Circuit Description The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in the J1 connector at the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

The engine speed is greater than 450 rpm for 10 seconds.

Conditions for Setting the DTC DTC P0562 sets when the TCM detects the following condition: •

12 volt TCM — Ignition voltage is detected below 8V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage threshold is temperature dependent varying from 5V at –60°C (–75°F) to 9V at 20°C (68°F).

•

24 volt TCM — Ignition voltage is detected below 17V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage threshold is temperature dependent varying from 14V at –60°C (–75°F) to 18V at 20°C (68°F). Copyright© 2004 General Motors Corp.

5–31

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets • • • •

• • •

If the DTC is active while vehicle is in a forward range, transmission shifts to neutral, 1st, 3rd, or 5th range. If the DTC is active while in reverse or neutral, transmission shifts to neutral. If the shift selector is moved to forward range, transmission shifts to neutral, 1st, 3rd, or 5th range. If the shift selector is moved to reverse or neutral, transmission shifts to neutral. Diagnostic response honors the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, transmission shifts to neutral range. If PRNDL is correct, GPI request is responded to. The CHECK TRANS light is illuminated. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids • • • •

A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and load capacity. A defective vehicle charging system may cause this DTC. Vehicle components such as an ignition switch or TCM ignition relay may cause this DTC to set and not be active, this indicates that an intermittent condition may exist in these components. Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition input voltage. 3. This step tests for an active DTC after clearing. 4. This step tests vehicle battery per OEM guidelines. 5. This step tests vehicle charging system per OEM guidelines.

DTC P0562 System Voltage Low Step 1

5–32

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0562 System Voltage Low (cont’d) Step 2

1. 2. 3. 4. 5.

Action Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Inspect the ignition voltage value on the Scan Tool.

NOTE: This DTC sets when ignition voltage drops below a predetermined level that is temperature dependent for 5 out of 7 seconds. 3

4

5

6

Is the ignition voltage below specified value? 1. Start the vehicle, if possible. 2. If the DTC is not active, drive the vehicle. Attempt to duplicate the same operating conditions observed in the failure records. Did the DTC return? Test the vehicle battery per OEM instructions. This should include a voltage test and a load test. Does test indicate the battery is good? Test the vehicle charging system per the OEM recommended testing procedure. Is the charging system operating properly? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions shown in the failure records when the DTC set. Did the DTC return?

Value(s) Voltage should be above 9V (12V TCM) or 18V (24V TCM) at 20°C (68°F). See conditions for setting the DTC.

Yes Go to Step 4

No Go to Step 3

—

Go to Step 4

Go to Diagnostic Aids

See OEM for correct battery specifications

Go to Step 5

Replace the vehicle battery and go to Step 6

See OEM for correct charging system specifications —

Go to Diagnostic Aids

Repair the charging system and go to Step 6

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

5–33

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0563 System Voltage High

J1 HARNESS CONNECTOR (GRAY)

TCM

J1-4 J1-3 J1-2 J1-1

J1-5

J2 J1

102 104 103

10a 10a

101

IGN SWITCH

105

+

J1-2 J1-4

IGNITION POWER

J1-3

BATTERY POWER

J1-1

GND

J1-5

GND

TCM

—

12V/24V BATTERY V06215.01.00

Circuit Description The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in the J1 connector at the TCM. Conditions for Running the DTC • The engine speed is greater than 450 rpm for one second. • The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Conditions for Setting the DTC DTC P0563 sets when the TCM detects the following condition: • •

12 volt TCM — Ignition voltage is above 18V for 6 out of 10 seconds. 24 volt TCM — Ignition voltage is above 32V for 6 out of 10 seconds.

5–34

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

If the DTC is active while the vehicle is in a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th range.

•

If the DTC is active while in reverse or neutral, the transmission shifts to neutral.

•

If the shift selector is moved to a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th range. If the shift selector is moved to reverse or neutral, the transmission shifts to neutral. Diagnostic response honors the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, the transmission shifts to neutral range. If PRNDL is correct, the GPI request is responded to.

•

The CHECK TRANS light is illuminated.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

A defective vehicle charging system that is overcharging may cause this DTC.

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition input voltage. 3. This step tests for an active DTC after clearing. 5. This step tests vehicle charging system per OEM guidelines.

DTC P0563 System Voltage High Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) 5–35

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0563 System Voltage High (cont’d) Step 1. 2 2. 3. 4. 5.

Action Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start vehicle engine and inspect the ignition voltage value on the Scan Tool.

Value(s) See Conditions for Setting the DTC

Yes Go to Step 4

No Go to Step 3

—

Go to Step 4

Go to Diagnostic Aids

—

Go to Diagnostic Aids

Repair the charging system and go to Step 5

—

Begin the diagnosis again. Go to Step 1

System OK

NOTE: This DTC sets when ignition voltage is detected above 18V for 12V systems or 32V for 24V systems for 6 out of 10 seconds. 3

4

5

5–36

Is the ignition voltage above specified value? 1. Start the vehicle, if possible. 2. If the DTC is not active, drive the vehicle. Attempt to duplicate the same operating conditions observed in failure records. Did the DTC return? Test the vehicle charging system per the OEM recommended testing procedure. Is the charging system operating properly? In order to verify your repair: 1. Clear DTC. 2. Drive vehicle under conditions shown in failure records when DTC set. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0602 TCM Not Programmed

NO SCHEMATIC FOR THIS DTC Circuit Description At the power up and after clearing codes, the Transmission Control Module (TCM) performs a self-test to determine if the calibration in memory is valid. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

This test will run before any TCM functions.

Conditions for Setting the DTC DTC P0602 sets if the TCM determines the present calibration is invalid. Action Taken When the DTC Sets •

DTC P0602 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM returns to the boot program, and then waits to be recalibrated.

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light TCM must be recalibrated.

DTC P0602 TCM Not Programmed Step Action Was the Beginning The Troubleshooting Process 1 (Paragraph 5–4A) performed?

2

3

4

1. Install the Scan Tool. 2. If DTC P0602 is present, the TCM must be recalibrated. Is recalibration complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is replacement complete? 1. Install the Scan Tool. 2. Start the vehicle. Did the DTC return?

Yes Go to Step 2

Go to Step 4

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) —

Go to Step 4

—

Go to Step 3

System OK

Copyright© 2004 General Motors Corp.

5–37

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0606 Controller Internal Performance

NO SCHEMATIC FOR THIS DTC Circuit Description The Transmission Control Module (TCM) completes numerous scheduled tasks during normal operation. If one of the scheduled tasks fails to complete within a specific time limit the TCM will re-attempt this task. NOTE:

The presence of DTC P0606 indicates a TCM software error has occurred and the Allison Transmission Service Department should be contacted at 1-800-252-5283.

Conditions for Running the DTC The components are powered and ignition voltage is greater than 9V and less than 18V for a 12V TCM, or greater than 18V and less than 32V for a 24V TCM. This test is run during the entire ignition cycle. Conditions for Setting the DTC DTC P0606 sets if a task fails to complete after two consecutive attempts. Action Taken When the DTC Sets • When DTC P0606 is active, the transmission will lock in N (Neutral). • DTC P0606 is stored in the TCM history. • The CHECK TRANS light illuminates. • The TCM freezes shift adapts (DNA). • The TCM inhibits TCC engagement. Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure.

5–38

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0614 Torque Control Data Mismatch — ECM/TCM

NO SCHEMATIC FOR THIS DTC Circuit Description Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from the engine controller. By reducing torque, shifts can be made quicker, at a more consistent output torque which reduces clutch temperatures and increases clutch life. When an engine torque rating exceeds 580 lb ft, Lower Range Torque Protection (LRTP) is used. This feature limits engine torque in lower ranges to protect the transmission from damage if a stall condition occurs. Conditions for Running the DTC •

No DTC U2105 CAN bus error.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

•

This test runs for 30 seconds for the first 20 engine starts after the engine is detected on the J1939 CAN.

•

Engine must be identified by the TCM as an approved make and model.

•

Engine’s torque configuration message (peak torque) must be greater than allowed without SEM (above 580 lb ft gross input torque).

NOTE:

Unapproved engines or low torque engines will operate without setting a P0614.

Conditions for Setting the DTC P0614 sets when the TCM detects one of the following conditions: •

TCM detects a valid engine having the proper torque rating but ECM software is not supporting all the messaging necessary for SEM.

•

TCM detects a valid engine having a torque rating exceeding 580 lb ft that does not support Lower Range Torque Protection (LRTP) messaging.

NOTE:

Valid engines with a torque rating exceeding 580 lb ft must have software that is compatible with LRTP or a P0614 is set.

Action Taken When the DTC Sets •

DTC P0614 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

If the TCM and engine ECM software are not compatible, the transmission will be restricted to reverse, neutral, first range, or third range.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests for an incompatible engine calibration. 5. This step tests for the proper engine torque limit.

DTC P0614 Torque Control Data Mismatch — ECM/TCM Step 1

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Value(s) —

Yes Go to Step 2

—

Go to DTC U2105 and resolve before proceeding to Step 7 Go to Step 4

2

If a DTC U2105 is present, troubleshoot and resolve before going to the next step. Is a DTC U2105 present?

3

Using the Scan tool, refer to the Transmission/ Scan Tool Engine shift energy management (SEM) indicates with Yes compatibility and the Lower Range Torque or No Answer Protection compatibility display. Is the ECM shown as being incompatible with TCM request for SEM or LRTP? This indicates that engine software does not — support shift energy management for either SEM or LRTP. Have the OEM install the proper engine software and calibration to support SEM. Is the proper software and calibration installed?

4

5

6

7

5–40

Using Scan Tool, refer to the engine torque Scan Tool rating display. indicates with Yes or No Answer Is the torque rating displayed as acceptable? This indicates that engine torque values are — above the transmission ratings set in the TCM calibration. Inspect the TCM for proper software and calibration to support SEM. If the proper TCM software and calibration are installed, the engine rating is too high for the transmission. Recalibrate the engine to a lower torque rating. Was one of the above conditions found and resolved? In order to verify your repair: — 1. Connect the Scan Tool. 2. Clear the DTC. 3. Drive the vehicle under normal operating conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

Go to Step 5

Go to Step 7

—

Go to Step 7

Go to Step 6

Go to Step 7

—

Begin the diagnosis again. Go to Step 1

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0701 Transmission Control System Performance

NO SCHEMATIC FOR THIS DTC Circuit Description The Transmission Control Module (TCM) monitors the status of the pressure switches at start-up to detect the presence of hydraulic pressure. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).

•

Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

•

This test is run after engine start-up and runs as part of the transmission hydraulic initialization.

Conditions for Setting the DTC DTC P0701 sets when transmission fluid temperature is above –25°C (–13°F) with an engine speed above 500 rpm for 6 seconds or 400 rpm for 15 seconds and forward or reverse range is selected and all the pressure switches do not indicate pressure. Action Taken When the DTC Sets •

DTC P0701 is stored in the TCM history.

•

The TCM inhibits TCC engagement.

Conditions for Clearing the MIL/DTC A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure. Diagnostic Aids •

DTC P0701 may be logged if a forward or reverse range is selected immediately after the engine is started and before the TCM detects pressure at the switches (2 to 6 seconds after engine start).

•

A plugged control main filter may cause this code to set. The control main filter is to be changed after the first 8000 km (5,000 miles). Failure to change the filter at this interval may cause this code and other pressure switch codes to set.

•

A cracked internal suction filter tube or damaged tube seal may cause this DTC to set.

•

A stuck lube regulator valve (located in the front support) may cause this DTC to set. A high static oil level with the vehicle running is often a good indication of this complaint. Often pressure switch DTCs are set in this scenario.

•

You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 5. This step tests for main pressure.

Copyright© 2004 General Motors Corp.

5–41

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0701 Transmission Control System Performance Step 1

2

3

4 5

6

7

5–42

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Yes Go to Step 2

1. Install the Scan Tool. 2. Turn the ignition to ON, with the engine OFF. 3. Record the DTC Failure Record data. 4. Clear the DTC. 5. Start the engine; Check the Transmission Fluid Level. Is the fluid at the appropriate level? This DTC can be set after performing fluid service and filter change, after replacement of the PSM, or after a long period of storage. Have any of these conditions occurred? Add fluid to the proper level. Is the fluid at the appropriate level? Check main pressure (refer to Main Pressure Check Procedure — Appendix B). Is the pressure within the specified value?

Go to Step 3

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 4

Go to Step 7

Go to Step 5

Go to Step 5

—

Go to Step 7

Go to Step 6

Go to Step 7

Go to General Troubleshooting (Section 7)

Go to Step 1

System OK

No main pressure at idle may be an indication of the following: • Stuck or sticking lube regulator valve • Stuck or sticking main pressure regulator valve • Loose or damaged suction filter • Defective suction filter seal Was the reason for no main pressure condition found and repaired? In order to verify your repair: 1. Clear the DTC. 2. Start the vehicle. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0703 Brake Switch Circuit Malfunction

TCM J1 HARNESS CONNECTOR (GRAY)

J1-14*

J1-7**

J2 J1-28*

J1

TCM 114

J1-14

128

DIGITAL INTERFACE

J1-28

*NOTE: Brake signal provides ground

TCM SWITCHED POWER

107

J1-7

DIGITAL INTERFACE

**NOTE: Brake signal provides power V06216.01.00

Circuit Description A mechanical switch attached to the brake pedal sends a signal to the Transmission Control Module (TCM) indicating the service brake has been applied. This signal is either ignition voltage or a ground signal depending on the calibration installed in the TCM. P0703 is a type C DTC. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).

•

No DTC P0721 or P0722.

Conditions for Setting the DTC The TCM sets a DTC when either of the following conditions occur: •

The vehicle has accelerated 10 or more times with TCM input indicating brakes applied.

•

Decelerated 10 or more times with TCM input indicating brakes released. Copyright© 2004 General Motors Corp.

5–43

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken when the DTC Sets •

No Grade Braking allowed.

•

Use the default assumption that the brake is off.

•

TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC active. Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: •

A bent terminal.

•

A backed-out.

•

A damaged terminal.

•

Poor terminal tension.

•

A chafed wire.

•

A broken wire inside the insulation.

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

DTC P0703 Brake Switch Circuit Malfunction Step Action Was the Beginning The Troubleshooting 1 Process (Section 5-4A) Performed?

2

3

4

5–44

1. Install the Scan Tool. 2. Turn the ignition ON, with the engine OFF. 3. Record the DTC Failure Record Data. 4. Apply and release the service brake. Does the Scan Tool indicate that brake switch is toggling off and on? 1. Using a DVOM, probe pin 5 and pin 7 on the C1 connector. 2. Apply and release the service brake. 3. There should be no voltage reading at pin 7 when the brake is applied, with the brake released there should be 12V. Was voltage reading proper according to brake status? 1. Go to the Stop Lamp Switch, with a DVOM probe pin C at the switch, supply a ground connection at other lead. 2. Apply and release the service brake. Is the switch turning voltage ON and OFF?

Value

Yes Go to Step 2

Go to Diagnostic Aids

No Go to Beginning The Troubleshooting Process (Paragraph 5–4a) Go to Step 3

Battery +

Go to Step 8

Go to Step 4

Battery +

Go to Step 6

Go to Step 5

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0703 Brake Switch Circuit Malfunction Step Action Using a DVOM, check the voltage at pin D on 5 the input side of the Stop Lamp Switch. Is voltage available at the input side of the Stop Lamp Switch? Replace the TCC Brake Switch/Cruise Control 6 harness. Is repair complete? Repair or replace the Stop Lamp Switch 7 assembly. Is repair complete? NOTE: In most cases, the TCM is not at fault. 8 Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

9

Value

Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle making at lease 10 accelerations and decelerations cycles. Did the test run and pass?

Copyright© 2004 General Motors Corp.

Yes Go to Step 7

No Resolve voltage problem

Go to Step 9

Go to Step 9

Go to Step 9

Begin the diagnosis again. Go to Step 1

System OK

5–45

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0708 Transmission Range Sensor Circuit High Input J2 HARNESS CONNECTOR (RED) J2-7 J2-8

TCM

J2-6 J2-5

J2 J2-20

J1 4-PIN AND 7-PIN

NSBU SWITCH P

4C

8

C

4B

6

B

4D

4

A

4A

5

7D

7

208 207 206 205 220

TCM

J2-8 J2-7

DIGITAL INTERFACE

J2-6 J2-5 J2-20

GND

12-PIN SINGLE CONNECTOR NSBU

FORMER NSBU SWITCH 4- AND 7-PIN

CURRENT NSBU SWITCH 12-PIN

V06217.01.00

Circuit Description The installation of a transmission-mounted Neutral Start/Back-Up (NSBU) switch is required. This switch mounts directly onto the transmission housing from the outside and detects the angular position of the shift selector shaft. This position is communicated to the Transmission Control Module (TCM) so that certain vehicle control functions can be coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to alert the TCM in the event of a single wire or switch failure. The neutral signal output of the NSBU switch is typically used as confirmation that the transmission is in N (Neutral) before the engine starter is engaged. The NSBU switch is interfaced to the starter circuit with weatherproof electrical connectors. The reverse signal provision may be used to activate vehicle back-up lights and/or reverse warning devices. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V.

•

Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

5–46

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC — Software Levels Prior To N11 DTC P0708 sets when the TCM detects an invalid condition or parity errors occurring over consecutive ignition cycles. Actions Taken When the DTC Sets — Software Levels Prior To N11 •

The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default mode or “limp home”. Shift selector and hydraulic state of logic valves determines range attained.

•

DTC P0708 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM inhibits TCC engagement.

•

Due to this failure and associated responses, P0722 and P0845 may also set.

Action Taken When the DTC Sets — Software Level N11 And Later •

The CHECK TRANS light illuminates but no diagnostic response is implemented until after 50 warm-up cycles occur when a NSBU switch parity error is active. A warm-up cycle is defined as a 20 degree change in transmission temperature.

•

The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default mode or “limp home.” Shift selector and hydraulic state of logic valves determines range attained.

•

DTC P0708 is stored in the TCM history.

•

The TCM inhibits TCC engagement.

•

Due to this failure and associated responses, P0722 and P0845 may also set.

•

A shift to R (Reverse) will allow reverse range if a P0876 (previously P1714) is not active.

Conditions for Clearing the MIL/DTC A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

You may have to drive the vehicle in order to experience a fault.

•

When a P0708 is shown in failure records, this indicates that conditions to set a P0708 were present at one time. If the condition was due to moisture intrusion, the moisture may no longer be present, and thus you may not be able to reproduce the DTC. In such case, variables such as vehicle mileage, external physical condition of the switch should be factored in when making a decision to replace the NSBU switch.

NOTE:

Due to the TCM logic used to detect and set a P0708, this code can remain active even after a NSBU switch replacement is complete and the ignition has been cycled. It is important to clear all active DTCs from the TCM after servicing the NSBU switch. Copyright© 2004 General Motors Corp.

5–47

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests NSBU switch status. 4. This step tests for proper TCM input response. 5. This step tests the wiring harness for opens or shorts.

DTC P0708 Transmission Range Sensor Circuit High Input Step 1

2 3

4

5

6

5–48

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Value(s) —

Is the NSBU switch and shift linkage properly — adjusted? Refer to NSBU 1. Install the Scan Tool. Switch Table 2. Turn the ignition ON with the engine OFF. (Page 5–9) 3. Record the DTC Failure Record data. 4. Using the Scan Tool, monitor PRNDL A, B, C, P status while moving the shift selector through each range. Does each switch toggle ON and OFF in the correct sequence, and does the range selected displayed on the Scan Tool match the actual physically selected range? 1. Turn the ignition OFF. A=pin 5 B=pin 6 2. Disconnect J2 connector from the TCM and C=pin 7 install J 39700 Breakout Box and J 43799 P=pin 8 Breakout Box Adapter. 3. Disconnect the NSBU 4-pin connector and Scan Tool Status the NSBU 7-pin connector. ON=Open circuit 4. Turn the ignition ON. 5. In sequence, connect J2 connector pin 20 to OFF=Grounded circuit J2 pins 5, 6, 7, and 8. 6. Monitor the switch status on the Scan Tool. Does each switch toggle ON and OFF in the correct sequence as each pin is grounded? Inspect the NSBU switch connector assembly. Does the NSBU have two connectors—a seven pin and four pin connector? 1. Turn the ignition OFF. Scan Tool Status ON=Open circuit 2. Reconnect J2 connector to the TCM. OFF=Grounded 3. In sequence, connect pins 4A, 4B, 4C, and circuit 4D at the 4-pin NSBU connector to pin 7D** on the NSBU 7-pin connector. * 7D=wire 220 4. Monitor the switch status on the Scan Tool. Does the Scan Tool indicate the proper switch status for each switch when grounded? Copyright© 2004 General Motors Corp.

Yes Go to Step 2

Go to Step 3 Go to Diagnostic Aids

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Mechanic’s Tips Go to Step 4

Go to Step 5

Go to Step 10

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0708 Transmission Range Sensor Circuit High Input (cont’d) Step 7

8

9

Action 1. Turn the ignition OFF. 2. Reconnect J2 connector to the TCM. 3. At the NSBU connector in sequence, connect pins 4, 5, 6, and 8 to pin 7** at the 12 pin connector. 4. Monitor the switch status on the Scan Tool. Does the Scan Tool indicate the proper switch status for each switch when grounded? Replace the NSBU switch (refer to Mechanic’s Tips). Is the replacement complete? Repair the vehicle wiring harness.

Value(s) Scan Tool Status ON=Open circuit OFF=Grounded circuit

Yes Go to Step 8

No Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

Refer to NSBU Switch Table (Page 5–9)

Begin the diagnosis again. Go to Step 1

System OK

7D=wire 220

NOTE: The vehicle OEM has responsibility for all external wiring, wherefore the OEM should perform vehicle harness repairs. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. 10

11

Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor PRNDL switch status while moving selector through all positions. Does each switch toggle according to switch table?

* If J 39700 Breakout Box and J 44722 Transmission Harness are available, they may be used to perform this operation. ** Use pin H at the magnetic overlay to provide a ground source when J 44722 Harness is used.

Copyright© 2004 General Motors Corp.

5–49

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED)

H

J2-10

G J2-20

TCM

TRANSMISSION BULKHEAD CONNECTOR H J2 G

J1

NOTE: Letters I, O, and Q are not used. C

A

D

B

E

C

R

D

G

210

J2-10

HI

TCM

TRANSMISSION E F

H

E

J2-20

LO

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

220

D C

F E D C B A V06214.01.00

Circuit Description The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference signal to the TFT sensor and measures the voltage drop in the circuit. When the transmission is cold, the sensor resistance is high and the TCM detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality and to determine torque converter clutch applies. If the TCM detects the TFT sensor resistance has no change, an unrealistic change in a short amount of time, or multiple changes within seconds, DTC P0711 sets. 5–50

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Running the DTC •

No DTC P0721, P0722, P0717, P0716, P0713, or P0712.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

The engine speed is greater than 200 rpm for more than 5 seconds.

•

The engine speed is greater than 450 rpm for more than 2 seconds with output speed of 100 rpm or above. This would indicate that a range is selected.

•

A valid start-up temperature is detected.

Conditions for Setting the DTC DTC P0711 sets when the TCM detects one of the following conditions: •

The TCM detects a temperature change that is under a set limit when compared to samples of the minimum and maximum temperature values.

•

The TFT has an unrealistic temperature change of more than 10°C (50°F) for 10 occurrences.

•

The temperature from start up decreases 40°C (104°F) or more within duration of 6 or more seconds.

Action Taken When the DTC Sets •

The TCM does not illuminate the CHECK TRANS light.

•

The TCM stores DTC P0711 in TCM history.

•

The TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light •

A Scan Tool may be used to clear the code from the TCM history.

•

The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

•

The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids •

The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then stabilize.

•

DTC P0218 may set after DTC P0711 has set. Follow the diagnostic table for DTC P0711 before proceeding to the diagnostic for DTC P0218.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper AT fluid level and condition. 3. This step tests for the proper reference voltage. 4. This step verifies which condition has set DTC P0711. 5. This step tests the resistance value of the internal wiring harness and TFT sensor. 6. This step tests for opens and shorts in the main wiring harness. 8. This step tests the resistance value of the internal TFT sensor. Copyright© 2004 General Motors Corp.

5–51

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

Value(s) —

Yes Go to Step 2

—

Go to Step 4

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P) Go to Step 11

2

Perform the A/T Fluid Checking Procedure (Appendix P). Is the transmission fluid level correct?

3

1. Turn the ignition OFF. 2. Disconnect J2 connector at the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. With the engine OFF, turn the ignition to the ON position, Measure voltage between J2 connector pins 10 and 20. Is voltage within the specified value?

4.75–5.25V

Go to Step 4

4

1. Install the Scan Tool. 2. With the engine OFF, turn the ignition to the ON position. 3. Record the failure records. 4. Clear the DTCs. 5. Monitor the TFT on the Scan Tool. 6. Drive the vehicle and observe the Scan Tool for one of the following conditions: • No transmission temperature change. • An unrealistic transmission temperature change of greater than 1.5°C in (2.7°F) in one second. Did either of these conditions occur? 1. Disconnect the wiring harness from the main transmission connector. 2. Using a DVOM, measure resistance at main transmission connector pins G and H.* Is resistance within the specified values?

1.5°C (2.7°F)

Go to Step 5

Go to Diagnostic Aids

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 6

Go to Step 8

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 7

5

6

5–52

1. Reconnect the wiring harness to the main transmission connector. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 10 and 20.* Is resistance within the specified values?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance (cont’d) Step Action NOTE: The vehicle OEM has responsibility 7 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

8

9

10 11

12

Have the vehicle wiring harness repaired. Is the repair complete? 1. Remove the oil pan. 2. Disconnect the PSM from the internal wiring harness. 3. Using a DVOM, measure PSM resistance at pins E and F. Is resistance within the specified values? Replace the internal wiring harness (refer to Mechanic’s Tips). Is the replacement complete? Replace the PSM (refer to Mechanic’s Tips). Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Using the Scan Tool, monitor the transmission fluid temperature. 3. Drive the vehicle under normal operating conditions. Look for significant changes in TFT. Did the DTC return?

Value(s) —

Yes Go to Step 12

No —

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 9

Go to Step 10

—

Go to Step 12

—

—

Go to Step 12

—

—

Go to Step 12

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

5–53

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED)

H

J2-10

G J2-20

TCM

TRANSMISSION BULKHEAD CONNECTOR H J2 G

J1

NOTE: Letters I, O, and Q are not used. C

A

D

B

E

C

R

D

G

210

J2-10

HI

TCM

TRANSMISSION E F

H

E

J2-20

LO

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

220

D C

F E D C B A V06214.01.00

Circuit Description The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality and to determine torque converter clutch applies. If the TCM detects a continuous short to ground in the TFT sensor or signal circuit, DTC P0712 is set. 5–54

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Running the DTC •

No TFT sensor DTC P0711 or P0713.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

The engine is greater than 200 rpm for more than 5 seconds.

•

The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

Conditions for Setting the DTC DTC P0712 sets when the TFT sensor indicates a voltage of less than 313mV for 2.5 seconds. Action Taken When the DTC Sets •

The TCM does not illuminate the CHECK TRANS light.

•

The TCM stores DTC P0712 in TCM history.

•

TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light •

A Scan Tool may be used to clear the code from the TCM history.

•

The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

•

The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

A short to ground on wire 210 may allow a code P0712 to set. A default value of 160°C (320°F) TFT on the Scan Tool would be a good indication this has occurred.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper AT fluid level and condition. 3. This step tests for the proper reference voltage. 4. This step verifies which condition has set DTC P0712. 5. This step tests the resistance value of the internal wiring harness and TFT sensor. 6. This step tests for opens and shorts in the main wiring harness. 8. This step tests the resistance value of the internal TFT sensor. Copyright© 2004 General Motors Corp.

5–55

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P) Go to Step 11

2

Perform the A/T Fluid Checking Procedure (Appendix P). Is the transmission fluid level correct?

3

1. Turn the ignition OFF. 2. Disconnect J2 connector at the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter at J2 connector. 3. With the engine OFF, turn the ignition to the ON position. Measure voltage at J2 connector pins 10 and 20. Is voltage within the specified value?

4.75–5.25V

Go to Step 4

4

1. Install the Scan Tool. 2. With the engine OFF, turn the ignition to the ON position. 3. Record the Failure Record data. 4. Clear the DTC. 5. Select TFT on the Scan Tool. Drive the vehicle and inspect for unrealistic TFT readings. Is the TFT reading at or above the specified value? This DTC may indicate a short to ground at wire 210. 1. Disconnect the wiring harness from the main transmission connector. 2. Using a DVOM, measure resistance at main transmission connector pins G and H.* Is resistance within the specified values?

150°C (302°F)

Go to Step 5

Go to Diagnostic Aids

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 6

Go to Step 8

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 7

5

6

5–56

1. Reconnect the wiring harness to the main transmission connector. 2. Disconnect J2 connector from the TCM. 3. Using a DVOM, measure resistance at J2 connector pins 10 and 20. Is the resistance within the specified values?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) (cont’d) Step Action NOTE: The vehicle OEM has responsibility 7 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

8

9

10 11

12

Have the vehicle wiring harness repaired. Is the repair complete? 1. Remove the oil pan. 2. Disconnect the PSM from the internal wiring harness. 3. Using a DVOM, measure PSM resistance at pins E and F. Is resistance within the specified values? Replace the internal wiring harness (refer to Mechanic’s Tips). Is the replacement complete? Replace the PSM (refer to Mechanic’s Tips). Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Using the Scan Tool, monitor the transmission fluid temperature. 3. Drive the vehicle under normal operating conditions making sure coolant temperature is over 20°C (68°F). 4. Watch for significant change in TFT. Did the DTC return?

Value(s) —

Yes Go to Step 12

No —

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 9

Go to Step 10

—

Go to Step 12

—

—

Go to Step 12

—

—

Go to Step 12

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

5–57

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature)

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED)

H

J2-10

G J2-20

TCM

TRANSMISSION BULKHEAD CONNECTOR H J2 G

J1

NOTE: Letters I, O, and Q are not used. C

A

D

B

E

C

R

D

G

210

J2-10

HI

TCM

TRANSMISSION E F

H

E

J2-20

LO

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

220

D C

F E D C B A V06214.01.00

Circuit Description The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality and to determine torque converter clutch applies. If the TCM detects a continuous open or short-to-power in the TFT sensor or signal circuit, DTC P0713 sets. 5–58

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Running the DTC •

No DTC P0711 or P0712.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Engine speed is greater than 200 rpm for more than 5 seconds.

•

The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

Conditions for Setting the DTC DTC P0713 sets when the TCM detects a voltage greater than 4.84V for 2.5 seconds. Action Taken When the DTC Sets •

The TCM does not illuminate the CHECK TRANS light.

•

The TCM stores DTC P0713 in TCM history.

•

TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light •

A Scan Tool may be used to clear the code from the TCM history.

•

The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

•

The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

An open or a short to power at wire 210 may allow DTC P0713 to set. A default value of –60°C (–76°F) would be a good indication this has occurred.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper AT fluid level and condition. 3. This step tests for the proper reference voltage. 4. This step verifies which condition has set DTC P0713. 5. This step tests the resistance value of the internal wiring harness and TFT sensor. 6. This step tests for opens and shorts in the main wiring harness. 8. This step tests the resistance value of the internal TFT sensor. Copyright© 2004 General Motors Corp.

5–59

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature) Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P) Go to Step 11

2

Perform the A/T Fluid Checking Procedure (Appendix P). Is the transmission fluid level correct?

3

1. Turn the ignition OFF. 2. Disconnect J2 connector at the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. With the engine OFF, turn the ignition to the ON position. Measure voltage between J2 connector pins 10 and 20. Is voltage within the specified value?

4.75–5.25V

Go to Step 4

4

1. Install the Scan Tool. 2. With the engine OFF, turn the ignition to the ON position. 3. Record the Failure Record data. 4. Clear the DTC. 5. Select TFT on the Scan Tool. Drive the vehicle and inspect for unrealistic TFT readings. Is the TFT reading at or below the specified value? This DTC may indicate an open or short to power at wire 210. 1. Disconnect the wiring harness from the main transmission connector. 2. Using a DVOM, measure resistance at main transmission connector pins G and H.* Is resistance within the specified values?

–36°C (–32.8°F)

Go to Step 5

Go to Diagnostic Aids

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 6

Go to Step 8

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 7

5

6

5–60

1. Reconnect the wiring harness to the main transmission connector. 2. Disconnect the J2 connector from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 10 and 20. Is resistance within the specified values?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature) (cont’d) Step Action NOTE: The vehicle OEM has responsibility 7 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

8

9

10 11

12

Repair the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. 2. Disconnect the PSM from the internal wiring harness. 3. Using a DVOM, measure PSM resistance at pins E and F. Is resistance within the specified values? Replace the internal wiring harness (refer to Mechanic’s Tips). Is the repair or replacement complete? Replace the PSM (refer to Mechanic’s Tips). Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Using the Scan Tool, monitor the transmission fluid temperature. 3. Drive the vehicle under normal operating conditions making sure coolant temperature is over 20°C (68°F). Did the DTC return?

Value(s) —

Yes Go to Step 12

No —

3398–3582 Ohms at 20°C (68°F) Refer to TFT Sensor Resistance Table Page 5–13)

Go to Step 9

Go to Step 10

—

Go to Step 12

—

—

Go to Step 12

—

—

Go to Step 12

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

5–61

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0716 Turbine Speed Sensor Circuit Performance J2 HARNESS CONNECTOR J2-13 (RED) J2-14

TCM

J2 J1

TCM

A B

TURBINE SPEED SENSOR

A B

213 214

J2-13

TURBINE SPEED HI

J2-14

TURBINE SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06219.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC • • • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). DTC P0717, P0721, or P0722 is not active. Turbine speed is above 200 rpm. Shift is complete and range attained is not neutral.

Conditions for Setting the DTC DTC P0716 is set when one of the following conditions occur: •

Unrealistic large change in turbine speed. Failure is set if an unrealistic change in transmission turbine speed is detected at or above 800 rpm for 0.15 seconds.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

Noisy turbine speed signal. Noise is determined with two counters. A low counter is incremented when turbine speed change is below 800 rpm for 2.0 seconds. A high counter is incremented when turbine speed change is above 800 rpm. When both counters accumulate 5 events, a failure is set.

Action Taken When the DTC Sets •

When DTC P0716 is active, the following conditions will occur: — If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the current range. — If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous range, except in post-shift state; then the transmission will continue to the commanded range.

•

DTC P0716 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — — — — — —

A bent terminal. A backed-out terminal. A damaged terminal. Poor terminal tension. A chafed wire. A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

•

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection. — Excessive vibration (driveline or engine torsionals). — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel).

•

Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed.

•

Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector.

•

Inspect the turbine speed tone wheel/PTO gear for possible damage.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness. 4. This step tests turbine speed sensor resistance. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0716 Turbine Speed Sensor Circuit Performance Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector at the TCM. 3. Using a DVOM, measure the resistance between connector J2 pin 13 and connector J2 pin 14. Is the speed sensor resistance within the specified values?

5

1. Disconnect the wiring harness from the turbine speed sensor. 2. Using a DVOM, check the resistance between the speed sensor terminals.* Is resistance within the specified values? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

6

Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

4

7

Replace the turbine speed sensor (refer to Mechanic’s Tips). Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor turbine speed sensor operation. Did the DTC return?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 4

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

—

Go to Step 7

—

—

Go to Step 7

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

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Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0717 Turbine Speed Sensor Circuit No Signal

J2 HARNESS CONNECTOR J2-13 (RED) J2-14

TCM

J2 J1

TCM

A B

TURBINE SPEED SENSOR

A B

213 214

J2-13

TURBINE SPEED HI

J2-14

TURBINE SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06219.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltagerelated fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC • • •

Components are powered and the ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V or less than 32V (24V TCM). DTC P0721, P0722, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active. When unrealistic large change in turbine speed is detected. — Engine is running. — Shift is not in process. — Range attained is not neutral. — Transmission fluid temperature is above –25°C (–13°F). Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

When unrealistic low turbine speed is detected. — Engine is running. — Shift is not in process. — Range attained is not neutral. — Transmission fluid temperature is above –25°C (–13°F). — Transmission output speed is at or above 150 rpm or engine speed is at or above 400 rpm.

Conditions for Setting the DTC DTC P0717 is set when one of the following conditions occur: •

Unrealistic large change in turbine speed. A Failure pending is set if an unrealistic change in transmission turbine speed is detected at or above 800 rpm. The failure pending response is to lock in the current range.

•

Unrealistic low value in turbine speed. A failure pending is set if turbine speed is detected below 61 rpm. A failure is set when turbine speed is below 61 rpm and output speed is detected above 500 rpm for more than 1 second.

Action Taken When the DTC Sets •

When DTC P0717 is active, the following conditions will occur: — If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the current range. — If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous range, except in post-shift state; then the transmission will continue to the commanded range. — If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th. — If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will lock in N (Neutral).

•

DTC P0717 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals)

• • •

— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel) Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed. Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector. Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness. 4. This step tests turbine speed sensor resistance at the sensor.

DTC P0717 Turbine Speed Sensor Circuit No Signal Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 13 and 14. Is resistance within the specified values? 1. Disconnect the wiring harness from the turbine speed sensor. 2. Using a DVOM, measure resistance at the speed sensor terminals.* Is resistance within the specified values?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 4

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0717 Turbine Speed Sensor Circuit No Signal (cont’d) Step Action NOTE: The vehicle OEM has responsibility 5 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

6

Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

Value(s) —

Yes Go to Step 7

No —

—

Go to Step 7

—

Replace the turbine speed sensor (refer to Mechanic’s Tips). Is the replacement complete? In order to verify your repair: Begin the 7 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor turbine speed sensor operation. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

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Copyright© 2004 General Motors Corp.

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0719 Brake Switch ABS Input Low TCM J1 HARNESS CONNECTOR (GRAY)

J1-13

J2 J1-28

J1

ANTI-LOCK BRAKE CONTROLS

TCM 113

J1-13

Customer–furnished relay is shown de-energized 128

DIGITAL INTERFACE

J1-28

SWITCHED POWER

NOTE: ABS System provides ground (–) signal when active.

ANTI-LOCK BRAKE CONTROLS

TCM 113

J1-13

Customer–furnished relay is shown de-energized 128

DIGITAL INTERFACE

J1-28

NOTE: ABS System provides power (+) signal when active. V08118.00.00

Circuit Description If the vehicle is equipped with anti-lock brake system (ABS), an interface between the ABS and TCM is required. This interface allows disengagement of the Torque Converter Clutch (TCC) when the ABS is activated. This ABS action is initiated with a discrete input from the ABS system, when the ABS is activated a ground signal is sent to TCM input wire 113. This may be a ground signal direct from the ABS controller or a positive signal from the ABS controller that powers a relay field coil to supply a ground through the relay contacts. (Some ABS systems require that the ground signal be switched through a relay.) Conditions for Running the DTC •

Components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTCs P0721, P0722 are not active.

Conditions for Setting the DTC DTC P0719 will set after the TCM detects one or more vehicle acceleration cycles where the TCM ABS brake switch input is in the “ON” activated state. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken when DTC sets • • •

The TCM uses the default assumption that the ABS is OFF. DTC P0719 is stored in the TCM history. The CHECK TRANS light illuminates.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

• •

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. ABS system interface to the TCM input can be wired one of three different ways, check with the OEM for proper wiring information concerning ABS applied input before troubleshooting.

DTC P0719 Brake Switch ABS Input Low Step Action Was the Beginning the Troubleshooting 1 Process (Section 5-4A) Performed?

2

3

4

5

5–70

Remove ABS input wire (113) from J1 connector. Clear code and test-drive vehicle. Did the code return? Return vehicle to OEM for troubleshooting of wiring leading to ABS controller. Was the problem found and corrected? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: Clear the DTC. 1. Operate the vehicle under normal driving conditions. Check for proper operation of ABS. Did the DTC return?

Value —

Yes Go to Step 2

—

Go to Step 4

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

—

Go to Step 5

—

—

Go to Step 5

—

—

Begin the diagnosis again. Go to Step 1.

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0721 Output Speed Sensor Circuit Performance

J2 HARNESS CONNECTOR (RED) J2-15 J2-16

TCM

J2 J1

TCM

A B

OUTPUT SPEED SENSOR

A B

215 216

J2-15

OUTPUT SPEED HI

J2-16

OUTPUT SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06220.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0716, P0717, or P0722 is not active.

•

Turbine speed is above 200 rpm.

•

Shift is complete and range attained is not neutral. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0721 is set when one of the following conditions occur: •

Unrealistic large change in output speed. A Failure pending is set if an unrealistic change in transmission output speed is detected at or above 500 rpm. The failure pending response is to lock in the current range.

•

Noisy output speed signal. Noise is determined with two counters. A low counter is incremented when output speed change is below 500 rpm for 2.5 seconds. A high counter is incremented when output speed change is above 500 rpm. When both counters accumulate 5 events, a failure is set.

Action Taken When the DTC Sets •

When DTC P0721 is active, the following conditions will occur: — If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the current range. — If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous range, except in post-shift state; then the transmission will continue to the commanded range. — If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th. — If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will lock in N (Neutral). — If a latched inhibit is present, the transmission locks to neutral.

•

DTC P0721 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — — — — — —

A bent terminal. A backed-out terminal. A damaged terminal. Poor terminal tension. A chafed wire. A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

•

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel

•

Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed.

•

Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper output speed sensor resistance. 4. This step tests for proper resistance at the output speed sensor. .

DTC P0721 Output Speed Sensor Circuit Performance Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

5

6

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 15 and 16. Is resistance within the specified values? 1. Disconnect the wiring harness from the output speed sensor. 2. Using a DVOM, measure resistance at the speed sensor terminals.* Is resistance within the specified values? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Resolve voltage problem (Refer to DTC P0562 and P0563)

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Go to Diagnostic Aids

Go to Step 4

2304–2815 Ohms at 20°C (68°F) Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

—

Go to Step 7

—

—

Go to Step 7

—

Replace the output speed sensor (refer to Mechanic’s Tips). Is the replacement complete?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0721 Output Speed Sensor Circuit Performance (cont’d) Step Action Value(s) Yes In order to verify your repair: 7 — Begin the diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor output speed sensor operation. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–74

Copyright© 2004 General Motors Corp.

No System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0722 Output Speed Sensor Circuit No Signal

J2 HARNESS CONNECTOR (RED) J2-15 J2-16

TCM

J2 J1

TCM

A B

OUTPUT SPEED SENSOR

A B

215 216

J2-15

OUTPUT SPEED HI

J2-16

OUTPUT SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06220.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0716, P0717, P0721, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active.

•

When unrealistic large change in output speed is detected, output speed is at or above 600 rpm for more than 1 second. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

When unrealistically low output speed is detected. — Engine is running. — Shift is not in process. — Range attained is not neutral. — Transmission fluid temperature is above –25°C (–13°F). — Transmission turbine speed is at or above 1050 rpm. — Manual selector valve is not being moved to a forward range.

Conditions for Setting the DTC DTC P0722 is set when one of the following conditions occur: •

Unrealistic large change in output speed. A failure pending is set if an unrealistic change in transmission output speed is detected at or above 600 rpm. A failure is set if neutral range is attained.

•

Unrealistic low value in output speed. A failure pending is set if output speed is detected below 61 rpm. A failure is set when output speed is below 61 rpm and transmission range is 3rd, 4th, or 5th for more than 1 second.

Action Taken When the DTC Sets •

When DTC P0722 is active, the following conditions will occur: — If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the current range. — If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous range, except in post-shift state; then the transmission will continue to the commanded range. — If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th. — If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range while the diagnostic response is active, the transmission will lock in N (Neutral). — If a latched inhibit is present, the transmission locks in neutral.

•

DTC P0722 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

5–76

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

• • •

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed. Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector. Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper output speed sensor resistance at the TCM side of the wiring harness. 4. This step tests for proper output speed sensor resistance.

DTC P0722 Output Speed Sensor Circuit No Signal Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 15 and 16. Is resistance within the specified values? 1. Disconnect the wiring harness from the output speed sensor. 2. Using a DVOM, measure resistance at the speed sensor terminals.* Is resistance within the specified values?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 4

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0722 Output Speed Sensor Circuit No Signal (cont’d) Step Action NOTE: The vehicle OEM has responsibility 5 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

6

Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

Value(s) —

Yes Go to Step 7

No —

—

Go to Step 7

—

Replace the output speed sensor (refer to Mechanic’s Tips). Is the replacement complete? In order to verify your repair: Begin the 7 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor output speed sensor operation. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–78

Copyright© 2004 General Motors Corp.

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0726 Engine Speed Input Circuit Performance

J2 HARNESS CONNECTOR (RED) TCM

J2-17 J2-18 J2 J1

TCM

A B

ENGINE SPEED SENSOR

A B

217 218

J2-17

ENGINE SPEED HI

J2-18

ENGINE SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06221.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0716, P0717, P0721, or P0727 is not active.

•

Engine speed is above 600 rpm for 1 second.

•

Shift is complete and range attained is not neutral. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0726 is set when one of the following conditions occur: •

Unrealistic large change in engine speed. Failure is set if an unrealistic change in transmission engine speed is detected at or above 600 rpm.

•

Noisy input speed signal. Noise is determined with two counters. A low counter is incremented when engine speed change is below 650 rpm for 2.5 seconds. A high counter is incremented when engine speed change is above 650 rpm. When both counters accumulate 5 events, a failure is set.

Action Taken When the DTC Sets •

DTC P0726 is stored in the TCM history.

•

The TCM defaults engine speed to turbine speed. Turbine speed is used to determine the missing engine speed.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

•

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection. — Excessive vibration (driveline or engine torsionals). — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.

•

Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed.

•

Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness. 4. This step tests for proper resistance value at the engine speed sensor. 5–80

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0726 Engine Speed Input Circuit Performance Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 17 and 18. Is resistance within the specified values?

5

1. Disconnect the wiring harness from the engine speed sensor. 2. Using a DVOM, measure resistance at the speed sensor terminals.* Is resistance within the specified values? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

6

Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

4

7

Replace the engine speed sensor (refer to Mechanic’s Tips). Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor engine speed sensor operation. Did the DTC return?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 4

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

—

Go to Step 7

—

—

Go to Step 7

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

5–81

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0727 Engine Speed Input Circuit No Signal

J2 HARNESS CONNECTOR (RED) TCM

J2-17 J2-18 J2 J1

TCM

A B

ENGINE SPEED SENSOR

A B

217 218

J2-17

ENGINE SPEED HI

J2-18

ENGINE SPEED LO

SPEED SENSOR CIRCUITS Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06221.01.00

Circuit Description The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0716, P0717, or P0726 is not active.

•

Unrealistically low engine speed detected.

•

Engine is running.

•

Transmission turbine speed is at or above 400 rpm.

•

Ignition is in the ON position.

5–82

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0727 is set when one of the following conditions occur: •

Unrealistic large change in engine speed. Failure pending is set if an unrealistic change in engine speed is detected at or above 1140 rpm.

•

Unrealistic low value in engine speed. Failure is set if engine speed is detected below 61 rpm for 4 seconds.

Action Taken When the DTC Sets •

The TCM defaults engine speed to turbine speed. Turbine speed is used to determine missing engine speed.

•

TCM inhibits TCC momentarily.

•

DTC P0727 is stored in TCM history

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

You may have to drive the vehicle in order to experience a fault.

•

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection. — Excessive vibration (driveline or engine torsionals). — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.

•

Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in the sensor removed.

•

Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor connector.

•

Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness. 4. This step tests for proper resistance value at the engine speed sensor. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0727 Engine Speed Input Circuit No Signal Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect connector J2 from the TCM. 3. Using a DVOM, measure resistance at connector J2 pins 17 and 18. Is resistance within the specified values?

5

1. Disconnect the wiring harness from the engine speed sensor. 2. Using a DVOM, measure resistance at the speed sensor terminals.* Is resistance within the specified values? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

6

Repair the vehicle wiring harness. Is the repair complete? NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may cause improper operation.

4

7

Replace the engine speed sensor (refer to Mechanic’s Tips). Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor engine speed sensor operation. Did the DTC return?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Diagnostic Aids

Go to Step 4

Refer to Speed Sensor Resistance Table Page 5–13)

Go to Step 5

Go to Step 6

—

Go to Step 7

—

—

Go to Step 7

—

—

Begin the diagnosis again. Go to Step 1

System OK

* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–84

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0731 Incorrect 1st Gear Ratio

REFER TO 1st RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current range. Conditions for Running the DTC • • •

Output speed exceeds 200 rpm. First range is selected and attained. DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0731 sets when the calculated first range ratio (steady state) differs from the known first range ratio. Action Taken When the DTC Sets •

When DTC P0731 is active, the following conditions will occur: — The transmission will fail to 2nd or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).

• • • •

— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral). DTC P0731 is stored in the TCM history. The CHECK TRANS light illuminates. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids • • • •

Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 or C5 for 1st range. An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid. You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed. Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with the correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families transmissions). Copyright© 2004 General Motors Corp.

5–85

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests for current first range ratio. 5. This step tests speed sensor readings. 6. This step tests for clutch slippage in first range. 7. This step checks for evidence of clutch failure.

DTC P0731 Incorrect 1st Gear Ratio Step 1

2

3

4

5

5–86

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Install the Scan Tool. 2. Monitor the gear ratio. Is the correct first range ratio shown? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. 2. Using the Scan Tool, monitor engine, turbine, and output speed readings. Is speed sensor data erratic or are signal dropouts detected?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

3.1 for 1000 3.51 for 2000/ 2400

Go to Step 5

Go to Diagnostic Aids

—

Go to the appropriate speed sensor DTC

Go to Step 6

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0731 Incorrect 1st Gear Ratio (cont’d) Step 6

Action

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

Go to Step 10

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path. CAUTION: Do not perform a clutch test In fourth or fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

7

8

9

10 11

1. Using the Scan Tool, select clutch test mode. 2. With brakes applied, move the selector lever to D (Drive). 3. With engine at idle, select and attain the range indicated by the DTC. Turbine speed should go to zero. 4. Monitor turbine speed while increasing engine speed to 1400 rpm. Did turbine speed remain at zero? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace A solenoid (refer to Mechanic’s Tips). Is replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

5–87

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0732 Incorrect 2nd Gear Ratio

REFER TO 2nd RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current range. Conditions for Running the DTC • • •

Output speed exceeds 200 rpm. Second range is selected and attained. DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0732 sets when the calculated second range ratio (steady state) differs from the known second range ratio. Action Taken When the DTC Sets •

When DTC P0732 is active, the following conditions will occur: — The transmission will fail to 3rd range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).

• • • •

— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral). DTC P0732 is stored in the TCM history. The CHECK TRANS light illuminates. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids • • • •

Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C4 for 2nd range. An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid. You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed. Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with the correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families transmissions).

5–88

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests speed sensor readings. 5. This step tests for turbine speed not remaining at zero in second range. 6. This step checks for evidence of clutch failure.

DTC P0732 Incorrect 2nd Gear Ratio Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. 2. Using the Scan Tool, monitor engine, turbine, and output speed readings. Is speed sensor data erratic or are signal dropouts detected?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

5–89

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0732 Incorrect 2nd Gear Ratio (cont’d) Step 5

Action

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 6

—

Go to Step 7

Go to Step 8

—

Go to Step 10

—

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

—

Begin the diagnosis again. Go to Step 1

System OK

WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path. CAUTION: Do not perform a clutch test In fourth or fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

6

7

8

9 10

5–90

1. Using the Scan Tool, select clutch test mode. 2. With brakes applied, move the selector lever to D (Drive). 3. With engine at idle, select and attain the range indicated by the DTC. Turbine speed should go to zero. 4. Monitor turbine speed while increasing engine speed to 1400 rpm. Did turbine speed remain at zero? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace B solenoid (refer to Mechanic’s Tips). Is replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0733 Incorrect 3rd Gear Ratio

REFER TO 3rd RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current range. Conditions for Running the DTC •

Output speed exceeds 200 rpm.

•

Third range is selected and attained.

•

DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0733 sets when the calculated third range ratio (steady state) differs from the known third range ratio. Action Taken When the DTC Sets •

When DTC P0733 is active, the following conditions will occur: — The transmission will fail to 4th range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to N (Neutral). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will lock in N (Neutral).

•

DTC P0733 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

5–91

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids • Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C3 for 3rd range. • An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid. • You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed. • Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with the correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families transmissions). Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests speed sensor readings. 5. This step tests for turbine speed not remaining at zero in third range. 6. This step checks for evidence of clutch failure.

DTC P0733 Incorrect 3rd Gear Ratio Step 1

2

3

4

5–92

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. 2. Using the Scan Tool, monitor engine, turbine, and output speed readings. Is speed sensor data erratic or are signal dropouts detected?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0733 Incorrect 3rd Gear Ratio (cont’d) Step 5

Action

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 6

—

Go to Step 7

Go to Step 8

—

Go to Step 10

—

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

—

Begin the diagnosis again. Go to Step 1

System OK

WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path. CAUTION: Do not perform a clutch test In fourth or fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

6

7

8

9 10

1. Using the Scan Tool, select clutch test mode. 2. With brakes applied, move the selector lever to D (Drive). 3. With engine at idle, select and attain the range indicated by the DTC. Turbine speed should go to zero. 4. Monitor turbine speed while increasing engine speed to 1400 rpm. Did turbine speed remain at zero? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace A solenoid (refer to Mechanic’s Tips). Is replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0734 Incorrect 4th Gear Ratio

REFER TO 4th RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current range. Conditions for Running the DTC • • •

Output speed exceeds 200 rpm. Fourth range is selected and attained. DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0734 sets when the calculated fourth range ratio (steady state) differs from the known fourth range ratio. Action Taken When the DTC Sets •

When DTC P0734 is active, the following conditions will occur: — The transmission will fail to 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the transmission is compromised by a direction change; then the transmission will shift to N (Neutral).

• • • •

— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will lock in N (Neutral). DTC P0734 is stored in the TCM history. The CHECK TRANS light illuminates. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids • • •

Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C2 for 4th range. An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid. You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests speed sensor readings. 5. This step tests for turbine speed not remaining at zero in fourth range. 6. This step checks for evidence of clutch failure.

DTC P0734 Incorrect 4th Gear Ratio Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. 2. Using the Scan Tool, monitor engine, turbine, and output speed readings. Is speed sensor data erratic or are signal dropouts detected?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0734 Incorrect 4th Gear Ratio (cont’d) Step 5

Action

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 6

—

Go to Step 7

Go to Step 8

—

Go to Step 10

—

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

—

Begin the diagnosis again. Go to Step 1

System OK

WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path. CAUTION: Do not perform a clutch test In fourth or fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

6

7

8

9 10

5–96

1. Using the Scan Tool, select clutch test mode. 2. With brakes applied, move the selector lever to D (Drive). 3. With engine at idle, select and attain the range indicated by the DTC. Turbine speed should go to zero. 4. Monitor turbine speed while increasing engine speed to 1400 rpm. Did turbine speed remain at zero? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace B solenoid (refer to Mechanic’s Tips). Is replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0735 Incorrect 5th Gear Ratio

REFER TO 5th RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current range. Conditions for Running the DTC •

Output speed exceeds 200 rpm.

•

Fifth range is selected and attained.

•

DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0735 sets when the calculated fifth range ratio (steady state) differs from the known fifth range ratio. Action Taken When the DTC Sets •

When DTC P0735 is active, the following conditions will occur: — The transmission will fail to 4th range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the transmission is compromised by a direction change; then the transmission will shift to N (Neutral). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will lock in N (Neutral).

•

DTC P0735 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids • Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C2 and C3 for 5th range. • An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid. • You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed. • Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with The correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families transmissions). Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests speed sensor readings. 5. This step tests for turbine speed not remaining at zero in fifth range. 6. This step checks for evidence of clutch failure.

DTC P0735 Incorrect 5th Gear Ratio Step 1

2

3

4

5–98

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. 2. Using the Scan Tool, monitor engine, turbine, and output speed readings. Is speed sensor data erratic or are signal dropouts detected?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0735 Incorrect 5th Gear Ratio (cont’d) Step 5

Action

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 6

—

Go to Step 7

Go to Step 8

—

Go to Step 10

—

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

—

Begin the diagnosis again. Go to Step 1

System OK

WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path. CAUTION: Do not perform a clutch test In fourth or fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

6

7

8

9 10

1. Using the Scan Tool, select clutch test mode. 2. With brakes applied, move the selector lever to D (Drive). 3. With engine at idle, select and attain the range indicated by the DTC. Turbine speed should go to zero. 4. Monitor turbine speed while increasing engine speed to 1400 rpm. Did turbine speed remain at zero? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace A solenoid (refer to Mechanic’s Tips). Is replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0736 Incorrect Reverse Ratio

REFER TO REVERSE RANGE HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current gear. Conditions for Running the DTC •

Output speed exceeds 200 rpm.

•

Reverse is selected and attained.

•

DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC DTC P0736 sets when the calculated reverse range ratio (steady state) differs from the known reverse range ratio. Action Taken When the DTC Sets •

When DTC P0736 is active, the transmission will lock in N (Neutral).

•

DTC P0736 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C3 and C5 for Reverse range.

•

An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific solenoid.

•

You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.

5–100

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step tests ignition voltage. 4. This step tests for current reverse range ratio. 5. This step tests for noise induced from the engine speed sensor. 6. This step tests for turbine speed not remaining at zero in reverse range. 7. This step checks for evidence of clutch failure.

DTC P0736 Incorrect Reverse Ratio Step 1

2

3

4

5

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Start the engine. 2. Record the DTC Failure Record data. 3. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? Using the Scan Tool, monitor the reverse gear ratio. Is the gear ratio correct for the transmission family that is installed in the vehicle? 1. Turn the ignition ON. 2. Start the engine and run at idle. 3. Using the Scan Tool, monitor engine, turbine, and output speed readings in Reverse range with the vehicle brakes applied. Is noise indicated on the output speed sensor or turbine speed sensor data?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

4.49 for 1000 Product Family; 5.09 for 2000 Product Family

Go to Step 5

Go to Diagnostic Aids

—

Go to appropriate speed sensor DTC

Go to Step 6

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0736 Incorrect Reverse Ratio (cont’d) Step 6

Action WARNING: To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: • Put the transmission in N (Neutral)...and • Apply the parking brake and service brake...and • Chock the vehicle wheels and take any other steps necessary to prevent the vehicle from moving...and Warn personnel to keep clear of the vehicle and its path.

Value(s) —

Yes Go to Diagnostic Aids

No Go to Step 7

—

Go to Step 9

Go to Step 8

—

Go to Step 10

—

—

Go to Step 10

—

CAUTION: NEVER perform a full throttle stall test (brakes held) in reverse range, or damage to the vehicle driveline or axle may occur. 1. Apply vehicle brakes and select Reverse. 2. With engine at idle and Reverse range attained, turbine speed should go to zero. 3. Using the Scan Tool, monitor turbine speed while increasing engine speed to 1000 rpm. Did turbine speed remain at zero? 7

8

Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Using the Scan Tool, monitor turbine speed while selecting first range. If turbine speed is ever greater than zero after first range is attained, there may be a problem with A solenoid or A trimmer valve. If shift to first range is harsh and delayed, there may be a problem with B solenoid or B trimmer valve. Remove the control valve body and inspect for stuck or sticking trimmer valves. If valves are moving freely, replace either solenoid A or B (refer to Mechanic’s Tips) based on the shift characteristics described.

9

Is replacement complete? Remove the transmission for overhaul or replacement (refer to Mechanic’s Tips). Is replacement complete?

5–102

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0736 Incorrect Reverse Ratio (cont’d) Step 10

Action In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle in all ranges under normal driving conditions. The ratio must fall within the specified range. Did the DTC return?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1

No System OK

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0741 Torque Converter Clutch System Stuck Off

N/C

V07737.01.00

Circuit Description The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to calculate torque converter slip value. The TCM then compares this calculated slip value to a preset value in the TCM calibration. Conditions for Running the DTC • • • • • •

DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active. The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm for 5 seconds. Transmission is in a valid forward range. Throttle position is over 10 percent but less than 90 percent. 6 seconds or more have expired since TCC was applied in a range.

5–104

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0741 sets when the TCM detects a torque converter clutch slip value greater than 80 rpm for more than 15 seconds, indicating no TCC apply. Action Taken When the DTC Sets •

DTC P0741 is stored in the TCM history.

•

The CHECK TRANS light illuminates on the second occurrence.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Residue or contamination may cause shift valves to stick intermittently.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a slip speed indicating the TCC is not applied when it should be. 4. This step verifies the repair performed.

DTC P0741 Torque Converter Clutch System Stuck Off Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

1. 2. 3. 4. 5. 6.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Drive the vehicle. With the Scan Tool, monitor converter slip speed indicated when a range is attained where the TCC should be applied.

Value(s) —

Yes Go to Step 2

More than 80 rpm

Go to Step 3

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Diagnostic Aids

NOTE: This DTC sets when converter slip speed is detected above 80 rpm for 15 seconds or more. This indicates the TCC has not applied. Is the slip speed value at or above the specified value when the TCC should be applied? Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0741 Torque Converter Clutch System Stuck Off (cont’d) Step Action This condition indicates that the TCC is 3 mechanically stuck OFF. Check for the following conditions: • Worn TCC clutch • Faulty solenoid F • Debris in the TCC valve bore (stuck valve) • Clogged or restricted converter relief passage Did you find and repair a problem? In order to verify your repair: 4 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Using the Scan Tool, monitor TCC slip speed. The TCC must engage/disengage when commanded. 4. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

5–106

Value(s) —

Yes Go to Step 4

No —

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0742 Torque Converter Clutch System Stuck On

N/C

V07737.01.00

Circuit Description The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to calculate the torque converter slip value. The TCM then compares this calculated slip value to a preset value in the TCM calibration. Conditions for Running the DTC •

DTC P0122, P0123, P0716, P0717, P0721, P0722, P0726, P0727, or P0743 (previously P1860) is not active.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Engine speed is greater than 200 rpm for 5 seconds.

•

Transmission is in a valid forward range.

•

The torque converter clutch is OFF. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0742 sets when the conditions listed below are present and the TCM detects converter slip speed between –5 and –40 rpm for over 2 seconds. •

Transmission output speed is 100 rpm or higher.

•

Engine throttle percentage is 15 percent or higher.

•

Engine torque is 130 N·m or higher.

•

Engine and turbine speed are under 5500 rpm.

Action Taken When the DTC Sets •

Illuminate CHECK TRANS light on second occurrence.

•

Response is calibration dependent.

•

If response is disabled, no action is performed.

•

If enabled, when DTC is set before or during a shift, response is a shift to neutral. If DTC is set after shifting is complete, transmission shifts to neutral or 1st range. While response is active, if the selector is moved to a forward range, transmission shifts to neutral or 1st range. If the selector is moved to reverse, the transmission shifts to neutral or reverse.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids This DTC sets when converter slip speed indicates the TCC is staying applied when it should be released for a period of time that is calibration dependent. This may indicate an internal failure of the TCC or a stuck or sticking TCC valve. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a slip speed indicating the TCC is locked up when it should be off. 4. This step verifies the repair performed.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0742 Torque Converter Clutch System Stuck On Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

1. 2. 3. 4. 5. 6.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Drive the vehicle. With the Scan Tool, observe converter slip speed indicated when a range is attained where TCC should not be applied.

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Diagnostic Aids

–5 to –40 rpm for more than 2 seconds. See Conditions for Setting the DTC

Go to Step 3

—

Go to Step 6

—

—

Begin the diagnosis again. Go to Step 1

System OK

NOTE: This DTC sets when converter slip speed is detected between –5 and –40 rpm for over 2 seconds. This indicates that TCC did not release properly and remained in a locked state for over a calibration dependent time. Is the slip speed value between the specified values? 3

4

This condition indicates that the TCC is mechanically stuck ON, check for the following conditions: • Worn TCC clutch • Faulty solenoid F • Stuck or sticking TCC valve • Clogged converter relief passage Did you find and repair a problem? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions in failure records. 3. Using the Scan Tool, monitor TCC slip speed. The TCC must engage/disengage when commanded. 4. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0743 (Previously P1860) Torque Converter Clutch Pulse Width Modulation (PWM) Solenoid Circuit — Electrical

TRANSMISSION HARNESS CONNECTOR S R

J2 HARNESS CONNECTOR (RED)

J

TCM J2-32 J2-30 J2-29

TRANSMISSION BULKHEAD CONNECTOR

S

J

J2

R

J1

NOTE: Letters I, O, and Q are not used.

TCM SOL F (PWM) LOCKUP

J

SOL G

TRANSMISSION

R S

229 230 232

J2-29 J2-30 J2-32

12V

NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G. V06222.01.00

Circuit Description The torque converter clutch (TCC) solenoid, solenoid F, is a pulse width modulated solenoid. Pulse width modulation (PWM) occurs when the signal from the transmission control module (TCM) to a solenoid is modulated at an established frequency, causing the steel check ball in the solenoid to rapidly open and close the solenoid passage. This serves to vary the output fluid pressure. Conditions for Running the DTC •

DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater 18V and less than 32V (24V TCM).

•

TCC is commanded on.

•

TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC P0743 sets when the TCM detects an open circuit, a short to power, or a short to ground in the solenoid F circuit for 6 seconds or longer. 5–110

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

DTC P0743 is stored in the TCM history.

•

The CHECK TRANS light illuminates on the second occurrence.

•

Reverse operation is disabled.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

If this DTC is cleared and does not return, but the TCC appears to be cycling, an intermittent circuit connection may exist that is not detected by the TCM since the circuit error must be present for more than 6 seconds. If a short to ground occurs at wire 229, the TCC will apply regardless of the range selected. A shudder in reverse may be caused by the intermittent apply or release of C5 clutch through the F solenoid valve.

•

Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A broken wire inside the insulation.

•

Inspect the OEM wiring harness routing looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Items to check would include the parking brake drum, suspension components, transmission shift linkage, etc.

•

Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 wire check procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.

•

If the DTC appears to be temperature related, suspect a defective F solenoid. It is possible for a shift solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper ignition voltage. 3. This step tests for an active DTC. 4. This step tests the TCM for proper command status. 5. This step tests the OEM wiring harness for an open condition. 6. This step tests for proper resistance at the main transmission connector. 8. This step tests for the proper resistance value at the shift solenoid. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM) Solenoid Circuit—Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Use the Scan Tool to measure ignition voltage. Is voltage within the specified value? 1. Turn ON the ignition, with the engine OFF. 2. Record the failure records. 3. Clear the DTC. 4. Drive the vehicle under the same condition noted in the failure records. 5. Using the Scan Tool, observe the TCC solenoid F status.

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

—

Go to Step 4

Go to Diagnostic Aids

85 percent duty cycle or above

Go to Step 5

Go to Step 11

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 6

Go to Diagnostic Aids

NOTE: This DTC sets when an open, a short to ground or a short to power is present in the TCC circuit for over 6 seconds. 4

5

Did the DTC return? With the Scan Tool in Solenoid Test Mode command F solenoid ON. Does the Scan Tool indicate a duty cycle at or above the indicated value? NOTE: Review Section 4 — Wire Check Procedures before performing the following steps. 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 3. Using a DVOM, attach leads to J2 pins 29 and 32. 4. Measure the resistance of the circuit. Is the resistance reading within the specified value

5–112

NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM) Solenoid Circuit—Electrical (cont’d) Step Action 1. Turn the ignition OFF. 6 2. Disconnect the transmission main connector from the back of the transmission. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 3. Using a DVOM, measure the resistance between pins S and J at the magnetic overlay. Is the resistance within the specified value? 7

8

9

10

11

NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the internal wiring harness from Solenoid F (TCC) connector. 3. Using a DVOM, measure the resistance of solenoid F. Is resistance within the specified values? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace F (TCC) Solenoid. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete?

Value(s) Refer to Solenoid Resistance Table (Page 5–12)

Yes Go to Step 7

No Go to Step 8

—

Go to Step 12

—

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 9

Go to Step 10

—

Go to Step 12

—

—

Go to Step 12

—

—

Go to Step 12

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM) Solenoid Circuit—Electrical (cont’d) Step Action 12 In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

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Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1

No System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off

REFER TO HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description Trim solenoid A is used to control on-coming, off-going, and holding pressure in any one of five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure supplied by this solenoid is proportional to the controlled current command. The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a clutch is slipping. The clutch being controlled by the solenoid A will vary depending on the shift that is being completed. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Turbine speed is greater than 60 rpm.

•

Output speed is greater than 125 rpm.

•

Transmission is at normal operating temperature.

•

DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC DTC P0746 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number of occurrences. Action Taken When the DTC Sets •

When DTC P0746 is active, the following conditions will occur: — If failure occurs while in a forward range, the transmission will shift to the previous range. — If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral). — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock in N (Neutral)). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will shift to N (Neutral).

•

DTC P0746 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

•

•

This DTC indicates the on-coming clutch being controlled by solenoid A is not applied or applied too slowly. This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record data for previous or current range information when the DTC was set to determine the specific shift when the DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect. If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel) Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.

NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the installation of a engine power package or module will not be covered under the Allison transmission warranty. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. 4. 5. 6.

This step tests the ignition voltage. This step tests for erratic speed sensor readings or signal dropout. This step tests for internal hydraulic leakage. This step tests for clutch capacity.

DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

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Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Install the Scan Tool. 2. Start the engine. 3. Record the DTC Failure Record data. 4. Use the Failure Record data to determine during which shift the code was set. 5. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. Make the shift determined in Step 3. 2. Using the Scan Tool, monitor turbine, engine, and output speed sensor readings. Is speed sensor data erratic or are dropouts in signal indicated?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to the appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off (cont’d) Step Action 1. Connect a 2000 kPa (300 psi) pressure 5 gauge to the main-pressure tap (refer to Mechanic’s Tips). 2. Use the Scan Tool, in clutch test mode, to cycle through all transmission ranges with the engine at idle and vehicle brakes applied. 3. Record main pressure in each range.

Value(s) —

Yes Go to General Troubleshooting — Low Pressure (Section 7)

No Go to Step 6

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Diagnostic Aids

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

Go to Step 10

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Was the main pressure low in a specific range or in ranges where the same clutch was applied? 6

7

8

9

10 11

CAUTION: Do not perform a clutch test on fourth and fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur. 1. Using the Scan Tool, select the clutch test mode. 2. With engine at idle speed (600 rpm), vehicle brakes applied, select D (Drive). 3. Using clutch test mode, select and attain first range. Turbine speed should go to zero. 4. Increase engine speed to 1400 rpm. Did turbine speed remain at zero? 5. Repeat the two previous steps for ranges two through five. Did turbine speed remain at zero in all ranges? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement. Is the overhaul or replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace A solenoid. Is solenoid replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Use the Scan Tool to reset adaptive for all shifts. 3. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On

REFER TO HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure supplied by this solenoid is proportional to the controlled current command. The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a clutch is in a tie-up condition or 3 clutches are applied. The clutch being controlled by solenoid A will vary depending on the shift. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

One of the following conditions occurs: — Output speed is greater than 200 rpm. — Turbine speed is greater than 200 rpm.

•

DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC DTC P0747 sets when the TCM detects an incorrect offgoing ratio (range-to-range) for an accumulated number of occurrences. Action Taken When the DTC Sets •

When DTC P0747 is active, the following conditions will occur: — If failure occurs while in a forward range, the transmission will shift to the previous range. — If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral). — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral) (some cases may lock in N (Neutral)). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will shift to N (Neutral).

•

DTC P0747 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. 5–118

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

•

•

This DTC indicates the off-going clutch being controlled by solenoid A is not releasing or is slow to release. This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record data for previous or current range information when the DTC was set to determine the specific shift when the DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect. If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel) Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.

NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the installation of a engine power package or module will not be covered under the Allison transmission warranty. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. 4. 5. 6.

This step tests the ignition voltage. This step tests for erratic speed sensor readings or signal dropout. This step tests for internal hydraulic leakage. This step tests for clutch capacity.

DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Install the Scan Tool. 2. Start the engine. 3. Record the DTC Failure Record data. 4. Use the Failure Record data to determine during which shift the code was set. 5. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. Make the shift determined in Step 3. 2. Using the Scan Tool, monitor turbine, engine, and output speed sensor readings. Is speed sensor data erratic or are dropouts in signal indicated?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to the appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On (cont’d) Step Action 1. Connect a 2000 kPa (300 psi) pressure 5 gauge to the main-pressure tap. Refer to Mechanic’s Tips. 2. Use the Scan Tool, in clutch test mode, to cycle through all transmission ranges with the engine at idle and vehicle brakes applied. 3. Record main pressure in each range.

Value(s) —

Yes Go to General Troubleshooting — Low Pressure (Section 7)

No Go to Step 6

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Diagnostic Aids

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

Go to Step 10

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Was the main pressure low in a specific range or in ranges where the same clutch was applied? 6

7

8

9

10 11

5–120

CAUTION: Do not perform a clutch test on fourth and fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur. 1. Using the Scan Tool, select the clutch test mode. 2. With engine at idle speed (600 rpm), vehicle brakes applied, select D (Drive). 3. Using clutch test mode, select and attain first range. Turbine speed should go to zero. 4. Increase engine speed to 1400 rpm. Did turbine speed remain at zero? 5. Repeat the two previous steps for ranges two through five. Did turbine speed remain at zero in all ranges? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement. Is the overhaul or replacement complete? Inspect the control valve body for stuck or sticking trimmer valves. Refer to Mechanic’s Tips. Was a valve problem found and repaired? Replace A solenoid. Is solenoid replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Use the Scan Tool to reset adaptive for all shifts. 3. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0748 Pressure Control Solenoid A Electrical TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED)

M

L

J2-22

TCM

J2-23

TRANSMISSION BULKHEAD CONNECTOR M J2 J1

L NOTE: Letters I, O, and Q are not used.

TCM M

SOL A (PCS)

223

J2-23

TRANSMISSION L

222

J2-22 BATTERY

NOTE: Wire 222 is a battery direct power source for trim solenoid A.

V06223.01.00

Circuit Description Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the pressure output is proportional to the amount of controlled current commanded by the TCM. The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter Clutch (TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to the high frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion proportional to the current commanded from the TCM. This supplies the desired signal pressure to control the trim valve. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine crank time is under 4 seconds.

Conditions for Setting the DTC DTC P0748 is set when one of the following conditions is detected for 125 milliseconds. •

Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim solenoid A. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) •

Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at trim solenoid A.

•

Short to power — TCM commanded duty cycle is under 15 percent with electrical current present.

•

Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check the connection at the transmission and clear codes.

Action Taken When the DTC Sets •

When DTC P0748 is active, the following conditions will occur: — If failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the transmission is compromised by a direction change; then the transmission will shift to or lock in N (Neutral). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will lock in N (Neutral).

•

DTC P0748 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness first, then at the transmission internal harness. •

Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector. Look for the following conditions: — — — — — — —

A bent terminal. A backed-out terminal. A damaged terminal. Poor terminal tension. A chafed wire. A broken wire inside the insulation. Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage, etc. — Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This data can be useful in reproducing the failure mode where the DTC was set.

•

If this DTC appears to be temperature-related, suspect a defective solenoid. A failing solenoid may be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition voltage. 3. This step tests the TCM for proper operation. 4. This step tests for the proper resistance at the OEM vehicle harness. 5. This step tests the resistance value at the transmission main connector. 7. This step tests the resistance value at the trim solenoid.

DTC P0748 Pressure Control Solenoid A Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

Value(s) —

1. 2. 3. 4.

Install the Scan Tool. 9–18V (12V TCM); Start the engine. 18–32V Record the DTC Failure Record data. (24V TCM) Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Install the Scan Tool. Duty cycle value of 75 percent is an 2. Turn the ignition ON, with the engine OFF. indication that 3. In solenoid test mode, command A trim the TCM is comsolenoid ON. manding the Did the Scan Tool indicate A solenoid as being solenoid ON. commanded ON? NOTE: Review Section 4 — Wire Check Refer to Solenoid Procedures before performing the following Resistance Table steps. (Page 5–12) 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 3. Using a DVOM, attach leads to J2 pins 22 and 23. 4. Measure the resistance of the circuit. Is the resistance reading within the specified value?

Yes Go to Step 2

Go to Step 3

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

Go to Step 4

Go to Step 10

Go to Diagnostic Aids

Go to Step 5

NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0748 Pressure Control Solenoid A Electrical (cont’d) Step Action Value(s) 1. Turn the ignition OFF. Refer to Solenoid 5 2. Disconnect the wiring harness from the main Resistance Table transmission connector at the back of the (Page 5–12) transmission. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 3. Using a DVOM, measure the resistance between pins L and M at the magnetic overlay. Is the resistance within the specified value? — NOTE: The vehicle OEM has responsibility 6 for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

7

8

9

10

Repair the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the internal wiring harness at solenoid A connector. 3. Using a DVOM, measure the resistance of solenoid A. Is the solenoid resistance within the specified value? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid A. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Yes Go to Step 6

No Go to Step 7

Go to Step 11

—

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

Replace the TCM. Is the replacement complete?

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0748 Pressure Control Solenoid A Electrical (cont’d) Step Action 11 In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1

No System OK

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0763 Shift Solenoid C Electrical

TRANSMISSION HARNESS CONNECTOR W

J2 CONNECTOR (RED) C

B A J2-31 J2-28

TRANSMISSION BULKHEAD CONNECTOR

TCM

J2-26 J2-27

W

C

J2

B

J1

A

NOTE: Letters I, O, and Q are not used.

C

231

J2-31

12V (A)

SOL C (ON/OFF) A

SOL D (ON/OFF)

TRANSMISSION B

226 227

TCM

J2-26 J2-27

SOL E (ON/OFF) W

228

J2-28 BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E.

V06230.01.00

Circuit Description Shift solenoid C is a normally closed (N/C) solenoid that provides control main pressure to stroke the C shift valve. The TCM determines the proper solenoid command logic to move the C shift valve to attain a particular range requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC P0763 is set when the TCM detects one of the following conditions for more than 100 milliseconds: •

Open circuit or short to ground detected when C solenoid is commanded OFF.

•

Short to power is detected when C solenoid is commanded ON.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

When DTC P0763 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse. — If the shift selector is moved to a forward range or reverse and transmission is compromised by overspeeding or direction change, transmission shifts to neutral. — If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.

•

DTC P0763 is stored in TCM history.

•

The CHECK TRANS light illuminates on first occurrence.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions at the OEM harness first and then at the transmission internal harness.

•

Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. — Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage etc. — Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where DTC was set.

•

If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

•

If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical DTCs may be present (C, D, E electrical codes). Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition voltage. 3. This step tests the TCM for proper command status. 4. This step tests the OEM harness for an open condition. 5. This step tests for the proper resistance at the main transmission connector. 7. This step tests for the proper resistance value at the shift solenoid.

DTC P0763 Shift Solenoid C Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector (RED) at the TCM. 3. Install J 39700 breakout box and J 43799 breakout box adapter 4. Turn ON the ignition, with the engine OFF. 5. Using the Scan Tool in solenoid test mode, command C solenoid to ON. 6. Using a DVOM measure the voltage between J2 terminal 26 and terminal 31. Is the voltage within the range specified when C solenoid is commanded ON? NOTE: Review Section 4 — Wire Check Procedures before performing the following steps. 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. 3. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter Harness, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 4. Using a DMM, attach leads to J2 pins 31 and 26 5. Measure the resistance of the circuit. Is the resistance within the specified value?

5–128

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Battery Voltage

Go to Step 4

Go to Step 10

22 Ohms at 68°F

Go to Diagnostic Aids

Go to Step 5

Refer to Solenoid Resistance Table (Page 5–12) NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0763 Shift Solenoid C Electrical (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Disconnect the wiring harness from the main transmission connector at the back of the transmission. 3. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 4. Using a DMM, measure resistance between bulkhead connector pins A and C at the magnetic overlay. Is the resistance within the specified values? 6

7

8

9

10

NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the connector from C solenoid. 3. Using a DMM, measure the resistance at the solenoid. Is the solenoid resistance within the specified value? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid C. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete?

Value(s) 22 Ohms at 68°F

Yes Go to Step 6

No Go to Step 7

—

Go to Step 11

—

22 Ohms at 68°F

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

Refer to Solenoid Resistance Table (Page 5–12)

Refer to Solenoid Resistance Table (Page 5–12)

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0763 Shift Solenoid C Electrical (cont’d) Step Action 11 In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

5–130

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1

No System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0768 Shift Solenoid D Electrical

TRANSMISSION HARNESS CONNECTOR W

J2 CONNECTOR (RED) C

B A J2-31 J2-28

TRANSMISSION BULKHEAD CONNECTOR

TCM

J2-26 J2-27

W

C

J2

B

J1

A

NOTE: Letters I, O, and Q are not used.

C

231

J2-31

12V (A)

SOL C (ON/OFF) A

SOL D (ON/OFF)

TRANSMISSION B

226 227

TCM

J2-26 J2-27

SOL E (ON/OFF) W

228

J2-28 BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E.

V06230.01.00

Circuit Description Shift solenoid D is a normally closed (N/C) solenoid that provides control main pressure to stroke the D shift valve. The TCM determines the proper solenoid command logic to move the D shift valve to attain a particular range requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC P0768 is set when the TCM detects one of the following conditions for more than 100 milliseconds: •

Open circuit or short to ground detected when D solenoid is commanded OFF.

•

Short to power is detected when D solenoid is commanded ON. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

When DTC P0768 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse. — If the shift selector is moved to a forward range or reverse and transmission is compromised by overspeeding or direction change, transmission shifts to neutral. — If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.

•

DTC P0768 is stored in TCM history.

•

The CHECK TRANS light illuminates on first occurrence.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions at the OEM harness first and then at the transmission internal harness.

•

Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. — Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage etc. — Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where DTC was set.

•

If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

•

If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical DTCs may be present (C, D, E electrical codes).

5–132

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition voltage. 3. This step tests the TCM for proper command status. 4. This step tests the OEM harness for an open condition. 5. This step tests for the proper resistance at the main transmission connector. 7. This step tests for the proper resistance value at the shift solenoid.

DTC P0768 Shift Solenoid D Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector (RED) at the TCM. 3. Install J 39700 breakout box and J 43799 breakout box adapter 4. Turn ON the ignition, with the engine OFF. 5. Using the Scan Tool in solenoid test mode, command D solenoid to ON. 6. Using a DVOM measure the voltage between J2 terminal 27 and terminal 31. Is the voltage within the range specified when D solenoid is commanded ON? NOTE: Review Section 4 — Wire Check Procedures before performing the following steps. 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. 3. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter Harness, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 4. Using a DMM, attach leads to J2 pins 27 and 31 5. Measure the resistance of the circuit. Is the resistance within the specified value?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Battery Voltage

Go to Step 4

Go to Step 10

22 Ohms at 68°F

Go to Diagnostic Aids

Go to Step 5

Refer to Solenoid Resistance Table (Page 5–12) NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0768 Shift Solenoid D Electrical (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Disconnect the wiring harness from the main transmission connector at the back of the transmission. 3. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 4. Using a DMM, measure resistance between pins B and C at the magnetic overlay. Is the resistance within the specified values? 6

7

8

9

10

11

5–134

NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the connector from D solenoid. 3. Using a DMM, measure the resistance at the solenoid. Is the resistance within the specified value? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid D. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Value(s) 22 Ohms at 68°F

Yes Go to Step 6

No Go to Step 7

—

Go to Step 11

—

22 Ohms at 68°F

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Refer to Solenoid Resistance Table (Page 5–12)

Refer to Solenoid Resistance Table (Page 5–12)

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0773 Shift Solenoid E Electrical

TRANSMISSION HARNESS CONNECTOR W

J2 CONNECTOR (RED) C

B A J2-31 J2-28

TRANSMISSION BULKHEAD CONNECTOR

TCM

J2-26 J2-27

W

C

J2

B

J1

A

NOTE: Letters I, O, and Q are not used.

C

231

J2-31

12V (A)

SOL C (ON/OFF) A

SOL D (ON/OFF)

TRANSMISSION B

226 227

TCM

J2-26 J2-27

SOL E (ON/OFF) W

228

J2-28 BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E.

V06230.01.00

Circuit Description Shift solenoid E is a normally closed (N/C) solenoid that provides control main pressure to stroke the E shift valve. The TCM determines the proper solenoid command logic to move the E shift valve to attain a particular range requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC P0773 is set when the TCM detects one of the following conditions for more than 100 milliseconds: •

Open circuit or short to ground detected when E solenoid is commanded OFF.

•

Short to power is detected when E solenoid is commanded ON. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

When DTC P0773 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse. — If the shift selector is moved to a forward range or reverse and transmission is compromised by overspeeding or direction change, transmission shifts to neutral. — If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.

•

DTC P0773 is stored in TCM history.

•

The CHECK TRANS light illuminates on first occurrence.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions at the OEM harness first and then at the transmission internal harness.

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. — Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage etc. — Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where DTC was set.

•

If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

•

If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical DTCs may be present (C, D, E electrical codes).

5–136

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition voltage. 3. This step tests the TCM for proper command status. 4. This step tests the OEM harness for an open condition. 5. This step tests for the proper resistance at the main transmission connector. 7. This step tests for the proper resistance value at the shift solenoid.

DTC P0773 Shift Solenoid E Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector (RED) at the TCM. 3. Install J 39700 breakout box and J 43799 breakout box adapter 4. Turn ON the ignition, with the engine OFF. 5. Using the Scan Tool in solenoid test mode, command E solenoid to ON. 6. Using a DVOM measure the voltage between J2 terminal 28 and terminal 31. Is the voltage within the range specified when E solenoid is commanded ON? NOTE: Review Section 4 — Wire Check Procedures before performing the following steps. 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. 3. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter Harness, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 4. Using a DMM, attach leads to J2 pins 31 and 28 5. Measure the resistance of the circuit. Is the resistance within the specified value?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Battery Voltage

Go to Step 4

Go to Step 10

22 Ohms at 68°F

Go to Diagnostic Aids

Go to Step 5

Refer to Solenoid Resistance Table (Page 5–12) NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0773 Shift Solenoid E Electrical (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Disconnect the wiring harness from the main transmission connector at the back of the transmission. 3. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 4. Using a DMM, measure resistance between pins W and C at the magnetic overlay. Is the resistance within the specified values? 6

7

8

9

10

11

5–138

NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the connector from E solenoid. 3. Using a DMM, measure the resistance at the solenoid. Is the resistance within the specified value? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid E. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Value(s) 22 Ohms at 68°F

Yes Go to Step 6

No Go to Step 7

—

Go to Step 11

—

22 Ohms at 68°F

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Refer to Solenoid Resistance Table (Page 5–12)

Refer to Solenoid Resistance Table (Page 5–12)

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off

REFER TO HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure supplied by this solenoid is proportional to the controlled current command. The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a clutch is slipping. The clutch being controlled by the solenoid B will vary depending on the shift that was being completed. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Turbine speed is greater than 60 rpm.

•

Output speed is greater than 125 rpm.

•

Transmission is at normal operating temperature.

•

DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC DTC P0776 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number of occurrences. Action Taken When the DTC Sets •

When DTC P0776 is active, the following conditions will occur: — If failure occurs while in a forward range, the transmission will shift to the previous range. — If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral). — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock in N (Neutral)). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral). — If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will shift to N (Neutral).

•

DTC P0776 is stored in the TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

This DTC indicates the on-coming clutch being controlled by solenoid B is not applied or applied too slowly. This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record data for previous or current range information when the DTC was set to determine the specific shift when the DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.

•

If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)

•

Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.

NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the installation of a engine power package or module will not be covered under the Allison transmission warranty. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. 4. 5. 6.

This step tests the ignition voltage. This step tests speed sensor readings. This step tests for internal hydraulic leakage. This step tests for clutch capacity.

DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

5–140

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Install the Scan Tool. 2. Start the engine. 3. Record DTC Failure Record data. 4. Use the Failure Record data to determine during which shift the code was set. 5. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. Make the shift determined in Step 3. 2. Using the Scan Tool, monitor turbine, engine, and output speed sensor readings. Is speed sensor data erratic or are dropouts in signal indicated?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to the appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off (cont’d) Step Action 1. Connect a 2000 kPa (300 psi) pressure 5 gauge to the main-pressure tap (refer to Mechanic’s Tips). 2. Use the Scan Tool, in clutch test mode, to cycle through all transmission ranges with the engine at idle and vehicle brakes applied. 3. Record main pressure in each range.

6

Was the main pressure low in a specific range or in ranges where the same clutch was applied? CAUTION: Do not perform a clutch test on fourth and fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur.

Value(s) —

Yes Go to General Troubleshooting — Low Pressure (Section 7)

No Go to Step 6

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Diagnostic Aids

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

Go to Step 10

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

1. Using the Scan Tool, select the clutch test mode. 2. With engine at idle speed (600 rpm), vehicle brakes applied, select D (Drive). 3. Using clutch test mode, select and attain first range. Turbine speed should go to zero. 4. Increase engine speed to 1400 rpm. Did turbine speed remain at zero? 5. Repeat the two previous steps for ranges two through five. Did turbine speed remain at zero in all ranges? 7

8

9

10 11

Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement. Is the overhaul or replacement complete? Inspect the control valve body for stuck or sticking trimmer valves (refer to Mechanic’s Tips). Was a valve problem found and repaired? Replace B solenoid. Is solenoid replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Use the Scan Tool to reset adaptive for all shifts. 3. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On

REFER TO HYDRAULIC SCHEMATIC (APPENDIX H) Circuit Description Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure supplied by this solenoid is proportional to the controlled current command. The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a clutch is in a tie-up condition or if three clutches are applied. The clutch being controlled by solenoid B will vary depending on the shift. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). One of the following conditions occurs: — Output speed is greater than 200 rpm.

•

— Turbine speed is greater than 200 rpm. DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC DTC P0777 sets when the TCM detects an incorrect off-going ratio, range-to-range, for an accumulated number of occurrences. Action Taken When the DTC Sets •

When DTC P0777 is active, the following conditions will occur: — If failure occurs while in a forward range, the transmission will shift to the previous range. — If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral). — If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral). — If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral) (some cases may lock in N (Neutral)).

• • • •

— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or a direction change, the transmission will shift to N (Neutral). DTC P0777 is stored in the TCM history. The CHECK TRANS light illuminates. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. 5–142

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

This DTC indicates the off-going clutch being controlled by solenoid B is not released or is released too slowly. This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record data for previous or current range information when the DTC was set to determine the specific shift when the DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect. • If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the signal is erratic, investigate and eliminate the following: — Intermittent wiring connection — Excessive vibration (driveline or engine torsionals) — Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel) • Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated. NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the installation of a engine power package or module will not be covered under the Allison transmission warranty. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. 4. 5. 6.

This step tests the ignition voltage. This step tests for correct speed sensor operation. This step tests for internal hydraulic leakage. This step tests for clutch capacity.

DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

Perform the A/T Fluid Checking Procedure (Appendix P) and correct the fluid level if necessary. Did you perform the procedure? 1. Install the Scan Tool. 2. Start the engine. 3. Record the DTC Failure Record data. 4. Use the Failure Record Data to determine during which shift the code was set. 5. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition ON and drive the vehicle under normal operating conditions. Make the shift determined in Step 3. 2. Using the Scan Tool, monitor turbine, engine, and output speed sensor readings. Is speed sensor data erratic or are dropouts in signal indicated?

Value(s) —

Yes Go to Step 2

—

Go to Step 3

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 4

Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to the appropriate speed sensor DTC

Go to Step 5

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On (cont’d) Step Action 1. Connect a 2000 kPa (300 psi) pressure 5 gauge to the main-pressure tap. Refer to Mechanic’s Tips. 2. Use the Scan Tool, in clutch test mode, to cycle through all transmission ranges with the engine at idle and vehicle brakes applied. 3. Record main pressure in each range.

Value(s) —

Yes Go to General Troubleshooting — Low Pressure (Section 7)

No Go to Step 6

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Diagnostic Aids

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

Go to Step 10

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Was the main pressure low in a specific range or in ranges where the same clutch was applied? 6

7

8

9

10 11

5–144

CAUTION: Do not perform a clutch test on fourth and fifth range under stall conditions (above 1400 rpm with brakes held), or possible clutch damage could occur. 1. Using the Scan Tool, select the clutch test mode. 2. With engine at idle speed (600 rpm), vehicle brakes applied, select D (Drive). 3. Using clutch test mode, select and attain first range. Turbine speed should go to zero. 4. Increase engine speed to 1400 rpm. Did turbine speed remain at zero? 5. Repeat the two previous steps for ranges two through five. Did turbine speed remain at zero in all ranges? Remove the dipstick and inspect the transmission fluid for clutch debris or burnt odor. If necessary, drain a small amount of fluid for this inspection. Are there signs of a clutch failure? Remove the transmission for overhaul or replacement. Is the overhaul or replacement complete? Inspect the control valve body for stuck or sticking trimmer valves. Refer to Mechanic’s Tips. Was a valve problem found and repaired? Replace B solenoid. Is solenoid replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Use the Scan Tool to reset adaptive for all shifts. 3. Operate the vehicle in all ranges under normal driving conditions. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0778 Pressure Control Solenoid B Electrical

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED)

P

N J2-24

J2-25

TCM

TRANSMISSION BULKHEAD CONNECTOR P J2 N

J1

NOTE: Letters I, O, and Q are not used.

TCM N

SOL B (PCS)

224

J2-24 BATTERY

TRANSMISSION P

225

J2-25

NOTE: Wire 225 is a battery direct power source for trim solenoid B.

V06224.01.00

Circuit Description Trim solenoid B is used to control on-coming, off-going, and holding pressure to any of the five clutches. This solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure supplied by this solenoid is proportional to the controlled current command. The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter Clutch (TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to the high frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion proportional to the current commanded from the TCM. This supplies the desired signal pressure to control the trim valve. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Engine crank time is under 4 seconds. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0748 is set when one of the following conditions is detected for 125 milliseconds. • • • •

Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim solenoid A. Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at trim solenoid A. Short to power — TCM commanded duty cycle is under 15 percent with electrical current present. Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check the connection at the transmission and clear codes.

Action Taken When the DTC Sets •

When DTC P0778 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission will shift to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — If the shift selector is moved to R (Reverse), the transmission will shift to reverse.

• • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or a direction change, the transmission shifts to neutral. DTC P0778 is stored in the TCM history. The CHECK TRANS light illuminates. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness first, then at the transmission internal harness. •

Inspect the wiring for poor electrical connections at the TCM connector and the main transmission connector. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. — Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage, etc.

•

— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) • •

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This data can be useful in reproducing the failure mode where the DTC was set. If this DTC appears to be temperature-related, suspect a defective trim solenoid. It is possible for a trim solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper ignition voltage. 3. This step tests the command signal from the TCM and tests the external wiring harness for shorts or opens. 4. This step tests for the proper resistance at the OEM vehicle harness. 5. This step tests for the proper resistance value at the main transmission connector. 8. This step tests for the proper resistance value at the trim solenoid.

DTC P0778 Pressure Control Solenoid B Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Install the Scan Tool. 2. Turn the ignition ON, with the engine OFF. 3. In solenoid test mode, command B trim solenoid ON. Did the Scan Tool indicate B solenoid as being commanded ON?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Duty cycle value of 75 percent is an indication that the solenoid is in the ON state.

Go to Step 4

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563) Go to Step 10

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P0778 Pressure Control Solenoid B Electrical (cont’d) Step Action NOTE: Review Section 4 — Wire Check 4 Procedures before performing the following steps.

5

6

7

5–148

1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 3. Using a DVOM, attach leads to J2 pins 24 and 25. 4. Measure the resistance of the circuit. Is the resistance reading within the specified value? 1. Turn the ignition OFF. 2. Disconnect the wiring harness from the main transmission connector at the back of the transmission. Using J 39700 Breakout Box and J 44722 Adapter Harness, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 3. Using a DVOM, measure resistance between transmission bulkhead connector pins N and P at the magnetic overlay. Is resistance within the specified values? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the internal wiring harness at solenoid B connector. 3. Using a DVOM, measure the resistance of solenoid B. Is the solenoid resistance within the specified value?

Value(s) Refer to Solenoid Resistance Table (Page 5–12)

Yes Go to Diagnostic Aids

No Go to Step 5

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 6

Go to Step 7

—

Go to Step 11

—

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 8

Go to Step 9

NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0778 Pressure Control Solenoid B Electrical (cont’d) Step Action Replace the internal wiring harness. Refer to 8 Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid B. Refer to Service Manual or 9 Mechanic’s Tips. Is the replacement complete? 10 NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

11

Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Value(s) —

Yes Go to Step 11

No —

—

Go to Step 11

—

—

Go to Step 11

—

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0840 Transmission Pressure Switch Solenoid C Circuit

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position. Conditions for Running the DTC • • • • •

Components are powered and the ignition voltage is greater than 5V. DTC P0561, P0562, or P0563 is not active. C shift valve is destroked. Transmission temperature is above –25°C (–13°F). Vehicle shutdown is not in process.

5–150

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0840 sets during steady state operation when C shift valve is in the destroked state (commanded OFF) and C pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command C solenoid ON and OFF. If the pressure switch state does not change, and remains in the ON state, DTCs P0840 and P0842 will set. Action Taken When the DTC Sets •

When DTC P0840 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse. — If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral.

•

DTC P0840 is stored in TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When only a P0840 is set, look for an intermittent short to ground at the pressure switch circuit or intermittent hydraulic failure (sticking valve). This code is set when the condition occurs more than 3 times during the current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.

•

When a P0840 and P0842 are set in combination, this may indicate a short to ground at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. Check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.

•

Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0840 Transmission Pressure Switch Solenoid C Circuit Step 1

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

2

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary?

3

Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values?

4

1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

—

Go to Step 3

Go to A/T Fluid Checking Procedure (Appendix P)

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates that a short circuit condition may exist in the OEM harness, the internal transmission wiring harness, or the PSM. Did DTC P0840 return?

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d) Step 5

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 1 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

Value(s) —

Yes Go to Step 6

No Go to Step 12

6

1. Turn the ignition OFF and reconnect the J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 201 (pin D) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

—

Go to Step 7

Go to Step 11

7

1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin A. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

—

Go to Step 8

Go to Step 10

8

1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch C membrane. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

—

Go To Diagnostic Aids

Go to Step 9

9

Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

—

Go to Step 13

—

10

Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d) Step 11

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

—

Begin the diagnosis again. Go to Step 1

System OK

Repair the vehicle wiring harness. Is the repair complete? 12

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete?

13

In order to verify your repair: 1. Clear the DTC. 2. Operate the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

* If J 39700 and J 44722 are available, they may be used to perform this operation.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F E NOTE: Letters I, O, and Q are not used.

C

A

D

B

D

TRANSMISSION

F

E

C

E

R

D

K

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0561, P0562, or P0563 is not active.

•

C shift valve is commanded to the ON (stroked) position. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0841 is set when C solenoid is commanded ON and C pressure switch status remains OFF for a period of time. The time period is 5 seconds at 0°C (32°F) to -40°C (-40°F). The intent of this DTC is to detect a stuck shift valve, in the destroked state, a mechanical solenoid failure, or an open circuit. Action Taken When the DTC Sets •

When DTC P0841 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse. — If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral.

•

DTC P0841 is stored in TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When a P0841 and P0843 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground or opens at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.

•

Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for opens in the OEM wiring harness. 7. This step tests for opens in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9) —

Go to Step 4

Go to General Troubleshooting (Section 7)

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

NOTE: This DTC may indicate a stuck shift valve, mechanically failed solenoid, open in switch circuit, or defective PSM. 5

Did DTC P0841 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 1 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d) Step 6

7

8

9

10

11

12

5–158

Action 1. Turn the ignition OFF and reconnect the J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 201 (pin D) on the harness connector to a known good ground.* Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin A. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch C membrane. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? Remove the control valve body and check for a stuck or sticking C shift valve. Refer to Service Manual or Mechanic’s Tips. Was the C shift valve stuck or sticking? Replace the C shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is replacement of solenoid and reinstalling of control valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 7

No Go to Step 14

—

Go to Step 8

Go to Step 13

Go to Step 9

Go to Step 12

Go to Step 11

Go to Step 10

Go to Step 16

Go to Step 16

—

Copyright© 2004 General Motors Corp.

Go to Step 16

—

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d) Step 13

14

Action Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

15

Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 16

No —

—

Go to Step 16

—

—

Go to Step 16

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Operate the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

D

TRANSMISSION

F

E

C

E

R

D

K

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

DTC P0561, P0562, or P0563 is not active.

•

C shift valve is commanded to the OFF (destroked) position.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0842 is set when C solenoid is commanded OFF and C pressure switch status remains ON for a period of time that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 6 seconds at –40°C (–40°F). The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit short to ground. Action Taken When the DTC Sets •

When DTC P0842 is active, the following conditions will occur: — — — —

• • • •

If the failure occurs while in a forward range, the transmission shifts to another forward range. If the shift selector is moved to N (Neutral), the transmission will shift to neutral. if the shift selector is moved to R (Reverse), the transmission shifts to reverse. If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0842 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

• •

•

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. When a P0842 and P0840 are set in combination, this may indicate a short to ground at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

—

Go to Step 7

Go to Step 14

NOTE: This DTC may indicate a stuck shift valve, mechanically failed solenoid, short to ground in the switch circuit, or a defective PSM. 5

6

5–162

Did DTC P0842 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 1 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect the J2 connector to the TCM. 2 Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 201 (pin D) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d) Step 7

8

9

10

11

12

13

14

Action 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin A. Does the Scan Tool indicate reverse pressure switch C status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch C membrane. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? Remove the control valve body and inspect for a stuck or sticking C shift valve. Refer to Service Manual or Mechanic’s Tips. Was the C shift valve stuck or sticking? Replace the C shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is replacement of solenoid and reinstalling of valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete?

Value(s) —

Yes Go to Step 8

No Go to Step 13

Go to Step 9

Go to Step 12

Go to Step 11

Go to Step 10

Go to Step 16

Go to Step 16

—

Go to Step 16

—

—

Go to Step 16

—

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d) Step 15

Action Value(s) Yes NOTE: In most cases, the TCM is not at fault. Go to Step 16 — Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Operate the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

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Copyright© 2004 General Motors Corp.

No —

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0843 Transmission Pressure Switch Solenoid C Circuit High

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position. Conditions for Running the DTC • • • • •

Components are powered and the ignition voltage is greater than 5V. DTC P0561, P0562, or P0563 is not active. C shift valve is commanded to the ON (stroked) position. Transmission temperature is above –25°C (–13°F). Vehicle shutdown is not in process. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0843 sets during steady state operation when C shift valve is in the stroked state (commanded ON) and C pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command C solenoid OFF and ON. If the pressure switch state does not change, and remains in the OFF state, DTCs P0841 and P0843 will set. Action Taken When the DTC Sets •

When DTC P0843 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0843 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

•

— A broken wire inside the insulation. When only a DTC P0843 is set, look for an intermittent open condition at the pressure switch circuit or an intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault. When a P0843 and P0841 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for an open condition at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for opens in the OEM wiring harness. 7. This step tests for opens in the internal wiring harness. 8. This step tests for PSM switch function.

DTC P0843 Transmission Pressure Switch Solenoid C Circuit High Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates an open circuit condition may exist in the OEM wiring harness, the internal transmission wiring harness, or the PSM. Did DTC P0843 return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d) Step 5

6

7

8

9

10

5–168

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 1 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect the J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 201 (pin D) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin A. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch C membrane. Does the Scan Tool indicate pressure switch C status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 12

—

Go to Step 7

Go to Step 11

—

Go to Step 8

Go to Step10

Go to Diagnostic Aids

Go to Step 9

—

Go to Step 13

—

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d) Step 11

12

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 13 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

5–169

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0845 Transmission Pressure Switch Solenoid D Circuit

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position. Conditions for Running the DTC • • • • •

Components are powered and the ignition voltage is greater than 5V. DTC P0561, P0562, or P0563 is not active. D shift valve is commanded to the OFF (destroked) position. Transmission temperature is above –25°C (–13°F). Vehicle shutdown is not in process.

5–170

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0845 sets during steady state operation when D shift valve is in the destroked state (commanded OFF) and D pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command D solenoid ON and OFF. If the pressure switch state does not change, and remains in the ON state, DTCs P0845 and P0847 will set. Action Taken When the DTC Sets •

When DTC P0845 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0845 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

•

— A broken wire inside the insulation. When only a DTC P0845 is set, look for an intermittent short to ground at the pressure switch circuit or an intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault. When a P0845 and P0847 are set in combination, this may indicate a short to ground is present at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed. Copyright© 2004 General Motors Corp.

5–171

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0845 Transmission Pressure Switch Solenoid D Circuit Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates a short circuit condition may exist in the OEM wiring harness, the internal transmission wiring harness, or the PSM. Did DTC P0845 return?

5–172

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d) Step 5

6

7

8

9

10

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 2 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 202 (pin F) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin B. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch D membrane. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 12

—

Go to Step 7

Go to Step 11

—

Go to Step 8

Go to Step 10

—

Go to Diagnostic Aids

Go to Step 9

—

Go to Step 13

—

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d) Step 11

12

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 13 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure report. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–174

Copyright© 2004 General Motors Corp.

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

D

TRANSMISSION

F

E

C

E

R

D

K

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

D shift valve is commanded to the ON (stroked) position. Copyright© 2004 General Motors Corp.

5–175

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0846 sets when D solenoid is commanded ON and D pressure switch status remains OFF for a period of time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift valve, in the destroked state, a mechanical solenoid failure, or an open circuit. Action Taken When the DTC Sets •

When DTC P0846 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse. — If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral.

•

DTC P0846 is stored in TCM history.

•

The CHECK TRANS light illuminates.

•

The TCM inhibits TCC engagement.

•

The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When a P0846 and P0848 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for an open condition at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set.

•

Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

5–176

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. 5. 6. 7. 8.

This step tests for an active DTC. This step tests the TCM for proper switch status. This step tests for opens in the OEM wiring harness. This step tests for opens in the internal wiring harness. This step tests the PSM switch function.

DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

NOTE: This DTC may indicate a stuck shift valve, solenoid mechanically failed, an open condition in the switch circuit, or a defective PSM. 5

Did DTC P0846 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 2 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

5–177

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d) Step 6

7

8

9

10

11

12

5–178

Action 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 202 (pin F) on the harness connector to a known good ground.* Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin B. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open?

Value(s) —

Yes Go to Step 7

No Go to Step 14

—

Go to Step 8

Go to Step 13

1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch D membrane. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? Remove the control valve body and check for a stuck or sticking D shift valve. Refer to Service Manual or Mechanic’s Tips. Was the D shift valve stuck or sticking? Replace the D shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is replacement of the solenoid and reinstalling of the control valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

—

Go to Step 9

Go to Step 12

—

Go to Step 11

Go to Step 10

—

Go to Step 16

—

—

Go to Step 16

—

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d) Step 13

14

Action Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

15

Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 16

No —

—

Go to Step 16

—

—

Go to Step 16

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

5–179

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). D shift valve is commanded to the OFF (destroked) position.

Conditions for Setting the DTC DTC P0847 sets when D solenoid is commanded OFF and D pressure switch status remains ON for a period of time that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 16 seconds at –40°C (–40°F). The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit short to ground. 5–180

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets •

When DTC P0847 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0847 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

— A broken wire inside the insulation. When a P0847 and P0845 are set in combination, this may indicate a short to ground is present at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests for the TCM proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

—

Go to Step 7

Go to Step 14

NOTE: This DTC may indicate a stuck shift valve, solenoid mechanically failed, a short to ground in the switch circuit, or a defective PSM. 5

6

5–182

Did DTC P0847 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 2 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 202 (pin F) on the harness connector to a known good ground.* Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d) Step 7

8

9

10

11

12

13

14

Action 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin B. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch D membrane. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? Remove the control valve body and check for a stuck or sticking D shift valve. Refer to Service Manual or Mechanic’s Tips. Was the D shift valve stuck or sticking? Replace the D shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is the replacement of the solenoid and reinstalling of the control valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced? Replace the PSM (refer to Service Manual or Mechanic’s Tips). Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete?

Value(s) —

Yes Go to Step 8

No Go to Step 13

Go to Step 9

Go to Step 12

Go to Step 11

Go to Step 10

Go to Step 16

Go to Step 16

—

Go to Step 16

—

—

Go to Step 16

—

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

5–183

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d) Step 15

Action Value(s) Yes NOTE: In most cases, the TCM is not at fault. Go to Step 16 — Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–184

Copyright© 2004 General Motors Corp.

No —

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0848 Transmission Pressure Switch Solenoid D Circuit High

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position. Conditions for Running the DTC • • • • •

Components are powered and the ignition voltage is greater than 5V. DTC P0561, P0562, or P0563 is not active. D shift valve is commanded to the ON (stroked) position. Transmission temperature is above –25°C (–13°F). Vehicle shutdown is not in process. Copyright© 2004 General Motors Corp.

5–185

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0848 sets during steady state operation when D shift valve is in the stroked state (commanded ON) and D pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command D solenoid OFF and ON. If the pressure switch state does not change, and remains in the OFF state, DTCs P0848 and P0846 will set. Action Taken When the DTC Sets •

When DTC P0848 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0848 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When only a DTC P0848 is set, look for an intermittent open condition at the pressure switch circuit or an intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.

•

When a P0848 and P0846 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for an open condition at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set.

•

Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

5–186

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for opens in the OEM wiring harness. 7. This step tests for opens in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0848 Transmission Pressure Switch Solenoid D Circuit High Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates an open circuit condition may exist in the OEM wiring harness, the internal transmission wiring harness, or the PSM. Did DTC P0848 return?

Copyright© 2004 General Motors Corp.

5–187

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d) Step 5

6

7

8

9

10

5–188

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 2 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 202 (pin F) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin B. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch D membrane. Does the Scan Tool indicate pressure switch D status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 12

—

Go to Step 7

Go to Step 11

—

Go to Step 8

Go to Step 10

—

Go to Diagnostic Aids

Go to Step 9

—

Go to Step 13

—

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d) Step 11

12

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 13 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

5–189

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position. Conditions for Running the DTC •

Components are powered and the ignition voltage is greater than 5V.

•

DTC P0561, P0562, or P0563 is not active.

•

E shift valve is commanded to the OFF (destroked) position.

•

Transmission temperature is above –25°C (–13°F).

•

Vehicle shutdown is not in process.

5–190

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0870 sets during steady state operation when E shift valve is in the destroked state (commanded OFF) and E pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command E solenoid ON and OFF. If the pressure switch state does not change, and remains in the ON state, DTCs P0870 and P0872 will set. Action Taken When the DTC Sets •

When DTC P0870 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0870 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

•

— A broken wire inside the insulation. When only a DTC P0870 is set, look for an intermittent short to ground at the pressure switch circuit or an intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault. When a P0870 and P0872 are set in combination, this may indicate a short to ground is present at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed. Copyright© 2004 General Motors Corp.

5–191

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates a short circuit condition may exist in the OEM wiring harness, the internal transmission wiring harness, or the PSM. Did DTC P0870 return?

5–192

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d) Step 5

6

7

8

9

10

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 3 to known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 203 (pin E) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin C. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger at the eraser end of a pencil to push gently on the pressure switch E membrane. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 12

—

Go to Step 7

Go to Step 11

—

Go to Step 8

Go to Step 10

—

Go to Diagnostic Aids

Go to Step 9

—

Go to Step 13

—

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

5–193

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d) Step 11

12

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 13 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–194

Copyright© 2004 General Motors Corp.

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0871 (Previously P1710) Transmission Pressure Switch Solenoid E Circuit Stuck Open

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F E NOTE: Letters I, O, and Q are not used.

C

A

D

B

D

TRANSMISSION

F

E

C

E

R

D

K

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

E shift valve is commanded to the ON (stroked) position. Copyright© 2004 General Motors Corp.

5–195

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0871 sets when E solenoid is commanded ON and E pressure switch status remains OFF for a period of time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift valve, in the destroked state, a mechanical solenoid failure, or an open circuit. Action Taken When the DTC Sets •

When DTC P0871 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0871 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

— A broken wire inside the insulation. When a P0871 and P0873 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for an open condition at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 5–196

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) 4. 5. 6. 7. 8.

This step tests for an active DTC. This step tests the TCM for proper switch status. This step tests for opens in the OEM wiring harness. This step tests for opens in the internal wiring harness. This step tests the PSM switch function.

DTC P0871 (Previously P1710) Trans Pressure Switch Solenoid E Circuit Stuck Open Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

NOTE: This DTC may indicate a stuck shift valve, solenoid mechanically failed, an open condition in the switch circuit, or a defective PSM. 5

Did DTC P0871 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 3 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

5–197

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0871 (Previously P1710) Trans Pressure Switch Solenoid E Circuit Stuck Open (cont’d) Step 6

7

8

9

10

11

5–198

Action 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector. 3. Turn the ignition ON. 4. Connect wire 203 (pin E) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin C. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open?

Value(s) —

Yes Go to Step 7

No Go to Step 14

—

Go to Step 8

Go to Step 13

1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch E membrane. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? Remove the control valve body and inspect for a stuck or sticking E shift valve. Refer to Service Manual or Mechanic’s Tips. Was the E shift valve stuck or sticking? Replace the E shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is replacement of the solenoid and reinstalling of the control valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced?

—

Go to Step 9

Go to Step 12

—

Go to Step 11

Go to Step 10

—

Go to Step 16

—

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0871 (Previously P1710) Trans Pressure Switch Solenoid E Circuit Stuck Open (cont’d) Step 12

13

14

Action Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Value(s) —

Yes Go to Step 16

No —

—

Go to Step 16

—

—

Go to Step 16

—

—

Go to Step 16

—

Repair the vehicle wiring harness. Is the repair complete? 15

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

5–199

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0872 (Previously P1711) Transmission Pressure Switch Solenoid E Circuit Stuck Closed

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F E NOTE: Letters I, O, and Q are not used.

C

A

D

B

D

TRANSMISSION

F

E

C

E

R

D

K

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

E shift valve is commanded to the OFF (destroked) position.

5–200

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0872 sets when E solenoid is commanded OFF and E pressure switch status remains ON for a period of time that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 20 seconds at –40°C (–40°F). The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit short to ground. Action Taken When the DTC Sets • When DTC P0872 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0872 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids • Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. •

•

• •

— A broken wire inside the insulation. When a P0872 and P0870 are set in combination, this may indicate a short to ground is present at the pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) 4. 5. 6. 7. 8.

This step tests for an active DTC. This step tests the TCM for proper switch status. This step tests for shorts in the OEM wiring harness. This step tests for shorts in the internal wiring harness. This step tests the PSM switch function.

DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E Circuit Stuck Closed Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Step 6

Go to Step 15

NOTE: This DTC may indicate a stuck shift valve, solenoid mechanically failed, a short to ground in the switch circuit, or a defective PSM. 5

5–202

Did DTC P0872 return? 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 3 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E Circuit Stuck Closed (cont’d) Step 6

7

8

9

10

11

Action 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 203 (pin E) at the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin C. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch E membrane. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? Remove the control valve body and check for a stuck or sticking E shift valve. Refer to Service Manual or Mechanic’s Tips. Was the E shift valve stuck or sticking? Replace the E shift solenoid and reinstall the control valve body. Refer to Service Manual or Mechanic’s Tips. Is replacement of the solenoid and reinstalling of the control valve body complete? Clean and/or polish the sticking valve to restore free movement or replace the control valve body assembly. Refer to Service Manual or Mechanic’s Tips. Was free movement restored or valve body replaced?

Value(s) —

Yes Go to Step 7

No Go to Step 14

—

Go to Step 8

Go to Step 13

—

Go to Step 9

Go to Step 12

—

Go to Step 11

Go to Step 10

—

Go to Step 16

—

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E Circuit Stuck Closed (cont’d) Step 12

13

14

Action Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Value(s) —

Yes Go to Step 16

No —

—

Go to Step 16

—

—

Go to Step 16

—

—

Go to Step 16

—

Repair the vehicle wiring harness. Is the repair complete? 15

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 16 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Operate the vehicle under conditions as noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

5–204

Copyright© 2004 General Motors Corp.

System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High

TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position. Conditions for Running the DTC •

Components are powered and the ignition voltage is greater than 5V.

•

DTC P0561, P0562, or P0563 is not active.

•

E shift valve is commanded to the ON (stroked) position.

•

Transmission temperature is above –25°C (–13°F).

•

Vehicle shutdown is not in process. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0873 sets during steady state operation when E shift valve is in the stroked state (commanded ON) and E pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure switch. Later software levels incorporate retry logic that allows the TCM to command E solenoid OFF and ON. If the pressure switch state does not change, and remains in the OFF state, DTCs P0873 and P0871 will set. Action Taken When the DTC Sets •

When DTC P0873 is active, the following conditions will occur: — If the failure occurs while in a forward range, the transmission shifts to another forward range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. DTC P0873 is stored in TCM history. The CHECK TRANS light illuminates. The TCM inhibits TCC engagement. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

•

•

•

— A broken wire inside the insulation. When only a DTC P0873 is set, look for an intermittent open condition at the pressure switch circuit or an intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault. When a P0873 and P0871 are set in combination, this may indicate an open circuit condition is present at the pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the Troubleshooting Process. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for an open condition at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed.

5–206

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for opens in the OEM wiring harness. 7. This step tests for opens in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High Step 1

2

3

4

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC indicates an open circuit condition may exist in the OEM wiring harness, the internal transmission wiring harness, or the PSM. Did DTC P0873 return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High (cont’d) Step 5

6

7

8

9

10

5–208

Action 1. Turn the ignition OFF. 2. Disconnect J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 3 to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect J2 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Turn the ignition ON. 4. Connect wire 203, pin E, on the main transmission connector to a known good ground.* Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin C. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the pressure switch E membrane. Does the Scan Tool indicate pressure switch E status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 12

—

Go to Step 7

Go to Step 11

—

Go to Step 8

Go to Step 10

—

Go to Diagnostic Aids

Go to Step 9

—

Go to Step 13

—

—

Go to Step 13

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High (cont’d) Step 11

12

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6).

Value(s) —

Yes Go to Step 13

No —

—

Go to Step 13

—

Replace the TCM. Is the replacement complete? In order to verify your repair: Begin the 13 — diagnosis again. 1. Clear the DTC. Go to Step 1 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return? * If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

System OK

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0875 (Previously P1713) Transmission Reverse Pressure Switch Circuit Malfunction TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD R

E

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open, when the manual selector valve is in any position except reverse. When the manual selector valve is moved to Reverse, pressure to the reverse pressure switch is cut off, allowing the switch to close. Conditions for Running the DTC • • • • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds. TFT is greater than 0°C (32°F). The hydraulic system is pressurized. DTC P0708 is not active.

5–210

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0875 sets when P (Park), N (Neutral), or a forward range is selected and the reverse pressure switch state remains in the mechanically closed/electrically ON position for a period of time that is calibration dependent. Action Taken When the DTC Sets •

When DTC P0875 is active, the following conditions will occur: — Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse.

• • • •

— If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault is present when this test fails, then hydraulic default is implemented. DTC P0875 is stored in TCM history. The CHECK TRANS light illuminates on the second occurrence. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

•

• •

•

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B. You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set. This DTC could indicate a hydraulic leak path exhausting pressure from the reverse pressure switch (refer to hydraulic schematic). Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting due to a plugged control main filter or slow pump prime, later software levels have a time delay up to 30 seconds before a pressure switch test is enabled. If a P0875 (previously P1713) is shown in failure records as being logged first on the failure list followed by P0872 (previously P1711) combined with P0708, this generally indicates a NSBU internal switch failure. Often when the codes are cleared they do not return. This may be due to moisture that was present at the time the code was logged, causing an internal short. Inspect the NSBU switch linkage for proper adjustment and for signs of damage. If the shift linkage is properly adjusted and no damage is noted, replacement of the switch may be indicated. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for shorts in the OEM wiring harness. 7. This step tests for shorts in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC is set when P (Park), N (Neutral), or a forward range has been selected and the reverse pressure switch indicates mechanically closed/electrically ON for a period of time that is calibration dependent. This DTC may indicate that a short circuit condition exists in the OEM harness, internal transmission harness or the PSM. A defective NSBU switch may also set this code. The intent of this DTC is to detect discrepancies between range selected at the NSBU and the actual position of the manual selector valve. Did DTC P0875 return? 5–212

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to A/T Fluid Checking Procedure (Appendix P)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Remove the J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. Leave the vehicle harness disconnected from the J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 4 on the Breakout Box panel to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect the J2 6 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Connect wire 204 (pin K) at the main transmission connector to a known good ground.* 4. Turn the ignition ON. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 7

8

9

1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin D. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the reverse pressure switch membrane. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 13

—

Go to Step 7

Go to Step 12

—

Go to Step 8

Go to Step 11

—

Go to Step 10

Go to Step 9

—

Go to Step 14

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d) Step Action 10 1. Inspect for a missing or a damaged seal at the reverse pressure switch assembly. 2. Inspect for loose reverse transfer tube. 3. Inspect for proper shift linkage adjustment. Shift linkage out of adjustment can allow pressure to apply the reverse pressure switch. Did you find and repair a problem? 11 Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? 12 NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Value(s) —

Yes Go to Step 14

No Go to Diagnostic Aids

—

Go to Step 14

—

—

Go to Step 14

—

—

Go to Step 14

—

—

Begin the diagnosis again. Go to Step 1

System OK

Repair the vehicle wiring harness. Is the repair complete? 13

14

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–214

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0876 (Previously P1714) Transmission Reverse Pressure Switch Circuit Stuck Open TRANSMISSION HARNESS CONNECTOR

J2 HARNESS CONNECTOR (RED) J2-3 J2-4

K D

E

J2-2 J2-1

TCM

F

TRANSMISSION BULKHEAD CONNECTOR K

D

J2 J1

F

E NOTE: Letters I, O, and Q are not used.

C

A

D

B

E

C

E

R

D

K

D

TRANSMISSION

F

201 202 203 204

TCM J2-1 J2-2 J2-3

DIGITAL INTERFACE

J2-4

E F

NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH MANIFOLD E

R

D C F E D C B A

V06213.01.00

Circuit Description The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open, when the manual selector valve is in any position except reverse. When the manual selector valve is moved to Reverse, pressure to the reverse pressure switch is cut off allowing the switch to close. Conditions for Running the DTC •

TFT is greater than 0°C (32°F).

•

DTC P0706, P0708, or P0875 is not active.

•

There are two cases where this DTC runs. — Case 1

Ignition voltage is above 9V (12V TCM) or 18V (24V TCM). The PRNDL state and the reverse pressure switch state do not agree.

— Case 2

Ignition voltage is under 9V (12V TCM) or 18V (24V TCM). All speed sensors are under 50 rpm. Copyright© 2004 General Motors Corp.

5–215

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC P0876 sets in two cases: •

When PRNDL and reverse pressure switch do not agree. When reverse range is selected and the reverse pressure switch is detected in the mechanically open/electrically OFF state for more than 1 second.

•

When engine shutdown and reverse pressure switch do not agree. When engine shutdown is in process and the reverse pressure switch is detected in an improper state, mechanically open/electrically OFF, for more than a period of time that is temperature dependent. The time period is 5 seconds at 35°C (95°F) to 30 seconds at –20°C (–4°F).

Action Taken When the DTC Sets •

When DTC P0876 is active, the following conditions will occur: — Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range. — If the shift selector is moved to N (Neutral), the transmission will shift to neutral. — if the shift selector is moved to R (Reverse), the transmission shifts to reverse. — If the shift selector is moved to a forward range or reverse and the transmission is compromised by overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault is present when this test fails, then hydraulic default is implemented.

•

DTC P0876 is stored in TCM history.

•

The CHECK TRANS light illuminates on the second occurrence.

•

The TCM freezes shift adapts (DNA).

•

The TCM inhibits TCC engagement

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when the DTC was set.

•

Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial 8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting due to a plugged control main filter or slow pump prime, later software levels have a time delay up to 30 seconds before a pressure switch test is enabled.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper fluid level. 3. This step tests for proper main pressure. 4. This step tests for an active DTC. 5. This step tests the TCM for proper switch status. 6. This step tests for an open condition in the OEM wiring harness. 7. This step tests for an open condition in the internal wiring harness. 8. This step tests the PSM switch function.

DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

Perform the A/T Fluid Checking Procedure (Appendix P). Did you perform the procedure and correct fluid level if necessary? Perform the Main Pressure Check Procedure (Appendix B). Is main pressure within the specified values? 1. 2. 3. 4. 5.

Install the Scan Tool. Turn ON the ignition, with the engine OFF. Record the failure records. Clear the DTC. Start the vehicle and perform a test drive. Attempt to duplicate the same operating conditions observed in failure records (range attained, transmission temperature, etc.).

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5– 4A) Go to A/T Fluid Checking Procedure (Appendix P)

—

Go to Step 3

Refer to Main Pressure Table (Pages 5–8 and 5–9)

Go to Step 4

Go to General Troubleshooting (Section 7)

—

Go to Step 5

Go to Diagnostic Aids

NOTE: This DTC is set when reverse range is selected and reverse switch status remains in the mechanically open/ electrically OFF state for more than a time that is calibration dependent. This DTC can also set at engine shutdown when the reverse pressure switch is detected in the mechanically open/electrically OFF state for a period of time that is temperature dependent. The time period is 5 seconds at 35°C (95°F) to 30 seconds at –20°C (–4°F). Did DTC P0876 return? Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Remove the J2 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. Leave the vehicle wiring harness disconnected from the J 43799 Breakout Box Adapter. 3. Connect J2 connector pin 4 on the Breakout Box panel to a known good ground. 4. Turn the ignition ON. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 1. Turn the ignition OFF and reconnect the J2 6 connector to the TCM. 2. Disconnect the transmission wiring harness from the main transmission connector at the back of the transmission. 3. Connect wire 204 (pin K) at the main transmission connector to a known good ground.* 4. Turn the ignition ON. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 7

8

9

5–218

1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Disconnect the internal wiring harness from the PSM and ground pin D. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? 1. Remove the PSM from the control valve body and leave the internal harness connected. Refer to Service Manual or Mechanic’s Tips. 2. Provide a ground connection for the PSM to either the control valve body or the transmission main case. 3. Use your finger or the eraser end of a pencil to push gently on the reverse pressure switch membrane. Does the Scan Tool indicate reverse pressure switch status as ON when grounded and OFF when circuit is open? Replace the PSM. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete?

Value(s) —

Yes Go to Step 6

No Go to Step 13

—

Go to Step 7

Go to Step 12

—

Go to Step 8

Go to Step 11

—

Go to Step 10

Go to Step 9

—

Go to Step 14

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d) Step Action 10 1. Inspect for a missing or a damaged seal at the reverse pressure switch assembly. 2. Inspect for loose reverse transfer tube. 3. Inspect for proper shift linkage adjustment. Shift linkage out of adjustment can allow pressure to apply the reverse pressure switch. Did you find and repair a problem? 11 Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? 12 NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Value(s) —

Yes Go to Step 14

No Go to Diagnostic Aids

—

Go to Step 14

—

—

Go to Step 14

—

—

Go to Step 14

—

—

Begin the diagnosis again. Go to Step 1

System OK

Repair the vehicle wiring harness. Is the repair complete? 13

14

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P0880 (Previously P1760) TCM Supply Voltage

J1 HARNESS CONNECTOR (GRAY)

TCM

J1-4 J1-3 J1-2 J1-1

J1-5

J2 J1

102 104 103

10a 10a

101

IGN SWITCH

105

+

J1-2 J1-4

IGNITION POWER

J1-3

BATTERY POWER

J1-1

GND

J1-5

GND

TCM

—

12V/24V BATTERY V06215.01.00

Circuit Description DTC P0880 sets if an abnormal power-down sequence has occurred. This condition means the Transmission Control Module (TCM) has lost supply voltage (wire 103) before it has finished saving information from that drive cycle. This process is usually completed in less than 10 seconds. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

Loss of TCM supply voltage before drive cycle data is saved.

Conditions for Setting the DTC DTC P0880 sets during the next ignition cycle if the TCM loses TCM supply voltage less than 10 seconds after the ignition voltage has been turned off. Action Taken When the DTC Sets •

DTC P0880 is stored in the TCM history.

•

The TCM loses adaptive information for the drive cycle.

•

The TCM reverts to previous adaptive settings.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

• •

— A broken wire inside the insulation. When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests the system voltage. 4. This step tests the vehicle charging system. 5. This step tests the external wiring harness for shorts or opens.

DTC P0880 (Previously P1760) TCM Supply Voltage Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

1. Install the Scan Tool. 2. Turn the ignition to the RUN position with the engine OFF. 3. Record the DTC Failure Record data.

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve battery problem

10.5V (12V TCM); 22V (24V TCM)

Go to Step 4

—

Repair charging system

Go to Step 4

13–15V (12V TCM); 25–30V (24V TCM)

Go to Step 5

Repair charging system

NOTE: If other DTCs are present refer to the applicable diagnostic tables before continuing.

3

4

4. Using a DVOM, measure and record voltage at the battery terminals. Is voltage greater than the specified value? Start the engine and warm to normal operating temperature. Is the Alternator/Check Engine lamp ON? 1. Increase the engine speed to 1000–1500 rpm. 2. Using the Scan Tool, monitor system voltage. Is voltage within the specified value?

Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P0880 (Previously P1760) TCM Supply Voltage (cont’d) Step 5

6

7

8

5–222

Action 1. Turn the ignition OFF. 2. Disconnect J1 connector from the TCM and install J 39700 Breakout Box and J 43799 Breakout Box Adapter. 3. Using a DVOM, measure voltage at connector J1 pins 1 and 2 with the ignition ON and J1 connector pins 1 and 3 with the ignition OFF. 4. Compare the battery voltage to the wire voltage. Is the voltage difference greater than the specified value? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Start the engine and warm to normal operating temperature. 3. Using the Scan Tool, monitor system voltage. System voltage should be 9–18V for a 12V TCM or 18–32V for a 24V TCM. Did the DTC return?

Value(s) 0.5V

Yes Go to Step 6

No Go to Step 7

—

Go to Step 8

—

—

Go to Step 8

—

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P1688 Unmanaged Engine Torque Delivered To TCM Signal TCM J1 HARNESS CONNECTOR (GRAY) J1-16

J1-09

J2 J1

J1-22

109

ENGINE CONTROL MODULE (ECM)

116 122

TCM J1-09 J1-16

DIGITAL INTERFACE

J1-22

V06538.01.00

Circuit Description The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire system to communicate engine torque data/requests between the powertrain control module (PCM) and the transmission control module (TCM). Unmanaged engine torque is sent from the PCM to the TCM over wire 109 (GM wire 2467). Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).

•

Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

•

Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration.

Conditions for Setting the DTC DTC P1688 sets if unmanaged (gross) engine torque signal (circuit 2467) is under 1.5 percent or over 98.5 percent for more than a 2 second period. Actions Taken When the DTC Sets •

DTC P1688 is stored in the TCM history.

•

The CHECK TRANS light illuminates on the second occurrence.

•

The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further troubleshooting.

DTC P1688 Engine Torque Unmanaged Delivered To TCM Signal Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Yes Go to Step 2

1. 2. 3. 4.

Go to Step 3

Install the Scan Tool. Start the engine. Record DTC failure records. Clear the DTC and drive the vehicle. Attempt to duplicate the same operating conditions observed in failure records.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Diagnostic Aids

NOTE: This DTC indicates that the unmanaged engine torque signal sent from the engine PCM to the transmission TCM is either under or over a set percentage value for a set period of time. 3

4

5

6

5–224

Did DTC P1688 return? Inspect the routing of wire 109 (GM wire circuit 2467) between the TCM and PCM. Was chafing or wire damage found? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? Return the vehicle to the OEM to troubleshoot for cause of low or high torque signal. Below are some possible causes for this DTC. • Defective engine PCM. • Circuit fault at wire 109. • Improper calibration for engine PCM. Was problem found and repaired? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Go to Step 4

Go to Step 5

Go to Step 6

—

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P1779 Engine Torque Delivered To TCM Signal TCM J1 HARNESS CONNECTOR (GRAY) J1-16

J1-09

J2 J1

J1-22

109

ENGINE CONTROL MODULE (ECM)

116 122

TCM J1-09 J1-16

DIGITAL INTERFACE

J1-22

V06538.01.00

Circuit Description The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire system to communicate engine torque data/requests between the powertrain control module (PCM) and the transmission control module (TCM). Managed engine torque is sent from the PCM to the TCM over wire 116 (GM wire 464). Conditions for Running the DTC • • • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds. Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration. No DTC is active at the time of this test.

Conditions for Setting the DTC DTC P1779 sets if managed engine torque (net) signal (circuit 464) is under 1.5 percent or over 98.5 percent for more than a 2 second period. Actions Taken When the DTC Sets • • • •

DTC P1779 is stored in the TCM history. The CHECK TRANS light illuminates on the second occurrence. The TCM defaults to a calculated managed torque (net) input value using throttle and engine speed. The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further troubleshooting. .

DTC P1779 Engine Torque Delivered To TCM Signal Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Yes Go to Step 2

1. 2. 3. 4.

Go to Step 3

Install the Scan Tool. Start the engine. Record DTC failure records. Clear the DTC and drive the vehicle. Attempt to duplicate the same operating conditions observed in failure records.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Diagnostic Aids

NOTE: This DTC indicates that the managed engine torque signal sent from the engine PCM to the transmission TCM is either under or over a set percentage value for a set period of time. 3

4

5

6

5–226

Did DTC P1779 return? Inspect the routing of wire 109 (GM wire circuit 2467) between the TCM and PCM. Was chafing or wire damage found? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? Return the vehicle to the OEM to troubleshoot for cause of low or high torque signal. Below are some possible causes for this DTC. • Defective engine PCM. • Circuit fault at wire 116. • Improper calibration for engine PCM. Was problem found and repaired? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Go to Step 4

Go to Step 5

Go to Step 6

—

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal Low Input

TCM J1 HARNESS CONNECTOR (GRAY) J2-16

J2 J1

TCM PWM THROTTLE SOURCE

116

J1-16

DIGITAL INTERFACE

V06228.01.00

Circuit Description The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width Modulation (PWM) signal. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). The components are powered and engine speed is within a 5 rpm range for 5 seconds.

Conditions for Setting the DTC DTC P1891 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage falls below 5 percent for 5 seconds. Action Taken When the DTC Sets • • • • •

DTC P1891 is stored in the TCM history. The TCM uses the default throttle value. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement. MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests the system voltage. 3. This step tests the PWM signal. 4. This step tests for shorts or opens at wire 116.

DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal Low Input Step 1

2

3

4

5–228

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Install the Scan Tool. 2. Turn the ignition to the RUN position with the engine OFF. 3. Record the DTC Failure Record data. 4. Verify that the throttle source is functioning correctly. Is PWM signal OK? Check wire 116 for shorts or opens. Did you find a problem?

Value(s) —

Yes Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

—

Go to Step 4

—

—

Go to Step 5

Go to Step 6

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal Low Input (cont’d) Step 5

6

7 8

9

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? Inspect the TCM and Engine Control Module (ECM) connectors and terminals for damage and/or corrosion. Did you find a problem? Repair and clean terminals if possible. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM, if necessary. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor throttle position and engine coolant temperature. Did the DTC return?

Value(s) —

Yes Go to Step 9

No —

—

Go to Step 7

Go to Step 8

—

Go to Step 9

Go to Step 8

—

Go to Step 9

—

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal High Input

TCM J1 HARNESS CONNECTOR (GRAY) J2-16

J2 J1

TCM PWM THROTTLE SOURCE

116

J1-16

DIGITAL INTERFACE

V06228.01.00

Circuit Description The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width Modulation (PWM) signal. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC P1892 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage exceeds 95 percent for 5 seconds. Action Taken When the DTC Sets • • • • •

DTC P1892 is stored in the TCM history. The TCM uses the default throttle value. The TCM freezes shift adapts (DNA). The TCM inhibits TCC engagement. MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. 5–230

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

You may have to drive the vehicle in order to experience a fault.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests the system voltage. 3. This step tests the PWM signal. 4. This step tests for shorts or opens at wire 116.

DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal High Input Step

Action

1

Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

2

1. 2. 3. 4.

3

4

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Install the Scan Tool. 2. Turn the ignition to the RUN position with the engine OFF. 3. Record the DTC Failure Record data. 4. Verify that the throttle source is functioning correctly. Is the PWM signal OK? Check wire 116 for shorts or opens. Did you find a problem?

Value(s)

Yes

No

—

Go to Step 2

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

—

Go to Step 4

—

—

Go to Step 5

Go to Step 6

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM) Signal High Input Step 5

6

7 8

9

5–232

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? Inspect the TCM and Engine Control Module (ECM) connectors and terminals for damage and/or corrosion. Did you find a problem? Repair and clean terminals if possible. Is the repair complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM, if necessary. Is the replacement complete? In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor throttle position and engine coolant temperature. Did the DTC return?

Value(s)

Yes

No

—

Go to Step 9

—

—

Go to Step 7

Go to Step 8

—

Go to Step 9

Go to Step 8

—

Go to Step 9

—

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2771 (Previously P0836, P1875) Four-Wheel Drive Switch Circuit (

TCM J1 HARNESS CONNECTOR (GRAY)

J1-10

J2 J1-28

J1

4WD Transfer Case Switch Signal Ground Wire 128

J1-28

TCM Input Wire 110

J1-10 V06560.01.00

Circuit Description Detects abnormal conditions for the four-wheel drive indication switch input. Four wheel-drive statuses are detected using speed and ratios. Conditions for Running the DTC • • • • • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds. DTCs P0721 and P0722 (output speed sensor circuits) are not active. Output speed is above 60 rpm. Transmission fluid temperature it between 20°C (68°F) and 130°C (266°F). Shift is complete and the range attained is not neutral.

Conditions for Setting the DTC P2771 sets when one of the following conditions occurs: • •

The transfer case switch indicates high range, and the calculated range is low range for 5 seconds or more. The transfer case switch indicates low range, and the calculated range is high range for 5 seconds or more.

Actions Taken When the DTC Sets • • •

DTC P2771 will be stored in the TCM memory. The CHECK TRANS light illuminates on the second occurrence. The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light •

A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without a failure. Copyright© 2004 General Motors Corp.

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DIAGNOSTIC TROUBLE CODES (DTC) Diagnostics Aids •

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

•

You may have to drive the vehicle in order to experience a fault.

•

Inspect for any transmission DTCs that may have reset.

•

When testing for a short or ground, the transmission should be in a range where the switch or solenoid is in the OFF state. When testing for an open, the transmission should be in a range where the switch or solenoid is in the ON state.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests the status of the 4WD Low switch. 3. This step tests for a 4WD switch failure to ground. 4. This step tests for a short in the wiring harness. 9. This step tests for 4WD switch failure to an open state. 10. This step tests for an open in the wiring harness.

DTC P2771 Four-Wheel Drive Switch Circuit Step Action Was the Beginning The Troubleshooting 1 Process (Section 5–4A) performed?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Section 5–4A)

2

1. Install the Scan Tool. 2. Turn the ignition to the RUN position with the engine OFF. 3. Record the DTC Failure Record data. 4. Using the Scan Tool, monitor 4WD low status and select 4HI followed by 4LO with the transfer case selector. Does the Scan Tool indicate 4WD low status as NO when 4HI is selected, and YES when 4LO is selected?

—

Go to Diagnostic Aids

Go to Step 3

3

Select 4HI followed by 4LO using the transfer case selector. Does the Scan Tool indicate 4WD low status as YES for both selector positions?

—

Go to Step 4

Go to Step 9

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2771 Four-Wheel Drive Switch Circuit (cont’d) Step Action Remove the connector at the transfer case 4 selector. Does the Scan Tool indicate 4WD low status as YES?

Value(s) —

Yes Go to Step 5

No Go to Step 7

5

Inspect wire 110 for a short to ground. Did you find a problem?

—

Go to Step 6

Go to Step 15

6

Repair the short to ground in wire 110. Is the repair complete (refer to OEM repair procedures)?

—

Go to Step 16

—

7

Inspect the transfer case switch for proper operation or a short to ground. Did you find a problem (refer to OEM repair procedures)?

—

Go to Step 8

Go to Step 15

8

Repair the short to ground in the switch? Is the repair complete?

—

Go to Step 16

—

9

Select 4HI followed by 4LO using the transfer case selector. Does the Scan Tool indicate 4WD low status as NO for both selector positions?

—

Go to Step 10

Go to Step 15

10

1. Remove the connector at the transfer case switch. 2. Ground wire 110 to a known ground. Does the Scan Tool indicate 4WD low status as NO?

—

Go to Step 11

Go to Step 13

11

Inspect wire 110 for an open condition. Did you find a problem?

—

Go to Step 12

Go to Step 15

12

Repair the open condition in wire 110. Is the repair complete (refer to OEM repair procedures)?

—

Go to Step 16

—

13

Inspect the transfer case switch for an open condition. Did you find a problem?

—

Go to Step 14

Go to Step 15

14

Repair the open condition in the switch? Is the repair complete?

—

Go to Step 16

—

15

NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete?

—

Go to Step 16

—

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2771 Four-Wheel Drive Switch Circuit (cont’d) Step Action In order to verify your repair: 16 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Using the Scan Tool, monitor the 4WD low status. The 4WD low status must indicate NO when 4WDHI is selected, and YES when 4WDLO is selected. Did the DTC return?

5–236

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1.

No System OK

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2773 Torque Control Request Ignored — ECM/TCM

NO SCHEMATIC FOR THIS DTC Circuit Description Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from the engine controller. By reducing torque during upshifts, shifts can be made quicker and at a more consistent output torque. This increases clutch life by reducing clutch engagement temperatures. Conditions for Running the DTC •

DTC U2105 CAN bus error is not active.

•

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater 18V and less than 32V (24V TCM).

•

Engine speed is greater than 200 rpm but less than 7500 rpm for 5 seconds.

•

SEM has been activated for this vehicle.

Conditions for Setting the DTC DTC P2773 sets when the TCM detects one of the following conditions for a minimum of four upshifts (consecutive or nonconsecutive) during one drive cycle: •

Engine ECM is not responding to torque reduction signal request from the TCM.

•

A nonapproved J1939 device is interfering with the torque reduction signal request.

Action Taken When the DTC Sets •

The CHECK TRANS light illuminates.

•

All 4–5 upshifts and full throttle 3–4 upshifts are inhibited.

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The DTC is cleared if, for one ignition cycle, actual engine torque follows TCM commanded torque for 20 consecutive upshifts. To be counted as one upshift, engine torque demand must be above 80 N·m (59 lb ft). Diagnostic Aids •

It will be necessary to drive the vehicle with heavy to moderate throttle settings for at least four upshift cycles in order to set a DTC P2773.

•

If DTC P2773 becomes active shortly AFTER an engine update and the troubleshooting procedure for P2773 has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ECM torque request response. 3. This step tests for the device causing the torque request to be ignored. 4. This step tests for the offending device by removing it from the J1939 network. 5. This step tests for the presence of the proper engine controller software. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2773 Torque Control Request Ignored — ECM/TCM Step 1

2

3

4

5

6

5–238

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Yes Go to Step 2

This code indicates that the engine controller — has disregarded the torque request sent by the TCM. Use the Scan Tool and refer to Transmission/Engine Torque Reduction Status. Does the Scan Tool indicate the ECM response to torque reduction request as incorrect? Use the Scan Tool to identify an unapproved The Scan Tool torque reduction device. shows the actual device at fault Is the unapproved device one of the following? 1. Engine 2. Null address or all /any (information not valid) If the Scan Tool is indicating another device — such as the brakes, cruise control, transmission, etc., inspect the controller for the device indicated. If possible, eliminate the device by disconnecting it from the J1939 CAN backbone. It may be possible that the device causing the interruption is only triggered under certain conditions. For example, a traction controller may only send commands under certain road conditions. Since these conditions may not be easily repeatable, replacement of the indicated controller with a known good controller may be the only way to verify the failure. Was the device causing the problem replaced or repaired? Verify that compatible engine controller — software is utilized. If the software is correct, replace the engine controller. If neither solves the problem, use a lower engine torque/power rating. Was the software updated or engine controller replaced? In order to verify your repair: — 1. Connect the Scan Tool. 2. Clear the DTC. 3. Drive the vehicle under heavy to moderate throttle settings for at least four upshift cycles. Did the DTC return?

Go to Step 5

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 6

—

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2810 Solenoid G Electrical

TRANSMISSION HARNESS CONNECTOR S

J2 HARNESS CONNECTOR (RED)

J

R

J2-32

TCM

J2-30

TRANSMISSION BULKHEAD CONNECTOR J

S

J2-29

R

J2 J1 NOTE: Letters I, O, and Q are not used.

TCM SOL F (PWM) LOCKUP

J

TRANSMISSION

R

229 230

J2-29 J2-30

SOL G S

232

J2-32

NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G.

12V

V08119.00.00

Circuit Description Solenoid G is a normally closed (N/C) solenoid used to modulate the transmission main pressure schedule. The TCM commands the G solenoid ON when specific transmission and engine conditions are met. When G solenoid is applied, pressure is routed to the main regulator valve. This in turn reduces the main pressure schedule and improves the volume of oil sent through the overage circuit. By modulating main pressure, cooler flow can be increased, allowing improved cooling and reduced pump noise. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

•

TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

•

The TCM must autodetect G solenoid for this test to run.

Conditions for Setting the DTC DTC P2810 is set when the TCM detects an open circuit, short to ground or short to power at G solenoid circuit for more than 2 seconds. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Action Taken When the DTC Sets When DTC P2810 is active, the following conditions will occur: •

DTC P2810 is stored in TCM history.

•

The CHECK TRANS light illuminates.

Conditions for Clearing the DTC/CHECK TRANS Light A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure. Diagnostic Aids •

When this code is set there will be a noticeable reduction of engine performance.

•

An intermittent circuit condition may allow this DTC to set. Make sure you check for the following conditions at the OEM harness first and then at the transmission internal harness.

•

Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation. — Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspension components, transmission shift linkage etc. — Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.

•

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness to isolate an intermittent condition. Refer to Section 4—Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where DTC was set.

•

If the DTC appears to be temperature related, suspect a defective G solenoid. It is possible for a solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for the proper ignition voltage. 3. This step tests the TCM for proper command status. 4. This step tests the OEM harness for an open condition. 5. This step tests for the proper resistance at the main transmission connector. 7. This step tests for the proper resistance value at the G solenoid. 5–240

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2810 Shift Solenoid E Electrical Step Action Was the Beginning The Troubleshooting 1 Process (Paragraph 5–4A) performed?

2

3

4

1. 2. 3. 4.

Install the Scan Tool. Start the engine. Record the DTC Failure Record data. Using the Scan Tool, measure ignition voltage. Is voltage within the specified value? 1. Turn the ignition OFF. 2. Disconnect the J2 connector (RED) at the TCM. 3. Install J 39700 breakout box and J 43799 breakout box adapter 4. Turn ON the ignition, with the engine OFF. 5. Using the Scan Tool in solenoid test mode, command G solenoid to ON. 6. Using a DVOM measure the voltage between J2 terminal 30 and terminal 32. Is the voltage within the range specified when G solenoid is commanded ON? NOTE: Review Section 4 — Wire Check Procedures before performing the following steps. 1. Turn the ignition OFF. 2. Disconnect J2 connector from TCM. 3. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter Harness, connect only to the J2 harness connector. See Beginning the Troubleshooting Process, Page 5–4, Figure 5–2 for diagram of J 43799 adapter harness hook-ups. 4. Using a DVOM, attach leads to J2 pins 30 and 32. 5. Measure the resistance of the circuit. Is the resistance within the specified value?

Value(s) —

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Resolve voltage problem (Refer to DTC P0562 and P0563)

9–18V (12V TCM); 18–32V (24V TCM)

Go to Step 3

Battery Voltage

Go to Step 4

Go to Step 10

Refer to Solenoid Resistance Table (Page 5–12)

Go to Diagnostic Aids

Go to Step 5

NOTE: To allow for resistance of harness wire, add 0.1 Ohms per foot of length for 18-gauge wire.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2810 Shift Solenoid E Electrical (cont’d) Step Action 1. Turn the ignition OFF. 5 2. Disconnect the wiring harness from the main transmission connector at the back of the transmission. 3. Using J 39700 Breakout Box and J 43799 Breakout Box Adapter, connect only to the transmission main connector at the rear of the transmission. Do not attach the other end of J 44722 to the vehicle transmission harness connector. See Beginning the Troubleshooting Process, Page 5–5, Figure 5–3 for diagram of J 44722 transmission harness hook-ups. 4. Using a DVOM, measure resistance between pins R and S at the magnetic overlay. Is the resistance within the specified values? 6

7

8

9

10

5–242

NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair or replace the vehicle wiring harness. Is the repair complete? 1. Remove the oil pan. Refer to Service Manual or Mechanic’s Tips. 2. Remove the connector from G solenoid. 3. Using a DMM, measure the resistance at the solenoid. Is the resistance within the specified value? Replace the internal wiring harness. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? Replace solenoid G. Refer to Service Manual or Mechanic’s Tips. Is the replacement complete? NOTE: In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. Refer to TCM Replacement Procedure (Section 3–6). Replace the TCM. Is the replacement complete?

Value(s) Refer to Solenoid Resistance Table (Page 5–12)

Yes Go to Step 6

No Go to Step 7

—

Go to Step 11

—

Refer to Solenoid Resistance Table (Page 5–12)

Go to Step 8

Go to Step 9

—

Go to Step 11

—

—

Go to Step 11

—

—

Go to Step 11

—

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC P2810 Shift Solenoid E Electrical (cont’d) Step Action 11 In order to verify your repair: 1. Clear the DTC. 2. Drive the vehicle under conditions noted in failure records. 3. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Begin the diagnosis again. Go to Step 1

No System OK

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low

TCM J1 HARNESS CONNECTOR (GRAY)

J2 J1-30

J1

J1850 PCM OR ECM POWERTRAIN CONTROLLER MODULE OR ENGINE CONTROLLER MODULE TCM

J1850 PCM or ECM

130

J1-30

CLASS II J1850 DATA LINK

V07481.01.00

Circuit Description Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and commands among the various control modules. Included modules would be Powertrain Control Module (PCM), Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH messages to monitor the condition of the devices on the class 2 serial link. Conditions for Running the DTC The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Conditions for Setting the DTC DTC U0031 is set when low voltage is detected on the class 2 data circuit for more than 3 seconds. This would normally indicate a short-to-ground at wire 130. Action Taken When the DTC Sets • • • •

The CHECK TRANS light does not illuminate. DTC U0031 is stored in the TCM history. TCM uses default values for missing/erroneous information. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC when software detects a failure recovery has occurred. 5–244

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

If communication can be established with the Scan Tool at the OBDII connector, then the U0031 should be shown in failure records only. This may indicate that an intermittent short-to-ground was present at one time. Refer to Appendix A—Identification of Potential Circuit Problems.

•

It is not possible to communicate with J1850 with this DTC active.

•

Use the J 43890 T-harness to communicate with the TCM to determine if the U0031 is still active.

•

U0031 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the malfunction occurred when the ignition was ON.

•

This code indicates that voltage is low at wire 130. Normally, this is an indication that a short-to-ground exists at wire 130. Inspect wire 130 for this condition.

•

Inspect wire 130 for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When this DTC is active an engine no–start condition may exist. Class 2 messages will not be sent to enable the fuel pump and starter.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step checks engine data. 3. This step tests for shorts or opens at wire 130.

DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

1. Install the Scan Tool. 2. Turn the ignition ON with the engine OFF. 3. Verify engine data is being communicated via J1850.

Yes Go to Step 2

Go to Diagnostic Aids

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

NOTE: U0031 is set when low voltage is detected on the J1850 serial communication link by the TCM for a time exceeding 3 seconds.This may indicate a shortto-ground exists at wire 130. 3

Is engine data communicated to the Scan Tool? Inspect wire 130 for a possible short-to-ground. Did you find a problem?

Go to Step 4

Copyright© 2004 General Motors Corp.

Go to Step 5

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low Step 4

5

6

5–246

Action NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? Switch the current TCM with a known good unit. Check for proper communication. If this repairs the condition, reinstall the “defective” TCM to verify the TCM failure and then install a new TCM. Is replacement complete? In order to verify your repair: 1. Connect the Scan Tool. 2. Clear the DTC. Did the DTC return?

Yes Go to Step 6

No —

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0032 (Previously U1301) J1850 (Class 2) Serial Data Communication Link High

TCM J1 HARNESS CONNECTOR (GRAY)

J2 J1-30

J1

J1850 PCM OR ECM POWERTRAIN CONTROLLER MODULE OR ENGINE CONTROLLER MODULE TCM

J1850 PCM or ECM

130

J1-30

CLASS II J1850 DATA LINK

V07481.01.00

Circuit Description Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and commands among the various control modules. Included modules would be Powertrain Control Module (PCM), Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH messages to monitor the condition of the devices on the class 2 serial link. Conditions for Running the DTC •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC DTC U0032 is set when high voltage is detected on the class 2 data circuit for more than 3 seconds. This would normally indicate a short-to-power at wire 130. Action Taken When the DTC Sets •

The CHECK TRANS light does not illuminate.

•

DTC U0032 is stored in the TCM history.

•

TCM uses default values for missing/erroneous information.

•

The TCM freezes shift adapts (DNA). Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC when software detects a failure recovery has occurred. Diagnostic Aids •

• • • • •

If communication can be established with the Scan Tool at the OBDII connector, then the U0032 should be shown in failure records only. This may indicate that an intermittent short-to-power was present at one time. Refer to Appendix A—Identification of Potential Circuit Problems. It is not possible to communicate with J1850 with this DTC active. Use the J 43890 T-harness to communicate with the TCM to determine if the U0032 is still active. U0032 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the malfunction occurred when the ignition was ON. This code indicates that voltage is high at wire 130. Normally, this is an indication that a short-to-power exists at wire 130. Inspect wire 130 for this condition. Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire.

•

— A broken wire inside the insulation. When this DTC is active an engine no-start condition may exist. Class 2 messages will not be sent to enable the fuel pump and starter.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step checks engine data. 3. This step tests for shorts or opens at wire 130.

DTC U0032 J1850 (Class 2) Serial Data Communication Link High Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

1. Install the Scan Tool. 2. Turn the ignition ON, with the engine OFF. 3. Verify engine data is being communicated via J1850.

Yes Go to Step 2

Go to Diagnostic Aids

NOTE: U0032 is set when high voltage is detected on the J1850 serial communication link by the TCM for a time exceeding 3 seconds. This may indicate a shortto-power exists at wire 130. Is the engine data communicated to the Scan Tool? 5–248

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0032 J1850 (Class 2) Serial Data Communication Link High (cont’d) Step 3 4

5

6

Action Inspect wire 130 for possible short-to-power. Did you find a problem? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? Switch the current TCM with a known good unit. Check for proper communication. If this repairs the condition, reinstall the “defective” TCM to verify the TCM failure and then install a new TCM. Is replacement complete? In order to verify your repair: 1. Inspect the Scan Tool. 2. Clear the DTC. Did the DTC return?

Yes Go to Step 4

No Go to Step 5

Go to Step 6

—

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0073 (Previously U2104) CAN Bus Reset Counter Overrun

ENGINE (ECM)

9-PIN DDL CONNECTOR

TRANS (TCM)

J1939 Data Link

J1939 Data Link

D E F

C A

B J

G

SHIELD

SHIELD

TERMINATION RESISTOR

131 GREEN 129

120Ω RESISTOR

Should not exceed 1 meter

PIN E PIN C (+) SHIELD PIN D (–)

Attached to ECM via Deutsch/P triangle 3-pin connector

SHIELD

SHIELD

Pin ID determined by Engine OEM

PIN 31 PIN 29 PIN 32

H

132

RED SHIELD

BLACK

SHIELD

120Ω RESISTOR

CONTROLLER AREA NETWORK (CAN) Should not exceed 40 meters

SAE J1939-11

V06460.01.00

Circuit Description J1939 is the protocol currently used in medium duty applications to allow communication between an electronically-controlled engine and the Allison 1000 and 2000 Product Families transmission. A signal is sent over a two-wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939 currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield wire. There is also J1939-15, which uses a two-wire connection without shielding. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC U0073 is set when the TCM detects no communication on the Controller Area Network (CAN) backbone harness for 3 seconds or more. This may be due to a shorted wire to ground or power in the CAN backbone harness. Action Taken When the DTC Sets • • • •

DTC U0073 is stored in the TCM history. The CHECK TRANS light does not illuminate. The TCM defaults to the last-used adaptive shift values and engine throttle percentage is calculated from torque clip speed. The TCM freezes shift adapts (DNA).

5–250

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Diagnostic Aids •

If communication can be established at the vehicle nine-pin connector and U0073 is listed in failure records, this indicates an intermittent short condition was present.

•

When diagnosing for intermittent shorts-to-ground, massage the wiring harness while watching the test equipment for a change. Refer to Section 4, Wire Check Procedures.

•

If an active U0073 is present, Scan Tool communication will not be possible. The cause of the active DTC must be discovered and repaired before communication can be established with the TCM.

•

A short between wires 129 and 132 within the CAN harness can cause this DTC.

•

A short between wires 129 and 131 within the CAN harness can cause this DTC.

•

A short to a vehicle ground and wire 129 can cause this DTC.

•

A short to vehicle power and wire 132 can cause this DTC.

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

For proper data communications it is necessary to have two 120 Ohm resistors installed in parallel at the J1939 CAN backbone harness.

•

If this DTC is present in a new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).

Test Description The number below refers to the step number on the diagnostic table. 3. This step inspects the CAN backbone harness for shorts-to-ground or power. 5. This step checks TCM function.

DTC U0073 CAN Bus Reset Counter Overrun Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

1. Install the Scan Tool. 2. Turn the ignition ON with the engine OFF. Is Scan Tool communication possible at the diagnostic connector?

Yes Go to Step 2

Go to Diagnostic Aids

Copyright© 2004 General Motors Corp.

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A) Go to Step 3

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DIAGNOSTIC TROUBLE CODES (DTC) DTC U0073 CAN Bus Reset Counter Overrun (cont’d) Step 3

Action 1. Inspect wires 129 (positive), 132 (negative), 131 (shield) at engine and transmission connectors for a possible shorting condition or terminal damage.

Yes Go to Step 4

No Go to Step 5

Go to Step 7

Go to Step 4

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

NOTE: No Scan Tool communication is possible when this DTC is active.

4

5

6

5–252

2. This DTC indicates that a CAN bus hardware error has occurred. This may indicate a short-to-power or ground has occurred at the CAN bus wiring harness. Was a wiring problem found? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle J1939 CAN wiring harness. Is the repair complete? Switch the current TCM with a known good unit. Check for proper communication. If this repairs the condition, reinstall the “defective” TCM to verify the TCM failure and then install a new TCM. Is replacement complete? In order to verify your repair: 1. If communication is established with the Scan Tool, clear the DTC. 2. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0100 (Previously U2105) CAN Bus ECM Error

ENGINE (ECM)

9-PIN DDL CONNECTOR

TRANS (TCM)

J1939 Data Link

J1939 Data Link

D E F

C A

B J

G

SHIELD

SHIELD

TERMINATION RESISTOR

131 GREEN 129

120Ω RESISTOR

Should not exceed 1 meter

PIN E PIN C (+) SHIELD PIN D (–)

Attached to ECM via Deutsch/P triangle 3-pin connector

SHIELD

SHIELD

Pin ID determined by Engine OEM

PIN 31 PIN 29 PIN 32

H

132

RED SHIELD

BLACK

SHIELD

120Ω RESISTOR

CONTROLLER AREA NETWORK (CAN) Should not exceed 40 meters

SAE J1939-11

V06460.01.00

Circuit Description J1939 is the protocol currently used in medium duty applications to allow communication between an electronically-controlled engine and the Allison 1000 and 2000 Product Families transmission. A signal is sent over a two-wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939 currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield wire. There is also J1939-15, which uses a two-wire connection without shielding. Conditions for Running the DTC • •

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC DTC U0100 is set when the TCM detects that no engine torque or throttle messages are being received on the Controller Area Network (CAN) backbone harness for 3 seconds or more. Action Taken When the DTC Sets • • • •

The CHECK TRANS light illuminates. DTC U0100 is stored in the TCM history. The TCM defaults to last-used adaptive shift values and engine throttle percentage is calculated from torque converter slip speed. The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Aids •

Often an active U0100 will prevent Scan Tool communication with the TCM. Install J1939 T-adapter harness J 43890 to confirm that the TCM is operational. This harness is only useful to confirm that the TCM is able to communicate with the Scan Tool. An active U0100 will be set whenever J 43890 is used.

•

When Scan Tool communication with the TCM can be established at the nine-pin vehicle connector and the U0100 is active, generally it points to an open connection at wires 129 or 132 at the ECM or a terminal in the wrong location at the engine ECM connector.

•

Engine ECM parameters improperly set can cause this DTC to set.

•

A missing terminating resistor can cause this DTC to set. This will prevent Scan Tool communication with the TCM or produce very erratic communication.

•

If DTC U0100 becomes active shortly AFTER an engine update and the troubleshooting procedure for U0100 has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.

•

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions: — A bent terminal. — A backed-out terminal. — A damaged terminal. — Poor terminal tension. — A chafed wire. — A broken wire inside the insulation.

•

When diagnosing for an intermittent open, massage the wiring harness while watching the test equipment for a change. It may be necessary to check for opens at individual wires within a harness to isolate an intermittent condition. Refer to Section 4, Wire Check Procedures.

•

You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.

•

Intermittent cycling of the TCC could indicate a J1939 wiring problem exists. It is possible to have an open condition at the CAN backbone harness allowing TCC to cycle without a U0100 setting. For a U0100 to set, an open condition needs to be present for 3 seconds.

•

For proper data communications, it is necessary to have two 120 Ohm resistors installed in parallel at the J1939 CAN backbone harness.

•

If this DTC is present in new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).

Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This step inspects the CAN backbone harness for open conditions to ground or terminal damage. 5.

This step tests the CAN backbone harness for the proper resistance value.

DTC U0100 CAN Bus ECM Error Step 1

5–254

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Value(s) —

Copyright© 2004 General Motors Corp.

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U0100 CAN Bus ECM Error (cont’d) Step 2

3

Action 1. Install the Scan Tool. 2. Turn the ignition ON, with the engine OFF. Is Scan Tool communication possible at the diagnostic connector? Inspect wires 129 (positive), 132 (negative), and 131 (shield) at engine and transmission connectors for a possible open condition or terminal damage.

Value(s) —

Yes Go to Step 3

No Go to Diagnostic Aids

—

Go to Step 4

Go to Step 5

Go to Step 7

—

60 Ohms

Go to Step 6

Go to Step 7

—

Go to Step 8

—

—

Go to Step 8

—

—

Begin the diagnosis again. Go to Step 1

System OK

NOTE: This DTC indicates that the TCM is not receiving engine information. This may indicate an open condition has occurred at the CAN bus wiring harness. 4

5

6

7

8

Was a wiring problem found? NOTE: The vehicle OEM has responsibility for all external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty. Repair the vehicle wiring harness. Is the repair complete? Using a DVOM, measure resistance between pins C and D at the vehicle 9-pin diagnostic connector. Does the resistance match the specified value? NOTE: A resistance reading other than 60 Ohms indicates that a terminating resistor is missing or a resistor with an improper value is installed. There should be two 120 Ohm resistors wired in parallel in the J1939 CAN. Return the vehicle to the OEM for repair. Is the repair complete? Return the vehicle to OEM for inspection of the following: 1. Confirm that the engine ECM is properly set to broadcast J1939 messages. 2. Improper pin location at the engine ECM. 3. Defective engine ECM. Is the repair complete? In order to verify your repair: 1. If communication is established with the Scan Tool, clear the DTC. 2. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U1000–U1096 Class 2 Controller State of Health Failure

TCM J1 HARNESS CONNECTOR (GRAY)

J2 J1-30

J1

POWERTRAIN CONTROLLER MODULE OR ENGINE CONTROLLER MODULE ABS J1850 PCM or ECM

130

IPC

J1-30

TCM

TBC V07477.01.00

Circuit Description Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and commands among the various control modules. The control modules included are the Powertrain Control Module (PCM), Antilock Brake System Controller (ABS), Truck Body Controller (TBC) and Instrument Panel Cluster (IPC). Each controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH messages to monitor the condition of the devices on the class 2 serial link. The following DTCs identify the specific controller noted: DTC Number

Control Module

U1000

Class II–Loss of Serial Data Communication

U1016

Powertrain Control Module (PCM)

U1041

Antilock Brake System Module (ABS)

U1064

Truck Body Controller Module (TBC)

U1096

Instrument Panel Cluster Module (IPC)

Conditions for Running the DTC The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM). 5–256

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) Conditions for Setting the DTC DTC U1000–U1096 is set when the TCM has not received a state of health (SOH) message from the Control Module indicated for a period of time exceeding 2 seconds. Action Taken When the DTC Sets • • • •

The CHECK TRANS light does not illuminate. DTC U1000–U1096 is stored in the TCM history. TCM uses default values for missing/erroneous information. For U1016 only—the TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears the DTC when the software detects a failure recovery has occurred. Diagnostic Aids • • • • •

An intermittent open between a module and the connector node may cause this DTC to set. A poor connection at a module or the connector node may cause this DTC to set. An intermittent open in a connector node may cause this DTC to set. An open voltage or ground circuit to a module may cause this DTC to set. An internal module malfunction may cause this DTC to set.

Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for proper power inputs at the indicated module. 3. This step tests for an open condition between the controller module and the connection at wire 130. 5. This step tests the module function per OEM procedures.

DTC U1000–U1096 Class 2 Controller State of Health Failure Step 1

2

Action Was the Beginning The Troubleshooting Process (Paragraph 5–4A) performed?

Yes Go to Step 2

No Go to Beginning The Troubleshooting Process (Paragraph 5–4A)

Test the following circuits of the module for an open or a short to ground: 1. The battery positive (fuses) and ground connections at the module. 2. The ignition positive (fuses) and ground connections.

Go to Step 6

Go to Step 3

NOTE: The DTC set indicates the module for which the state of health (SOH) message was not detected by the TCM for a period of time exceeding 2 seconds. This may indicate an open wire leading to the module, or a defective module. Did you find and correct the condition? Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC) DTC U1000–U1096 Class 2 Controller State of Health Failure (cont’d) Step 3

4

Action Inspect for opens at the connector and the wire connecting the module to the TCM (wire 130). Did you find a problem?

Yes Go to Step 4

No Go to Step 5

Repair the module class 2 wiring harness connection.

Go to Step 6

—

Go to Step 6

—

Begin the diagnosis again. Go to Step 1

System OK

NOTE: The vehicle OEM has responsibility for all external wiring harness repairs. Harness repairs performed by Allison Transmission distributors and dealers are not covered under Allison Transmission warranty. Is the repair complete? 5

Refer to troubleshooting procedures specific to the controller module indicated. Replace the module, if defective. Is replacement or repair complete?

6

In order to verify your repair: 1. Clear the DTC. 2. Use the Scan Tool, in the test passed section, to confirm the diagnostic test was run. Did the DTC return?

5–258

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 6—INPUT AND OUTPUT FUNCTIONS 6–1.

SPECIAL INPUT AND OUTPUT FUNCTIONS

Each transmission control system provides additional functional control of transmission and/or vehicle operations tailored to the expected duty of the vehicle. Specific vocational requirements can be satisfied using input and output functions. Although these features may be used independently to control the function of the TCM, they can be combined to provide more comprehensive vehicle control functions. An example of the combined use of input and output functions is the combination of control signals which automatically commands the transmission to Neutral when a PTO is operated. NOTE:

Wiring diagrams for input and output functions are shown in Appendix N. A.

Input Functions Input functions are control signals that send vehicle data to the TCM to designate the operating state of other vehicle systems. “Ground input” control wires activate the programmed function when the input wire is switched to an isolated circuit ground. “Power input” control wires activate the programmed function when the input wire is switched to 12V or 24V power. Typical input functions are: • • • • • • • • •

B.

Secondary Shift Schedule PTO Enable Auxiliary Function Range Inhibit Exhaust Brake and Preselect Request (Standard, Optional, and Special) Automatic Neutral for PTO Reverse Enable Kickdown Refuse Packer Step Switch Overdrive Disable

Output Functions Output function signals send data from the TCM for use in controlling the operation of nontransmission components. As determined by programmed logic or attainment of preselected conditions, the TCM activates the appropriate output control wire (the circuit goes from OPEN to GROUND). This energizes a customer-supplied relay or switch to complete the external vehicle circuit. The output functions may be turned on and off based on the state of the input function signals and the operating state of the transmission. Typical output functions are: • Sump Temperature Indicator • Range Indicator • Output Speed Indicator

Copyright© 2004 General Motors Corp.

6–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

INPUT AND OUTPUT FUNCTIONS NOTES

6–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 7—GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS IMPORTANT: Make the following general checks before beginning specific troubleshooting, removing the transmission, or removing attached components. • Are there active DTCs? • Is the shift selector lever in N (Neutral), P (Park), or PB (Park Brake Apply) to allow starting the engine? • Is the battery properly connected and charged? • Is isolated battery properly connected (if used)? • Is the fluid level correct? • Is voltage to the TCM correct? • Is the engine properly tuned? • Is fuel flow to the engine correct? • Are wheel chocks in place? • Is air flow to the cooler and radiator unrestricted? • Is the driveline properly connected? • Are there signs of fluid leakage under the vehicle? What is the origination point? • Are hydraulic connections correctly made and not leaking? • Is vehicle acceleration from a stop changed? • Are electrical connections correctly made? • Are there any other obvious vehicle or transmission problems? After making these general checks use the various sections of this manual to isolate the listed problems. The following charts address specific vehicle complaints. Some complaints involve DTCs, so all troubleshooting checks should involve checking the system for DTCs.

Copyright © 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints Problem VEHICLE WILL NOT START — ENGINE WILL NOT CRANK

Possible Cause

Suggested Remedy

Lever shift selector not in N (Neutral) or P (Park) or PB (Park Brake Apply)*

Select N (Neutral) and restart

Dead battery

Recharge battery

Disconnected battery*

Reconnect battery

Faulty starter circuit

Repair vehicle starter circuit

Faulty NSBU switch*

Replace NSBU switch (refer to Mechanic’s Tips)

Misadjusted NSBU switch*

Adjust NSBU switch (refer to Mechanic’s Tips)

Faulty wiring in vehicle neutral start circuit*

Repair wiring

Connectors not properly seated on NSBU switch*

Properly install connector

CHECK TRANS LIGHT WILL NOT GO OUT AT START-UP

TCM has logged a DTC

Install Scan Tool to determine if DTC is present

A. Vehicle Drives Normally

Faulty CHECK TRANS light, relay, or circuit.

Replace relay or repair circuit

B. Vehicle Does Not Drive Normally Bad or no calibration in TCM

CHECK TRANS LIGHT FLASHES INTERMITTENTLY

Vehicle cannot establish communication with TCM

Repair J1939 backbone

Faulty wiring harness

Repair wiring harness (refer to Section 4 and Appendix E)

Faulty TCM

Replace the TCM

Intermittent power to TCM*

Check input power to the TCM and correct if necessary

Faulty vehicle wiring

Repair vehicle wiring

Loose wiring to CHECK TRANS light

Repair wiring

Faulty or incorrect ground wire attachment

Repair ground circuit

Intermittent opening in Circuit 125

Repair Circuit 125

* See Inhibit Section 2–5 7–2

Calibrate TCM via PCCS

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem NO CHECK TRANS LIGHT AT IGNITION

TRANSMISSION WILL NOT SHIFT TO FORWARD OR REVERSE — STAYS IN NEUTRAL

Possible Cause

Suggested Remedy

Faulty light bulb or socket

Replace light bulb or socket

Incorrect wiring to and from CHECK TRANS light bulb

Repair wiring (refer to Appendix E)

Faulty vehicle wiring

Repair vehicle wiring

Circuit 125 open

Repair Circuit 125

Faulty TCM

Replace TCM

Engine rpm too high*

Reduce engine rpm (it may be necessary to reselect Neutral also, and then D or R)

Low fluid level*

Add fluid to correct level (refer to Mechanic’s Tips for proper dipstick calibration)

Faulty throttle sensor or circuit*

See throttle sensor section for installation and operation information (Appendix F)

Faulty throttle signal from engine

Correct engine throttle signal

Faulty or misadjusted shift selector*

Repair or adjust shift selector

Faulty speed sensor or circuit*

Repair circuit or replace speed sensor(s) (refer to speed sensor DTCs and Appendix E)

Mechanical failure to C5 clutch

Repair transmission

Mechanical failure in transmission torque converter, shafts, or planetaries

Repair transmission

Low main pressure*

See Low Pressure Section

Faulty wiring in TCM Input/Output function circuits*

Correct circuit wiring

Auxiliary function range inhibit active*

Correct circuit wiring

Misadjusted NSBU switch*

Adjust NSBU switch (refer to Mechanic’s Tips)

* See Inhibit Section 2–5 Copyright © 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem TRANSMISSION WILL NOT STAY IN FORWARD OR REVERSE

TRANSMISSION WILL NOT MAKE A SPECIFIC SHIFT

TRANSMISSION DOES NOT SHIFT PROPERLY — ROUGH SHIFTS, SHIFTS OCCURRING AT TOO LOW OR TOO HIGH SPEED

Possible Cause Faulty auto-neutral for PTO circuit (input function)*

Repair quick-to-neutral circuit

Low fluid level*

Add fluid to correct level (refer to Mechanic’s Tips for proper dipstick calibration)

Low main pressure*

See Low Pressure Section

Faulty solenoid — leaking*

Replace solenoid (refer to Mechanic’s Tips)

Low engine power

Correct engine problem (refer to engine Service Manual)

Extreme fluid temperature

Inspect cooling system and fluid level

Faulty speed sensor or circuit*

Repair circuit or replace speed sensor(s) (refer to speed sensor DTCs and Appendix E)

Faulty temperature sensor or circuit

Check for temperature reading which inhibits shifts

Incorrect calibration

Install proper calibration

Faulty or misadjusted shift selector*

Repair or adjust shift selector

Engine idle speed too high (neutral to range shift)*

Adjust engine idle speed (refer to vehicle Service Manual)

Faulty throttle sensor or circuit*

See throttle sensor section for installation and operation information (Appendix F)

Faulty or sticking bleed ball in C1 piston housing

Replace C1 piston housing

Excessive clutch running clearance*

Rebuild transmission and adjust clearances

Incorrect TCM calibration

Install correct calibration

Instrument panel tachometer incorrect

Repair or replace tachometer

Incorrectly calibrated electronic speedometer

Calibrate electronic speedometer

Faulty speed sensor or circuit*

Repair circuit or replace speed sensor(s) (refer to speed sensor DTCs and Appendix E)

Degraded fluid

Change transmission fluid and filter (refer to Mechanic’s Tips)

* See Inhibit Section 2–5 7–4

Suggested Remedy

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem TRANSMISSION DOES NOT SHIFT PROPERLY — ROUGH SHIFTS, SHIFTS OCCURRING AT TOO LOW OR TOO HIGH SPEED (cont’d)

Possible Cause

Suggested Remedy

Loose speed sensor

Tighten speed sensor retainer bolt

Incorrect fluid level*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Low main pressure*

See Low Pressure Section

Intermittent problems*

Check wiring harnesses and connectors (refer to Appendix E)

Loose or damaged speed gear

Replace speed gear

Sticking valves in control valve assembly*

Overhaul control valve assembly

Leaking trim solenoids*

Repair or replace trim solenoids (refer to Service Manual)

Incorrect TCM calibration

Install correct calibration

A. Excessive Creep in First and Reverse Gears

Engine idle speed too high*

Adjust engine idle speed (refer to vehicle Service Manual)

B. Vehicle Moves Forward in Neutral

C1 clutch failed or not released*

Rebuild C1 clutch assembly (refer to transmission Service Manual)

C. Vehicle Moves Backward in Neutral

C3 clutch failed or not released*

Rebuild C3 clutch assembly (refer to transmission Service Manual)

EXCESSIVE FLARE — ENGINE OVERSPEED ON FULLTHROTTLE UPSHIFTS

TPS Adjustment:

ABNORMAL TRANSMISSION ACTIVITIES OR RESPONSES

— Overstroke

— Adjust TPS linkage for proper stroke (refer to Appendix F)

— Loose

— Tighten loose bolts or connections

Incorrect TCM calibration

Install correct calibration

Incorrect fluid level*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Sticking valves in control valve assembly*

Rebuild control valve assembly

Low main pressure*

See Low Pressure Section

* See Inhibit Section 2–5 Copyright © 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem EXCESSIVE FLARE — ENGINE OVERSPEED ON FULLTHROTTLE UPSHIFTS (cont’d)

SHUDDER WHEN SHIFTING INTO FORWARD OR REVERSE RANGE

Possible Cause

Suggested Remedy

Leaking trim solenoids*

Repair or replace trim solenoids (refer to Service Manual)

G solenoid mechanical failure

Repair or replace trim solenoids (refer to Service Manual)

Erratic speed sensor signal

See speed sensor DTCs

Leaking piston seals or slipping clutch plates in range involved*

Overhaul transmission (refer to transmission Service Manual)

Intermittent short to ground at F (TCC) solenoid circuit (wire 229). Could be accompanied by a P0743—F solenoid electrical DTC. It is possible to have this complaint without a DTC setting on earlier software.* This complaint is worse with preN04 software levels due to the different hydraulic schedule. Reverse range is not fully attainable due to TCC valve application blocking C5 feed circuit. This causes the range inhibit light to illuminate.

Repair or replace wire 229

Low main pressure*

See Low Pressure Section

Faulty trim solenoid*

Replace solenoid (refer to Service Manual or Mechanic’s Tips)

Sticky trim valve*

Rebuild control valve assembly (refer to Service Manual or Mechanic’s Tips)

C–1 or C-3 clutch failure*

Repair transmission (refer to Service Manual)

Not in gear

Select D (Drive)

Low fluid level, aerated fluid*

Add fluid to correct level (refer to Mechanic’s Tips for proper dipstick calibration)

Faulty torque converter

Replace torque converter

Incorrect torque converter

Replace torque converter (refer to transmission Service Manual)

Clutch pressure low*

See Low Pressure Section and Appendix B

ABNORMAL STALL SPEEDS (Stall In First Range — Fifth Range) A. High Stall Speeds

* See Inhibit Section 2–5 7–6

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem ABNORMAL STALL SPEEDS (Stall In First Range — Fifth Range) (cont’d)

B. Low Stall Speeds

OVERHEATING IN ALL RANGES

Possible Cause

Suggested Remedy

C1 or C5 clutch slipping* Note: Use the Scan Tool to check turbine speed

Rebuild C1 or C5 clutch assembly (refer to transmission Service Manual)

Engine too powerful

Confirm proper engine match

Engine not performing efficiently (may be due to plugged or restricted injectors, high altitude conditions, dirty air filters, out of time, throttle linkage, electronic engine controls problem)

Repair engine (refer to engine Service Manual or vehicle Service Manual)

Stall speeds 66 percent of normal implies freewheeling stator

Replace converter assembly (refer to transmission Service Manual)

Engine smoke controls

Compare lugback vs. static stall speed

Incorrect torque converter

Install correct torque converter (refer to transmission Service Manual)

Aerated fluid — incorrect fluid level*

Correct fluid level, check for defective pump (refer to Mechanic’s Tips and transmission Service Manual)

Air flow to cooler obstructed

Remove air flow obstruction

Engine overheat

Correct overheat situation (refer to vehicle Service Manual)

Inaccurate temperature gauge or sending unit

Replace gauge and/or sending unit

Inaccurate sump temperature sensor

Replace Pressure Switch Manifold (PSM) or internal harness (refer to transmission Service Manual)

Inadequate cooler sizing

See vehicle OEM for specifications

Excessive cooler circuit pressure drop

Check for plugged cooler, lines too small, collapsed hose, too many elbows in circuit

Transmission cooler lines reversed

Connect cooler lines properly (oil and water should flow in opposite directions)

Fluid cooler lines restricted

Remove restrictions, clean or replace lines (refer to Vehicle Service Manual)

* See Inhibit Section 2–5 Copyright © 2004 General Motors Corp.

7–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem

Possible Cause

Suggested Remedy

OVERHEATING IN ALL RANGES (cont’d)

Torque converter (wrong converter, no lockup, stuck stator, or slipping stator)

Replace or repair converter assembly (refer to transmission Service Manual) Note: Stuck stator will not allow cool down in neutral

Cooler flow loss due to internal transmission leakage

Overhaul transmission (refer to transmission Service Manual)

Low fluid level*

Add fluid to correct level (refer to Mechanic’s Tips for proper dipstick calibration)

Air leak in oil suction screen canister*

Replace suction filter (refer to Mechanic’s Tips)

Clogged filter*

Replace filter (refer to Mechanic’s Tips)

Aerated fluid causes noisy pump*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Low main pressure causes main regulator valve to oscillate*

See transmission Service Manual

Dipstick loose

Tighten cap, replace if necessary

Incorrect fluid level*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Breather stopped up — clogged

Clean or replace breather (refer to transmission Service Manual)

Fluid contaminated with foreign liquid

Drain and replace fluid. Locate and fix source of additional fluid (refer to transmission Service Manual)

Dipstick or fill tube seal worn

Replace seals or dipstick

Incorrect dipstick marking

Calibrate dipstick (refer to Mechanic’s Tips)

Faulty or missing seal at output flange

Install new lip-type seal in rear of transmission housing (refer to Mechanic’s Tips)

Machine lead on output flange seal surface

Replace flange

Rear cover porosity

Repair or replace cover

INTERMITTENT NOISE — BUZZING

LEAKING FLUID — FILL TUBE AND/OR BREATHER

LEAKING FLUID — TRANSMISSON OUTPUT

* See Inhibit Section 2–5 7–8

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem LEAKING FLUID — TRANSMISSON OUTPUT (cont’d)

LEAKING FLUID — TRANSMISSION INPUT

DIRTY FLUID

Possible Cause

Suggested Remedy

Flange worn at seal surface

Replace flange

Insufficient seal around seal OD

Replace seal (refer to Mechanic’s Tips)

Damaged, missing, or loose output flange bolt

Replace and/or torque output flange bolts

Leaking front seal

Replace front seal (refer to Mechanic’s Tips)

Leaking manifold seal

Replace manifold seal (refer to Mechanic’s Tips)

Leaking front support bolt seals

Replace bolt seals

Leaking converter

Check converter seals, cracked converter pump tangs, converter cover, or converter housing porosity; replace parts as required (refer to transmission Service Manual)

Leaking spin-on filter

Replace filter (refer to Mechanic’s Tips)

Leaking main pressure plug

Replace or torque main pressure plug

Worn pump bushing

Rebuild and repair pump

Failure to change fluid and filters

Change fluid and install new filters (refer to Mechanic’s Tips)

Excessive heat

Check cooling system for restrictions and proper capacity

Substandard fluid

Use recommended fluid (refer to Mechanic’s Tips)

Clutch/transmission failure*

Overhaul transmission (refer to transmission Service Manual)

* See Inhibit Section 2–5 Copyright © 2004 General Motors Corp.

7–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem

Possible Cause

Suggested Remedy

RANGE CLUTCH TROUBLESHOOTING SECTION EXCESSIVE SLIPPAGE AND CLUTCH CHATTER

Incorrect TCM calibration

Install correct calibration

Throttle Position Sensor out of adjustment or failed*

Adjust or replace throttle position sensor (refer to Appendix F)

Incorrect speed sensor readings*

See speed sensor DTCs

Incorrect fluid level*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Low main pressure*

See Low Pressure Section

TCC clutch not applied

Inspect lockup clutch system wiring, pressure, and controls; repair as necessary (refer to transmission Service Manual and Appendix B)

A. Ranges 1, 2, 3, 4 Only

C1 clutch slipping, leaks at rotating clutch seals, leaks at piston seals, C1 clutch plates worn*

Inspect C1 clutch plates, piston seals, and rotating seals; replace/rebuild as necessary (refer to transmission Service Manual and Appendix B)

B. Ranges 4, 5 Only

C2 clutch slipping, leaks at rotating clutch seals, leaks at piston seals, C2 clutch plates worn*

Inspect C2 clutch plates, piston seals, and rotating seals; replace/rebuild as necessary (refer to transmission Service Manual and Appendix B)

C. Ranges 3, 5, R Only

C3 clutch slipping, leaks at piston seals, C3 clutch plates worn*

Inspect C3 clutch plates and piston seals; replace/rebuild as necessary (refer to transmission Service Manual and Appendix B)

D. Range 2 Only

C4 clutch slipping, leaks at piston seals, C4 clutch plates worn*

Inspect C4 clutch plates and piston seals; replace/rebuild as necessary (refer to transmission Service Manual and Appendix B)

E. Ranges 1, R Only

C5 clutch slipping, leaks at piston seals, C5 clutch plates worn*

Inspect C5 clutch plates and piston seals; replace/rebuild as necessary (refer to transmission Service Manual and Appendix B)

* See Inhibit Section 2–5 7–10

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 7–1. Troubleshooting Performance Complaints (cont’d) Problem

Possible Cause

Suggested Remedy

LOW PRESSURE SECTION A. Low or No Main Pressure in All Ranges

Incorrect fluid level*

Correct fluid level (refer to Mechanic’s Tips for proper dipstick calibration)

Clogged or faulty oil filter element*

Replace oil filter (refer to Mechanic’s Tips)

Plugged or faulty suction filter*

Clean or replace oil suction filter element and refill the transmission (refer to Mechanic’s Tips)

Sticking main pressure regulator valve*

Overhaul front support assembly (refer to transmission Service Manual)

Leaking solenoids in control valve assembly*

Repair or replace solenoids (refer to Mechanic’s Tips)

G solenoid failure

Replace G solenoid. See transmission Service Manual.

Weak, broken, or missing main pressure regulator valve spring*

Check spring and replace if necessary (refer to transmission Service Manual)

Control valve body leakage* (loose control valve body bolts)

Replace or rebuild control valve assembly. Care should be taken when removing and labeling shift springs (refer to transmission Service Manual)

Faulty or incorrect fluid pressure gauge*

Repair or replace gauge

Worn or damaged oil pump*

Replace or rebuild oil pump (refer to transmission Service Manual)

Leak in suction circuit*

Check suction circuit for leaking seal, gasket, or mating surface

B. Low Main Pressure in Specific Ranges, Normal Pressure in Other Ranges

See transmission Service Manual

* See Inhibit Section 2–5 Copyright © 2004 General Motors Corp.

7–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS NOTES

7–12

Copyright © 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDICES—INDEX APPENDICES Appendix A

Diagnosing Intermittent DTCs

Appendix B

Main Pressure Check Procedure

Appendix C

Solenoid and Clutch Table

Appendix D

Wire/Connector Table

Appendix E

Connector Repair Information

Appendix F

TPS Adjustment

Appendix G

Welding on Vehicle

Appendix H

Hydraulic Schematics

Appendix J

Wiring Schematics

Appendix K

Resistance vs. Temperature

Appendix L

Electronic Interference

Appendix M

Diagnostic Tool Information

Appendix N

Input/Output Function Schematics

Appendix P

Fluid Check Procedure

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDICES NOTES

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX A—DIAGNOSING INTERMITTENT DTCS Intermittent Diagnostic Trouble Codes (DTC) are a result of faults that are detected, logged, and then disappear, only to recur later. If, when troubleshooting, a DTC is cleared in anticipation of it recurring and it does not, check the items in the following list for the fault’s source. A.

Circuit Inspection 1. Intermittent power/ground problems — can cause voltage problems during TCM diagnostic checks which can set various DTCs depending upon where the TCM was in the diagnostic process. 2. Damaged terminals. 3. Dirty or corroded terminals. 4. Terminals not fully seated in the connector. Check indicated wires by uncoupling connector and gently pulling on the wire at the rear of the connector and checking for excessive terminal movement. 5. Connectors not fully mated. Check for missing or damaged locktabs. 6. Screws or other sharp pointed objects pushed into or through one of the harnesses. 7. Harnesses which have rubbed through and may be allowing intermittent electrical contact between two wires or between wires and vehicle frame members. 8. Broken wires within the braiding and insulation.

B.

Finding an Intermittent Fault Condition

To find a fault, like one of those listed, examine all connectors and the external wiring harnesses. Harness routing may make it difficult to see or feel the complete harness. However, it is important to thoroughly check each harness for chafed or damaged areas. Road vibrations and bumps can damage a poorly installed harness by moving it against sharp edges and cause some of the faults. If a visual inspection does not identify a cause, move and wiggle the harness by hand until the fault is duplicated. The next most probable cause of an intermittent DTC is an electronic part exposed to excessive vibration, heat, or moisture. Examples of this are: 1. Exposed harness wires subjected to moisture. 2. A defective connector seal allows moisture to enter the connector or part. 3. An electronic part (TCM, solenoid, or throttle sensor) affected by vibration, heat, or moisture may cause abnormal electrical conditions within the part. When troubleshooting Item 3, eliminate all other possible causes before replacing any parts. Another cause of intermittent DTCs is good parts in an abnormal environment. The abnormal environment will usually include excessive heat, moisture, or voltage. For example, a TCM that receives excessive voltage will generate a diagnostic code as it senses high voltage in a circuit. The DTC may not be repeated consistently because different circuits may have this condition on each check. The last step in finding an intermittent DTC is to observe if the DTC is set during sudden changes in the operating environment. Troubleshooting an intermittent DTC requires looking for common conditions that are present whenever the DTC is diagnosed. Use the failure record information from the scan tool to identify the conditions when the DTC was set.

Copyright© 2004 General Motors Corp.

A–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIXAA—DIAGNOSING APPENDIX — DIAGNOSINGINTERMITTENT INTERMITTENTDTC DTCSS C.

Recurring Conditions

A recurring condition might be: • • • •

Rain Outside temperature above or below a certain temperature Only on right-hand or left-hand turns When the vehicle hits a bump, etc.

If such a condition can be related to the DTC, it is easier to find the cause. If the time between DTC occurrences is very short, troubleshooting is easier than if it is several weeks or more between DTC occurrences. • Repair parts for the internal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained through the vehicle OEM and the OEM is responsible for warranty on these parts.

A–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX B—MAIN PRESSURE CHECK PROCEDURE Checking main pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical problem. Properly making these pressure checks requires transmission and vehicle (or test stand) preparation, recording of data, and comparing recorded data against specifications provided.

MAIN PRESSURE TAP

BOTTOM VIEW V05742

Figure B–1. Main Pressure Check Point

WARNING!

Observe safety precautions during hydraulic pressure check procedures. All personnel must stand clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges (vacuum, pressure, tachometer) have extended lines so that they can be read from inside the vehicle.

1. All transmission fluid level and pressure checks must be made at normal operating temperatures 71–93°C (160–200°F) sump; 82–104°C (180–220°F) converter-out. Check transmission fluid level. 2. Connect a 0–2070 kPa (0–300 psi) oil pressure gauge at the main pressure tap (Figure B–1). Use the scan tool to check engine rpm. See Table B–1 for main pressure levels. 3. Disconnect the driveshaft. 4. With brakes applied, check main pressure with the engine running at 2100 rpm and 600 rpm. 5. Continue the procedure for all ranges.

Copyright© 2004 General Motors Corp.

B–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX B—MAIN PRESSURE CHECK PROCEDURE Table B–1. Main Pressure Test Conditions (Used Prior To S/N 6310004116) Range

Main Pressure @ 600 rpm

Main Pressure @ 2100 rpm

800–1380 kPa (115–200 psi)

1515–1795 kPa (220–260 psi)

—

1000–1170 kPa (145–170 psi)

Reverse

800–1380 kPa (115–200 psi)

1515–1795 kPa (220–260 psi)

Neutral/Park

900–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi)

Forward (Converter — Torque Converter Clutch not applied) Forward (Torque Converter Clutch Applied)

(Used Starting With S/N 6310004116) Range

Main Pressure @ 600 rpm

Main Pressure @ 2100 rpm

700–1280 kPa (101–186 psi)

1515–1795 kPa (220–260 psi)

—

1000–1170 kPa (145–170 psi)

Reverse

700–1280 kPa (101–186 psi)

1515–1795 kPa (220–260 psi)

Neutral/Park

800–1655 kPa (130–240 psi)

1515–1795 kPa (220–260 psi)

Forward (Converter) Forward (Torque Converter Clutch Applied)

Table B–2. Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid) Range

Main Pressure @ 600 rpm

Main Pressure @ 2100 rpm

Forward/Reverse Converter with G Solenoid Active

590–720 kPa (85–105 psi)

634–758 kPa (92–110 psi)

Forward Converter with G Solenoid Inactive

700–1380 kPa (101–200 psi)

1515–1795 kPa (220–260 psi)

Forward Lockup with G Solenoid Active*

—

510–627 kPa (74–91 psi)

Forward Lockup with G Solenoid Inactive*

—

1000–1170 kPa (145–170 psi)

Neutral/Park with G Solenoid Active

590–720 kPa (85–105 psi)

Neutral/Park

800–1655 kPa (130–240 psi)

* Medium duty gasoline engines only.

B–2

Copyright© 2004 General Motors Corp.

— 1515–1795 kPa (220–260 psi)

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX C—SOLENOID AND CLUTCH TABLE Normal operation of the transmission requires application of two clutches to attain a forward or reverse range. A unique combination of solenoid and shift valve actuation produces clutch application in a given range. Table C–1 lists the transmission range shifts, the clutches that are applied in each range, and the electrical state (On/Off) of each solenoid for each range. C–1. Solenoid and Clutch Table — Software Levels Prior To N04

Logic

Clutch To Main

R

—

Garage Shift

R–N

—

Garage Shift

N–R

—

Steady State

N

—

Garage Shift

N–1

—

Garage Shift

1–N

—

Steady State

1

C1

Upshift

1–2

C1

Downshift

2–1

C1

2

C1

Upshift

2–3

C1

Downshift

3–2

C1

3

C1

Upshift

3–4

C1

Downshift

4–3

C1

4

C2

Upshift

4–5

C2

Downshift

5–4

C2

5

C2

Range Status Steady State

Steady State

Steady State

Steady State

Steady State

Trim Solenoids A De-energized; C3 Applied De-energizing; C3 Trimming Off Energizing; C3 Trimming On De-energized; C5 Applied De-energizing; C5 Applied De-energizing; C5 Applied De-energized; C5 Applied Energizing; C5 Trimming Off Energizing; C5 Trimming On Energized; C3 Exhausted De-energizing; C3 Trimming On De-energizing; C3 Trimming Off De-energized; C3 Applied Energizing; C3 Trimming Off Energizing; C3 Trimming On Energized; C3 Exhausted De-energizing; C3 Trimming On De-energizing; C3 Trimming Off De-energized; C3 Applied

B Energized; C5 Applied Energizing; C5 Applied Energizing; C5 Applied De-energized; — Exhausted Energizing; C1 Trimming On Energizing; C1 Trimming Off De-energized; C4 Exhausted Energizing; C4 Trimming On Energizing; C4 Trimming Off Energized; C4 Applied De-energizing; C4 Trimming Off De-energizing; C4 Trimming On De-energized; C2 Exhausted Energizing; C2 Trimming On Energizing; C2 Trimming Off Energized; C1 Applied De-energizing; C1 Trimming Off De-energizing; C1 Trimming On De-energized;

Shift Solenoids

TCC Sol

C

D

E

F

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

OFF

OFF

OFF

ON or OFF *

OFF

OFF

OFF

ON

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

OFF

OFF

ON

ON

* Depending upon output speed

Copyright© 2004 General Motors Corp.

C–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX C—SOLENOID AND CLUTCH TABLE Table C–1. Solenoid and Clutch Table — Software Level N04 And Later Range Status Steady State with Throttle Steady State at Closed Throttle Garage Shift

Logic R R

Trim Solenoids Clutch To Main A B — De-energized; Energized; C3 Applied C5 Applied — De-energized; Energized; C5 Applied C3 Applied

R–N

—

Garage Shift

N–R

—

Steady State

N

—

Garage Shift

N–1

—

Garage Shift

1–N

—

Steady State

1

C1

Upshift

1–2

C1

Downshift

2–1

C1

2

C1

Upshift

2–3

C1

Downshift

3–2

C1

3

C1

Upshift

3–4

C1

Downshift

4–3

C1

4

C2

Upshift

4–5

C2

Downshift

5–4

C2

5

C2

Steady State

Steady State

Steady State

Steady State

De-energizing; C3 Trimming Off Energizing; C3 Trimming On De-energized; C5 Applied De-energizing; C5 Applied De-energizing; C5 Applied De-energized; C5 Applied Energizing; C5 Trimming Off Energizing; C5 Trimming On Energized; C3 Exhausted De-energizing; C3 Trimming On De-energizing; C3 Trimming Off De-energized; C3 Applied Energizing; C3 Trimming Off Energizing; C3 Trimming On Energized; C3 Exhausted De-energizing; C3 Trimming On De-energizing; C3 Trimming Off De-energized; C3 Applied

Energized; C5 Applied Energizing; C5 Applied De-energized; — Exhausted Energizing; C1 Trimming On Energizing; C1 Trimming Off De-energized; C4 Exhausted Energizing; C4 Trimming On Energizing; C4 Trimming Off Energized; C4 Applied De-energizing; C4 Trimming Off De-energizing; C4 Trimming On De-energized; C2 Exhausted Energizing; C2 Trimming On Energizing; C2 Trimming Off Energized; C1 Applied De-energizing; C1 Trimming Off De-energizing; C1 Trimming On De-energized

Shift Solenoids C ON

D ON

E ON

F OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON or OFF ** ON

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

OFF

OFF

ON

ON

Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range: At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch. Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5. Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule. * Values are calibration dependent ** Depending upon output speed

C–2

Copyright© 2004 General Motors Corp.

TCC Sol

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES The connector information in this appendix is provided for the convenience of the servicing technician. The connector illustration and pin identifications for connection to Allison Transmission components will be accurate. Allison Transmission components are the TCM, speed sensors, and transmission connectors. Other kinds of connectors for optional or customer-furnished components are provided based on typical past practice for an Allison-designed system. Contact your vehicle manufacturer for information on connectors not found in this appendix.

Copyright© 2004 General Motors Corp.

D–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES COLOR CODE RED 16

1

32

17 V06211

Figure D–1. TCM Connector J2

TCM CONNECTOR J2 (RED) Terminal No. 1 2 3 4 5 6 7 8 9 10 11

D–2

Color Blue Pink White Green Blue Yellow Gray White Blue Tan Orange

Wire No. 201 202 203 204 205 206 207 208 209 210 211

12

Blue

212

13 14 15 16 17 18 19 20

Orange Blue Yellow Green Tan Orange Pink Green

213 214 215 216 217 218 219 220

21 22

Yellow Yellow

221 222

23

White

223

24

Pink

224

25

Orange

225

26 27 28 29 30 31 32

Green Blue Gray White Blue Tan Green

226 227 228 229 230 231 232

Description PSM Input PSM Input PSM Input PSM Input NSBU Input NSBU Input NSBU Input NSBU Input Throttle Position Sensor Sump Temperature Input Retarder Temperature Input (optional) Engine Coolant Temperature Input (optional) Turbine Speed Sensor High Turbine Speed Sensor Low Output Speed Sensor High Output Speed Sensor Low Engine Speed Sensor High Engine Speed Sensor Low Sensor Power Analog Ground

A Solenoid High (VBS) Variable Bleed Solenoid A Solenoid Low (VBS) Variable Bleed Solenoid B Solenoid High (VBS) Variable Bleed Solenoid B Solenoid Low (VBS) Variable Bleed Solenoid C Solenoid Low (ON/OFF) D Solenoid Low (ON/OFF) E Solenoid Low (ON/OFF) F Solenoid Low (PWM) G Solenoid Low (ON/OFF) ON/OFF Solenoid High PWM Solenoid High/G Solenoid Copyright© 2004 General Motors Corp.

Termination Point(s) TRANS-D TRANS-F TRANS-E TRANS-K NSBU-4A NSBU-4D NSBU-4B NSBU-4C TPS-B TRANS-G RTEMP-A ENGWAT TEMP-A NT-A NT-B NO-A NO-B NE-A NE-B TPS-C TRANS-H, R-TEMP-B, ENG-WAT TEMP-B, NSBU-7D, TPS-A TRANS-T TRANS-L TRANS-M TRANS-N TRANS-P TRANS-A TRANS-B TRANS-W TRANS-J TRANS-R TRANS-C TRANS-S

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES COLOR CODE GRAY 16

1

32

17

V06212

Figure D–2. TCM Connector J1

TCM CONNECTOR J1 (GRAY) Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Color Gray Yellow Pink Yellow Gray Blue Orange Green White Yellow Green Blue Pink Orange

Wire No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114

White Pink Green Tan Orange White Blue Pink White Green Tan Pink Yellow Red Blue Green Black

116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132

Description Battery Ground Ignition Power Battery Power Ignition Power Battery Ground GPI 1 GPI 2 GPI 3 GPI 4 GPI 5 GPI 6 GPI 7 GPI 8 GPI 9

Termination Point(s) Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System

PWM Throttle Sensor Power (optional) Analog Ground GPO 1 GPO 2 GPO 3 GPO 4 Range Inhibit Indicator GPO 6 CHECK TRANS Vehicle Speed Vehicle Speed Digital Ground CAN High ISO 9141 Class II J-1850 CAN Shield CAN Low

Vehicle System RMR-C RMR-A Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System J1939 A or H Vehicle System J1939 C or S J1939 B or L

Copyright© 2004 General Motors Corp.

D–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

TRANSMISSION HARNESS CONNECTOR S

TRANSMISSION BULKHEAD CONNECTOR

K

K D

R W

S

R

D

W

COLOR CODE GREEN

HARNESS

DEVICE T

A E NOTE: Letters I, O, and Q not used

L

A E

L

T V03369.01.00

Figure D–3. Delphi-Packard Main Transmission Connector

DELPHI-PACKARD MAIN TRANSMISSION CONNECTOR Terminal No.* A B C D E F G H J K L

Color Green Yellow/Black Pink Light Green Red Dark Blue Yellow Black Brown Tan Red/Black

Wire No. 226 227 231 201 203 202 210 220 229 204 222

M

Light Blue

223

N

Gray

224

P

Purple

225

R S T U V W

Blue Black White Dark Green Dark Green Black/White

230 232 221 — — 228

Description C Solenoid Low (ON/OFF) D Solenoid Low (ON/OFF) ON/OFF Solenoid High PSM Input PSM Input PSM Input Sump Temperature Input Analog Ground F Solenoid Low (PWM) PSM Input A Solenoid High Variable Bleed Solenoid (VBS) A Solenoid Low Variable Bleed Solenoid (VBS) B Solenoid High Variable Bleed Solenoid (VBS) B Solenoid Low Variable Bleed Solenoid (VBS) G Solenoid Low (ON/OFF) PWM Solenoid High/F, G Solenoid — — E Solenoid Low (ON/OFF)

Termination Point(s)* TCM J2-26 TCM J2-27 TCM J2-31 TCM J2-1 TCM J2-3 TCM J2-2 TCM J2-10 TCM J2-20 TCM J2-29 TCM J2-4 TCM J2-22 TCM J2-23 TCM J2-24 TCM J2-25 TCM J2-30 TCM J2-32 TCM J2-21 — — TCM J2-28

* Terminal number and termination points shown only apply when an Allison Transmission recommended harness configuration and bulkhead connector are used.

D–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

PIN A

B

PIN B

A

RECEPTACLE

PLUG

V05738

Figure D–4. Speed Sensor Connector

ENGINE SPEED SENSOR CONNECTOR Terminal No. A B

Color Tan Orange

Wire No. 217 218

Description Engine Speed Sensor Hi Engine Speed Sensor Lo

Termination Point(s) TCM J2-17 TCM J2-18

TURBINE SPEED SENSOR CONNECTOR Terminal No. A B

Color Orange Blue

Wire No. 213 214

Description Turbine Speed Sensor Hi Turbine Speed Sensor Lo

Termination Point(s) TCM J2-13 TCM J2-14

OUTPUT SPEED SENSOR CONNECTOR Terminal No. A B

Color Yellow Green

Wire No. 215 216

Description Output Speed Sensor Hi Output Speed Sensor Lo

Copyright© 2004 General Motors Corp.

Termination Point(s) TCM J2-15 TCM J2-16

D–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

C

A

PIN C B

PIN B

PIN A

PLUG

RECEPTACLE

V05739

Figure D–5. TPS Connector

THROTTLE POSITION SENSOR CONNECTOR Terminal No. A B C

D–6

Color Green Blue Pink

Wire No. 220 209 219

Description Analog Ground TPS Signal TPS Hi

Copyright© 2004 General Motors Corp.

Termination Point(s) TCM J2-20 TCM J2-9 TCM J2-19

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

A or H

B or L

B or L

C or S

MALE CONNECTOR

A or H

C or S

FEMALE CONNECTOR V06532

Figure D–6. J1939 Interface Connector

J1939 INTERFACE CONNECTOR J1939 Connector Terminal No. Color A or H Yellow B or L Green C or S Uninsulated

Wire No. 129 132 131

Description J1939 Controller, High J1939 Controller, Low J1939 Shield/Ground

Copyright© 2004 General Motors Corp.

TCM Connector Terminal No. Color TCM J1-29 Red TCM J1-32 Black TCM J1-31 Green

D–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

7A

7G

PIN 7A

PIN 7G

PIN 7D

PIN 7E

4C 4A

4D 4B 7E

7D 7-WAY RECEPTACLE

4-WAY RECEPTACLE

PIN 4C

PIN 4A

PIN 4D

PIN 4B PLUG V05740

Figure D–7. NSBU Switch Connectors

NSBU SWITCH CONNECTOR Terminal No. 4A 4B 4C 4D 7A 7B 7C

D–8

Color Blue Gray White Yellow — Tan Blue

Wire No. 205 207 208 206 — — —

7D 7E

Green Yellow

220 —

7F 7G

Pink Orange

— —

Description NSBU Output NSBU Output NSBU Output NSBU Output — NSBU Input NSBU Output Analog Ground NSBU Output NSBU Input NSBU Input

Copyright© 2004 General Motors Corp.

Termination Point(s) TCM J2-5 TCM J2-7 TCM J2-8 TCM J2-6 — Park Accessory Reverse and Park Accessory Feed TCM J2-20 Park and Neutral Start Feed Reverse Lamps Starter Solenoid/Starter Relay

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES PIN 12 12

PIN 11

6 11

PIN 6 PIN 7 3

PIN 3

7

1

PIN 1

PIN LOCATION ON NSBU SWITCH CONNECTOR END VIEW

SINGLE CONNECTOR NILES NSBU SWITCH (P/N 29541852)

V08100.00.00

Figure D–8. Single Connector NSBU

NSBU SWITCH CONNECTOR Terminal No. 1

Color Orange

Wire No. —

2 and 3 4 5 6 7 8 9 10 11

— Yellow Blue Gray Green White — Pink Blue

— 206 205 207 220 208 — — —

12

Yellow

—

Description NSBU Input — NSBU Output NSBU Output NSBU Output Analog Ground NSBU Output — NSBU Input NSBU Output NSBU Output

Copyright© 2004 General Motors Corp.

Termination Point(s) Starter Solenoid/Starter Relay — TCM J2-6 TCM J2-5 TCM J2-7 TCM J2-20 TCM J2-8 — Reverse Lamps Reverse and Park Accessory Feed Park and Neutral Start Feed

D–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

D E

C A

F

B J

G H

9-PIN V06481

Figure D–9. Deutsch DDR Connector

SAE STD 9-PIN DIAGNOSTIC (J1939 DIAGNOSTIC LINK) CONNECTOR Terminal No. A B B (Optional) C D E F G

D–10

Color Determined By OEM Determined By OEM Determined By OEM Yellow Green Uninsulated Determined By OEM Determined By OEM

Wire No. — — — 129 132 131 — —

Description Battery Ground (–) Ignition Power (+) Battery Power (+) J1939 High J1939 Low J1939 Shield/Ground Serial Communication (+) Serial Communication (–)

Copyright© 2004 General Motors Corp.

Termination Point(s) Vehicle System Vehicle System Vehicle System J1939 Backbone A J1939 Backbone B J1939 Backbone C Vehicle System Vehicle System

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

SOL C 13 mm EXTENSION PSM SOL G MAIN TRANSMISSION CONNECTOR SOL A SOL B SOL E SOL D SOL F

V05732.01.02

Figure D–10. Transmission Internal Harness

TRANSMISSION INTERNAL HARNESS CONNECTORS Connector Name Solenoid A Solenoid B Solenoid C Solenoid D Solenoid E Solenoid F Solenoid G Pressure Switch Manifold

Connector Pin No. 1 2 1 2 A B A B A B A B A B A B C D E F

Main Connector Pin No. M L N P C A C B C W S J S R D F E K G H,T (Trans ID)

Wire Color Light Blue Red/Blk Strp Gray Purple Pink Dark Green Pink Yellow/Blk Strp Pink Black/Wht Strp Black Brown Black Orange Light Green Dark Blue Red Tan Yellow Blk (H), White (T)

Copyright© 2004 General Motors Corp.

TCM Pin No. J2–23 J2–22 J2–24 J2–25 J2–31 J2–26 J2–31 J2–27 J2–31 J2–28 J2–32 J2–29 J2–32 J2–30 J2–1 J2–2 J2–3 J2–4 J2–10 J2–20, J2–21

D–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D—WIRE/CONNECTOR TABLES

NOTES

D–12

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION Contents

Page

List of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses . E–2 1–1.

Delphi-Packard Micro Pack 100W Connectors (TCM J1 and J2, Main Transmission E–5 Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–2.

Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat (Speed Sensors) . . . . . . . . . E–9

1–3.

Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch). . . . . . . . . . E–13

1–4.

Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–16

1–5.

Delphi-Packard WeatherPack Connectors (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–19

1–6.

Deutsch IPD/ECD (J1939 Diagnostic 9-Way Connector Link Connector). . . . . . . . . . . . . . . . . . . E–23

1–7.

Deutsch DT Series Connectors (3-Way J1939 Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–27

1–8.

Repair of a Broken Wire with In-Line Butt Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–29

1–9.

List of 1000 and 2000 Product Families Connector Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–31

NOTE:

Allison Transmission is providing for service of wiring harnesses and wiring harness components as follows: • Repair parts for the internal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained through the vehicle OEM and the OEM is responsible for warranty on these parts.

Copyright© 2004 General Motors Corp.

E–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION List Of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses

E–2

Tool Number

Tool Type

Paragraph Reference

23046604

Splice, Sealed (14–16 AWG)

1–8

23046605

Splice, Sealed (18–22 AWG)

1–8

J 25070

Heat Gun

1–8

J 34182

Crimper 1

1–6, 1–7

J 34513

Remover 1

1–6

J 35123

Crimper (Alternate)

1–2, 1–3

J 35606

Crimper (Alternate)

1–5

J 35615

Wire Stripper 1

1–2, 1–3, 1–8

J 35689-A

Remover

1–2, 1–3

J 38125-10

Remover

1–5

J 38125-6

Crimper

1–5

J 38125-7

Crimper

1–2

J 38125-8

Crimper

1–8

J 38582-3

Remover

1–6

J 38852

Crimper (Alternate)

1–5

J 39227

Remover

1–1

J 41194

Extractor/Inserter

1–6

J 42215

Crimper

1–1

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION RETAINER SOCKET TERMINAL (FEMALE)

CONNECTOR

TYPICAL WIRE SEAL LOCKTAB (SECURES RETAINER) TERMINAL LOCKING FINGER LOCKING POST

STRAIN RELIEF

LOCKTABS CAVITY PLUG

Lock terminal here

SOCKET TERMINAL

WIRE

J 42215 CRIMPING TOOL V03419

Figure E–1A. Delphi-Packard Micro Pack Connector (TCM J1 and J2) Copyright© 2004 General Motors Corp.

E–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

J 39227 REMOVAL TOOL

MATING CONNECTOR WITH FEMALE (SOCKET) TEMINALS

SECONDARY LOCK VIEW A

LOCKING FINGERS

WIRE

WIRE SEAL

VIEW A

CAVITY PLUG CONDUIT CLIP

SOCKET TERMINAL

Lock terminal here PIN TERMINAL

WIRE

J 42215 CRIMPING TOOL V05743

Figure E–1B. Delphi-Packard Micro Pack Connector (Main Transmission Connector) E–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–1.

DELPHI-PACKARD MICRO PACK 100W CONNECTORS (TCM J1 AND J2, MAIN TRANSMISSION CONNECTOR) A.

Connector/Terminal Repairs Required Tools

B.

Crimping Tool Remover Tool

J 42215 J 39227

Use

Description

Manufacturers P/N

Main Transmission Connector

Connector, 20F MIC/P 100W Gray Lock, Secondary 20F Green Terminal, Socket 100W Cavity Plug, 100W Conduit Clip, 13mm Black

12160280 12160494 12084912 12129557 12176394

Terminal Removal 1. TCM Harness Connectors (Figure E–1A) a. Use a small-bladed screwdriver to gently release the locktabs at the splitline of the strain relief. b. Spread the strain relief open. c. Remove the retainer from the connector by using a small-bladed screwdriver to depress the locktabs on the side of the connector. d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and pulling the wire and terminal rearward out of the connector. 2. Main Transmission Connectors (Figure E–1B) a. Use a small bladed screw driver to gently release the locktabs at the split line of the conduit clamp. b. Remove conduit clamp. c. Use a small-bladed screw driver to gently release the locktab remove the lock assembly. d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and pulling the wire and terminal rearward out of the connector.

C.

Terminal Crimping 1. Carefully strip 5.0 mm ±0.5 mm (0.20 ±0.02 inch) of insulation from the end of the wire. 2. Insert the new terminal to be crimped in the J 42215 crimping tool. There is a spring-loaded terminal positioner at the front of the tool to hold the terminal in place. Squeeze the crimper handles for a few clicks to start the crimping process but leave room to insert the wire end. 3. Insert the bare wire end into the terminal. Squeeze the crimper handles to complete the crimping process and until the crimper handles open when released to remove the terminal/wire from the tool.

Copyright© 2004 General Motors Corp.

E–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION C.

Terminal Crimping (cont’d) 4. Complete terminal installation for Main Transmission Connector as follows: (Figure E–1B) a. Insert the wire seal in the back of the connector. b. Push the terminal/wire assembly through the proper hole in the back of the wire seal. Push the wire in until the terminal clicks into position. Gently pull rearward on the wire to be sure that the terminal is fully seated. Install cavity plugs as needed. c. Install the lock assist or secondary lock into the connector body. d. Close the conduit clip around the conduit and lock the clip into the rear of the connector body. 5. Complete terminal installation of the TCM Connectors as follows: (Figure E–1A) a. Align the locking posts on the connector with the seal and push the locking posts through the seal into the mating holes in the strain relief (if the connector was removed from the strain relief). b. Push the terminal/wire assembly through the proper hole in the back of the seal. Push the wire in until the terminal clicks into position.

NOTE:

All terminals must be properly positioned to install the retainer in Step (5c). c. Install the retainer on the connector body to lock the terminals in position. Pull gently on the wire to be sure that the terminal is fully seated. Install cavity plugs as needed. d. Position the conduit inside the strain relief and snap the strain relief halves together.

E–6

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2004 General Motors Corp.

E–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

Seal plug butts up here

RETAINER CONNECTOR

Remove in this direction

WIRE AND TERMINAL

J 35689-A

Seat in this direction

Insertion of removal tool (J 35689-A) forces lock tang toward body of terminal

VIEW A

Butt wire against terminal holder

Use wire gauge 18-16 slot

18-16

B D

J 38125-7

22-20

A C E

WIRE SIDE

TERMINAL

VIEW B Push lock to insert terminal end J 35123 WIRE SIDE

18-16

22-20

TERMINAL HOLDER

VIEW C Figure E–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat (Speed Sensors)

E–8

Copyright© 2004 General Motors Corp.

V05744

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–2.

DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PULL-TO-SEAT (SPEED SENSORS) A.

Connector/Terminal Repairs Required Tools

B. NOTE:

Crimping Tool

J 38125-7

Wire Crimp

Anvil “E”

Insulation Crimp

Anvil “C”

Alternate Crimping Tool

J 35123

Remover Tool

J 35689-A

Automatic Wire Stripper

J 35615

Use

Description

Manufacturers P/N

Engine Speed (Ne) Sensor

Connector Terminal

12162193 12103881

Turbine Speed (Nt) Sensor

Connector Terminal

12162193 12103881

Output Speed (No) Sensor

Connector Terminal

12162193 12103881

Terminal Removal Do not solder crimps. 1. Insert the needle end of terminal remover J 35689-A into the small notch between the connector and the terminal to be removed (Figure E–2, View A). Push the lock tang toward the terminal. 2. Push the wire and terminal out of the connector (this is a “pull-to-seat” terminal). 3. Pull the terminal as far as necessary from the connector. This will be limited by the number of other wires inserted into the connector and by the distance between the back side of the connector and the beginning of the harness covering. 4. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to minimize wire loss.

C.

Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool) 1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if used), through the wire seal, and out the other side of the connector before stripping. 2. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp from an old terminal without damaging the wire. 3. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper enough to keep the terminal from dropping (Figure E–2, View B). 4. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp. Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool).

Copyright© 2004 General Motors Corp.

E–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION C.

Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool) (cont’d) 5. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and a portion of the terminal between the core and insulation crimp areas are supported by the anvil. Complete the insulation crimp. 6. Be sure the lock tang is lifted to allow proper reseating of the terminal. 7. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the terminal should stay in place if the wire is pushed.)

D.

Terminal Crimping Using Alternate Tool J 35123 1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if used) and the wire seal, and out the other side of the connector prior to stripping. 2. Insert the remover tool in the front side of the connector to release the locktab, and push the terminal out the front of connector. Pull the terminal and wire out the front of the connector to complete Steps (3) through (7). 3. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening marked 18–16 (Figure E–2, View C) so that the crimp ends point up. Release the terminal holder. 4. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal. Place the terminal on the wire so it is in the same position as it will be when pulled back into the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool). 5. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and insulation should be properly positioned for the core and insulation crimp wings.) 6. Squeeze the crimper fully until it opens when released. 7. Open the terminal holder and remove the wire and terminal from the crimping tool. 8. Pull on the terminal to assure a tight crimp. 9. Be sure the lock tang is lifted to allow proper reseating of the terminal. 10. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the terminal should stay in place if the wire is pushed.)

E–10

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2004 General Motors Corp.

E–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

Install in this direction SECONDARY LOCK Remove in this direction WIRE AND TERMINAL Insertion of removal tool (J 35689) forces lock tang toward body of terminal

D

A

B

C

J 35689-A

VIEW A

Butt wire against terminal holder Use wire gauge 18-16 slot

B D

22-20

J 38125-7

18-16

A C E

WIRE SIDE

VIEW B

TERMINAL

Push lock to insert terminal end J 35123 22-20

18-16

WIRE SIDE

TERMINAL HOLDER

VIEW C

Figure E–3. Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch)

E–12

Copyright© 2004 General Motors Corp.

V05745

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–3.

DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PUSH-TO-SEAT (NSBU SWITCH) A.

Connector/Terminal Repairs Required Tools

B. NOTE:

Crimping Tool

J 38125–7

Wire Crimp

Anvil “E”

Insulation Crimp

Anvil “C”

Alternate Crimping Tool

J 35123

Remover Tool

J 35689–A

Automatic Wire Stripper

J 35615

Use

Description

Manufacturers P/N

NSBU Switch

4 Way Tower Connector Wire Type Seal, Dk Red 150f Terminal

12191757 12048086 12048074

Terminal Removal Do not solder crimps. 1. Remove the secondary lock. 2. Insert the needle end of terminal remover J 35689-A into the small notch between the connector and the terminal to be removed (Figure E–3, View A). Push the lock tang toward the terminal. 3. Pull the wire and terminal out the rear of the connector (this is a “push-to-seat” terminal). 4. Pull the terminal as far as necessary from the connector. This will be limited by the number of other wires inserted into the connector and by the distance between the back side of the connector and the beginning of the harness covering. 5. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to minimize wire loss.

C.

Terminal Crimping 1. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp from an old terminal without damaging the wire. 2. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper enough to keep the terminal from dropping (Figure E–3, View B). 3. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp. Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool). 4. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and a portion of the terminal between the core and insulation crimp areas are supported by the anvil. Complete the insulation crimp.

Copyright© 2004 General Motors Corp.

E–13

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION C.

Terminal Crimping (cont’d) 5. Be sure the lock tang is lifted to allow proper reseating of the terminal. 6. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the terminal should stay in place when the wire is lightly pulled.)

D.

Terminal Crimping Using Alternate Tool J 35123 1. Insert the remover tool in the front side of the connector to release the locktab, and pull the terminal out the rear of the connector. Pull the terminal and wire out the rear of the connector to complete Steps (3) through (7). 2. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening marked 18–16 (Figure E–3, View C) so that the crimp ends point up. Release the terminal holder. 3. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal. Place the terminal on the wire so it is in the same position as it will be when pulled back into the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool). 4. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and insulation should be properly positioned for the core and insulation crimp wings.) 5. Squeeze the crimper fully until it opens when released. 6. Open the terminal holder and remove the wire and terminal from the crimping tool. 7. Pull on the terminal to assure a tight crimp. 8. Be sure the lock tang is lifted to allow proper reseating of the terminal. 9. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the terminal should stay in place if the wire is lightly pulled.)

E–14

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2004 General Motors Corp.

E–15

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

V06482.01.00

Figure E–4. Internal Wiring Harness

E–16

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–4.

INTERNAL WIRING HARNESS Service with internal wiring harness assembly P/N 15321154 (Figure E–4).

Copyright© 2004 General Motors Corp.

E–17

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

WIRE SEAL TERMINAL

CONNECTOR SECONDARY LOCK

THROTTLE POSITION SENSOR CONNECTOR

J 38125-10 REMOVER TOOL

VIEW A

VIEW B WIRE SEAL CORE CRIMP INSULATED WIRE STRIPPED WIRE

VIEW C

WIRE SEAL CORE CRIMP TERMINAL INSULATION & SEAL CRIMP

J 38125-6

2

4

2

4

1 3 5

1 3 5

VIEW D

VIEW E V01689

Figure E–5A. Delphi-Packard WeatherPack Connectors (TPS)

E–18

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–5.

DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS) A.

Connector/Terminal Repairs Required Tools

B.

Crimping Tool Wire Crimp Insulation Crimp Alternate Crimping Tool Remover Tool

J 38125-6 Anvil “2” Anvil “5” J 35606 or J 38852 J 38125-10

Use

Description

Manufacturers P/N

Throttle Position Sensor (TPS)

Connector Terminal Wire Seal

12015793 12089040 12089444

Terminal Removal 1. Unlatch and open the secondary lock on the connector (Figure E–5A, View A). 2. From the front of the connector, insert remover tool J 38125-10 over the terminal. Push the tool over the terminal and pull the terminal out the back of the connector (Figure E–5A, View B). 3. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to minimize wire loss.

NOTE:

Two special tools are available for this operation — tool J 38125-6 (Paragraph C) and tool J 35606 or J 38852 (Paragraph D). C.

Terminal Crimping Using Crimping Tool J 38125-6 1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C). 2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire. 3. Place the terminal onto crimping tool J 38125-6 (Figure E–5A, View E), anvil “2.” 4. Slightly close the crimping tool to hold the terminal steady. 5. Insert the wire so that the stripped portion of the wire is in the core crimp area and the insulated portion of the wire is in the insulation crimping area (Figure E–5A, View C). 6. Crimp the stripped section of the wire. 7. Remove the terminal from the crimping tool. 8. Push the wire seal onto the terminal (Figure E–5A, View D). The second crimp will wrap around the wire seal. This will seal the insulated area of the wire. 9. Use a pair of needle nose pliers, if necessary, to squeeze the terminal wings together to fit in anvil “5.” 10. Crimp the wire seal in anvil “5.” 11. Tug on the terminal to be sure the crimp is tight.

Copyright© 2004 General Motors Corp.

E–19

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION C.

Terminal Crimping Using Crimping Tool J 38125-6 (cont’d) 12. Insert the terminal into the connector. The terminal will click into place and should not pull out. 13. Secure the secondary lock. Both sides of the connector must be latched.

D.

Terminal Crimping Using Alternate Crimper Pliers J 35606 or J 38852 1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C). 2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire. 3. Insert terminal into crimping tool J 35606 (Figure E–5B, View A), opening marked 18–20. 4. Position the terminal so the crimp wings are pointing up from the bottom jaw of the crimper and are properly positioned. 5. Slightly close the crimping tool to hold the terminal steady. 6. Slide the wire seal to the edge of the insulation and insert the wire and seal into the terminal (Figure E–5B, View B). 7. Position the wire and seal and squeeze the crimping tool until it opens when released. 8. Tug on the terminal to be sure the crimp is tight. 9. Insert the terminal into the connector. The terminal will click into place and should not pull out. 10. Secure the secondary lock. Both sides of the connector must be latched.

Figure E–5B. Terminal Crimping With Tool J 35606

E–20

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2004 General Motors Corp.

E–21

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

9-PIN RECEPTACLE PIN REMOVER J 34513

WIRES

VIEW C

CONNECTOR

RECEPTACLE

REMOVER J 34513

REMOVER J 38582-3

VIEW A

J 34182 CRIMPER

INSPECTION HOLE

PIN TERMINAL

TO ROT A ISE

SEL NO.

TERMINAL

WIRE SIZE INDICATOR

INSPECTION HOLE

SOCKET TERMINAL

LOCKING RING CAVITY PLUG

TE

RA

TERMINAL EXTRACTOR / INSERTER J 41194

DEPTH ADJUSTMENT SCREW

;; ;

VIEW B V05748

Figure E–6. Deutsch IPD/ECD Connectors (9-Way DDR)

E–22

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–6.

DEUTSCH IPD/ECD CONNECTORS (J1939 DIAGNOSTIC LINK 9-WAY DDR) A.

Connector/Terminal Repairs Required Tools

NOTE:

Crimping Tool

J 34182

Extractor/Inserter Tool

J 41194 (18 GA ECD Bulkhead)

Remover Tool Set

J 34513

Remover Tool (DDR Connector)

J 38582-3 (12–14 GA)

Use

Description

Manufacturers P/N

J1939 Diag Link (9-Way DDR)

9-Way Receptacle

HD10-9-1939P

If difficulty is encountered in removing or installing the plug backshell, insert the plug into the receptacle, do not lock it into place, and loosen the backshell. B.

NOTE:

Terminal Removal (Figure E–6, View A) When using remover/inserter tool J 41194, take care not to break the tip of the tool. Lay the wire in the widest part of the wire slot and work toward the tool tip. 1. Loosen and slide the backshell along the convolute conduit. 2. Remove the convolute conduit from the base of the backshell follower. Peel enough conduit from the harness to allow working access. 3. Slide the backshell follower clear of the connector housing. 4. Remove as much tape wrap as necessary to allow working access. 5. Fully insert the proper remover/extractor tool into the back of the connector until it releases the terminal. 6. Pull the terminal, wire, and tool out the back of the connector. 7. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.

C.

Terminal Crimping (Figure E–6, View B) 1. Strip approximately 6–8 mm (0.236–0.315 inch) of insulation from the end of the wire. 2. Set the crimping tool wire size to number 12. To set the wire size, remove the retainer pin. Lift and rotate the indicator until the number 12 is aligned with the SEL NO. arrow. Reinstall the retainer pin. 3. Insert the contact end of the terminal into crimping tool J 34182. To adjust the crimping tool depth, loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until the top of the terminal is just above flush with the top of the crimping hole (the crimp jaws will contact the middle of the terminal barrel). Tighten the locking ring to retain the adjustment. 4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area. A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION C.

Terminal Crimping (Figure E–6, View B) (cont’d) 5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire. 6. Remove the terminal and wire from the crimping tool. 7. Tug on the terminal to be sure the crimp is tight. 8. Install a 25 mm (one inch) long piece of heat shrink tubing over the wire insulation just behind the terminal. Apply heat to shrink and lock the tubing to the insulation.

D.

Terminal Insertion (all connectors except ECD bulkhead) 1. Insert the terminal and attached wire through the proper hole in the grommet. 2. Push on the terminal and wire until the terminal clicks into position. Pull gently on the wire to be sure that the terminal is fully seated.

E–24

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2004 General Motors Corp.

E–25

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

WEDGELOCK

CONNECTOR SEAL

CONNECTOR

Shrink tubing goes here

STANDARD SOCKET TERMINAL

Extended terminal for uninsulated shield wire

TO ROT A ISE

TE

RA

J 34182 CRIMPER

SEL NO.

WIRE SIZE INDICATOR

TERMINAL

LOCKING RING DEPTH ADJUSTMENT SCREW

;; ;; V03424

Figure E–7. Deutsch DT Series Connector (3-Way J1939 Interface) E–26

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–7.

DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE) A.

Connector/Terminal Repair Required Tools

B.

Crimping Tool

J 34182

Use

Description

Manufacturers P/N

J1939 Interface

Connector, Plug, 3-Way Wedgelock, Plug Contact, Socket (Standard) Contact, Socket (Extended) Cable, J1939 Databus

DT06-3S-E008 W3S-1939 3662-204-1690 0462-221-1631 23-000-13

Terminal Removal (Figure E–7) 1. Use a small-bladed screwdriver to remove the wedgelock that holds the terminals in place. 2. Use a sharp knife to carefully remove the shrink tubing from the rear of the connector plug. 3. Use a small screwdriver to release the locking lever for all of the terminals. Pull the wire and terminal out the rear of the connector. 4. Slide a new piece of shrink tubing over the removed terminals and onto the cable. 5. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.

C.

Terminal Crimping (Figure E–7) 1. Strip approximately 6–8 mm (0.24–0.31 inch) of insulation from the end of the wire. (There is no insulation on the shield wire.) 2. Set the crimping tool wire size to number 18. To set the wire size, remove the retainer pin. Lift and rotate the indicator until the number 18 is aligned with the SEL NO. arrow. Reinstall the retainer pin. 3. Insert the contact end of the terminal down into crimping tool J 34182. To adjust the crimping tool depth, loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until the wire end of the terminal is just above flush with the top of the crimping hole. The depth adjustment screw will need to be backed out a large amount to accept the extended shield terminal. The crimp jaws will now contact the middle of the terminal barrel. Tighten the locking ring to retain the adjustment. 4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area. A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel. 5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire. 6. Remove the terminal and wire from the crimping tool. 7. Tug on the terminal to be sure the crimp is tight.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION D.

Terminal Insertion 1. Insert the terminal and attached wire into the back of the connector. 2. Push on the terminal and wire until the terminal clicks into position. Check the front of the connector to see that the terminal is at the same height as other terminals. Pull gently on the wire to be sure that the terminal is fully seated. 3. Insert the wedge lock to hold the terminals in place. Slide the sealing plug back into place at the rear of the connector. 4. Slide the shrink tubing over the raised area at the rear of the connector. Use a heat gun to shrink the tubing into position over the connector and cable.

E–28

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION 1–8.

REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE A.

NOTE:

Connector Check Before Repair Before repairing or replacing wiring harness, sensor, solenoid, switch, or TCM as indicated for a diagnosed problem, follow the procedure below: 1. Disconnect the connector or connectors associated with the problem and inspect for: • • • • • • •

Bent terminals Broken terminals Dirty terminals Pushed back terminals Missing terminals Condition of mating tabs Condition of mating terminals

Ensure that terminals are secure in the connector. Clean, straighten, or replace parts as required. 2. Reconnect all previous unmated connectors. Ensure connectors are fully inserted or twisted until they lock in place. Connectors with locking tabs make an audible click when the lock is engaged. 3. If the trouble recurs after starting the vehicle, follow the repair procedures for the trouble code or complaint. 4. If the trouble does not recur, or if the appropriate repairs and/or replacements have been made, the problem should be corrected. B.

Special Tools • Heat Gun, J 25070 or equivalent • Crimping Tool for Pre-insulated Crimp J 38125-8 (Figure E–8)

NOTE:

Use crimping anvils “F” and “G.” • Wire Strippers, J 35615 • Splices P/N 23046604 14–16 AWG • Splices P/N 23046605 18–22 AWG

NOTE:

Each splice must be properly crimped and then heated to shrink the covering to protect and insulate the splice. Insulation-piercing splice clips should not be used.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

G

F

J 38125-8

V01694

Figure E–8. Crimper J 38125-8 C.

Straight Lead Repair Procedure 1. Locate the damaged wire. 2. Remove 8.0 mm (0.3 inch) of insulation from the end of each segment of the damaged wire. 3. Insert the stripped end of one wire into the crimp barrel of the splice, and crimp. 4. Insert the stripped end of the other wire into the other end of the crimp barrel, and crimp. 5. Pull on the connection to be sure of crimping integrity. 6. Heat the splice with a heat gun until the covering shrinks and adhesive flows from under the covering. 7. The splice is now sealed and insulated. Electrical tape is not necessary and should not be used.

E–30

Copyright© 2004 General Motors Corp.

TCM J2 TCM J2 TCM J2 TCM J2 TCM J2 TCM J2 TCM J2 TCM J1 TCM J1 TCM J1 TCM J1 TCM J1 TCM J1 TCM J1 TCM J1 GP19 GP19 GP19 GP19 J1939 J1939 J1939 J1939 J1939 VIW X VIW X VIW X VIW X VIW X VIW X VIW Y VIW Y VIW Y VIW Y VIW Y VIW Y RMR RMR RMR

CONNECTOR

12160542 12110693 12191178 12160551 12129557 12176394 12160280 15304882 12191172 12084912 12129557 12176394 12015795 12089040 12089444

15336800 15305333 15305371 12129024 12084912 12129557 12177289 12191002 15305333 15305371 12129022 12084912 12129557 12177289 12084913 15300027 12077411 12089444 15300014 DT06-3S-E008 W3S 29511366 29538614

MFG. P/N

STRAIN RELIEF, 32-WAY RED SEAL, 32-WAY INNER CONNECT, 32-WAY TPA, 32-WAY RED TERMINAL, SOCKET 100W CAVITY PLUG, 100W CPA, 32-WAY RED STRAIN RELIEF, 32-WAY GRAY SEAL, 32-WAY INNER CONNECT, 32-WAY TPA, 32-WAY GRAY TERMINAL, SOCKET 100W CAVITY PLUG, 100W CPA, 32-WAY RED TERMINAL, SOCKET 100W CONNECTOR, 2-WAY TERMINAL, SOCKET SEAL, WIRE TYPE, SILICONE LOCK, SECONDARY CONNECTOR, PLUG 3-WAY WEDGELOCK, PLUG CONTACT, SOCKET #16 CONTACT, EXTENDED SOCKET CABLE, J1939 DATABUS CONN 20M MIC/P 100W GRAY CABLE SEAL, 14M GREEN LOCK ASSIST/SEAL, 20M WHITE TERMINAL, PIN 100W CAVITY PLUG, 100W CONDUIT CLIP, 13 mm BLACK CONN 20F MIC/P 100W GRAY CABLE SEAL, 16F RED LOCK SECONDARY, 20F BLUE TERMINAL, SOCKET 100W CAVITY PLUG, 100W CONDUIT CLIP, 13 mm BLACK CONNECTOR, 3-WAY TERMINAL, PIN SEAL, WIRE TYPE, SILICONE

PART NAME

DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD

DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DEUTSCH DEUTSCH DEUTSCH DEUTSCH

MANUFACTURER 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J2 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/TCM J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1 1-PC/COMP J1

CONFIG

12160280 15304882 12191173 12084912 12129557 12176394 12160280 15304882 12191172 12084912 12129557 12176394 12015092 12089188 12089444

29511369

12160280 15304882 12191173 12084912 12129557 12176394 12160280 15304882 12191172 12084912 12129557 12176394 12015092 12089188 12089444

15300002 12048159 12089444 15300014 DT04-3P-E008 W3P 3660-201-1690 0460-247-1631

12186043

12186043

15300002 12048159 12089444 15300014

12186041

MFG. P/N

MATING P/N 12186041

CONN 20F MIC/P 100W GRAY CABLE SEAL, 14F GRAY LOCK, SECONDARY 20F WHITE TERMINAL, SOCKET 100W CAVITY PLUG, 100W CONDUIT CLIP, 13 mm BLACK CONN 20F MIC/P 100W GRAY CABLE SEAL, 14F GRAY LOCK, SECONDARY 20F BLUE TERMINAL, SOCKET 100W CAVITY PLUG, 100W CONDUIT CLIP, 13 mm BLACK CONNECTOR, SHROUD 3-WAY TERMINAL, SOCKET SEAL, WIRE TYPE, SILICONE

CONNECTOR, 2-WAY TERMINAL, PIN SEAL, WIRE TYPE, SILICONE LOCK, SECONDARY CONNECTOR, REC., 3-WAY WEDGELOCK, RECEPTACLE CONTACT, PIN #16 CONTACT, EXTENDED PIN

TCM HEADER

TCM HEADER

MATING PART NAME

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

Copyright© 2004 General Motors Corp.

E–31

E–32

NE NE NO NO NT NT TPS TPS TPS H2OT H2OT H2OT NSBU NSBU NSBU NSBU NSBU NSBU NSBU NSBU NSBU NSBU TLCT TLCT TLCT TLCT TLCT TLCT BLKHD RCP BLKHD RCP BLKHD RCP BLKHD RCP BLKHD RCP BLKHD RCP BLKHD RCP BLKHD RCP BLKHD PGP BLKHD PGP BLKHD PGP BLKHD PGP

CONNECTOR

12162193 12103881 12162193 12103881 12162193 12103881 12015793 12089040 12089444 12015792 12089040 12089444 12191757 12048086 12129802 15416722 15441828 12191819 12191818 15366684 15304719 15304718 12160280 12177159 12160494 12084912 12129557 12176394 29511368 29511369 29511371 29514041 29514042 29514043 29527000 29512839 29511855 29511369 29511371 29514041

MFG. P/N

CONNECTOR, 2-WAY TERMINAL, 150F CONNECTOR, 2-WAY TERMINAL, 150F CONNECTOR, 2-WAY TERMINAL, 150F CONNECTOR, 3-WAY TERMINAL, PIN SEAL, WIRE TYPE, SILICONE CONNECTOR, TOWER, 2-WAY TERMINAL, PIN SEAL, SILICONE CONNECTOR, TOWER, 4-WAY SEAL, WIRE TYPE, DK RED TERMINAL, 150F CONNECTOR, 12-WAY BACKSHELL 18 GAUGE, 18AWG TXL 20 GAUGE, 20AWG TXL 14 GAUGE, 14AWG TXL 18 GAUGE, 18AWG TXL 20 GAUGE, 20AWG TXL CONN 20F MIC/P 100W GRAY CABLE SEAL, 20F ORANGE LOCK, SECONDARY 20F GREEN TERMINAL, SOCKET 100W CAVITY PLUG, 100W CONDUIT CLIP, 13MM BLACK CONNECTOR, REC., 31-WAY CONTACT, PIN #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19 GROMMET, BACKSHELL #24 NUT, PANEL O-RING CONNECTOR, PLUG, 31-WAY CONTACT, PIN #16 SEALING PLUG HOUSING, BACKSHELL, 24/19

PART NAME DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DELPHI-PACKARD DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH

MANUFACTURER 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 ADAPTER (MDR) ADAPTER (MDR) ADAPTER (MDR) 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 1-PC/COMP J2 TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP COMP J2 COMP J2 COMP J2 COMP J2

CONFIG

MFG. P/N

MATING PART NAME

Copyright© 2004 General Motors Corp.

CONNECTOR, REC., 31-WAY CONTACT, SOCKET #16 SEALING PLUG HOUSING, BACKSHELL, 24/19

CONNECTOR, PLUG, 31-WAY CONTACT, SOCKET #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19 GROMMET, BACKSHELL, 24/19

29511365 29511366 29511371 29514041 29514042 29514043 — — 29511854 29511366 29511371 29514041

CONN 20M MIC/P 100W LOCK ASST/SEAL 20M MIC/P100W TERMINAL, PIN 100W

15317365 12160551

12160782

12066016 ENGINE SPEED SENSOR Actual sensor uses molded receptacle similar to 12066016 OUTPUT SPEED SENSOR Actual sensor uses molded receptacle similar to 12066016 TURBINE SPEED SENSOR Actual sensor uses molded receptacle similar to 12066016 TPS HEADER TPS header similar to 12010717 connector with 12089188 sockets molded into the TPS. 12010973 12010973 CONNECTOR, SHROUD, 2-WAY 12089188 12089188 TERMINAL, SOCKET 12089444 12089444 SEAL, WIRE TYPE, SILICONE 12459915 NSBU

MATING P/N

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

MFG. P/N

BLKHD PGP 29514042 BLKHD PGP 29514043 BLKHD RCS 29511854 BLKHD RCS 29511366 BLKHD RCS 29511371 BLKHD RCS 29514041 BLKHD RCS 29514042 BLKHD RCS 29527000 BLKHD RCS 29512839 BLKHD PGS 29511365 BLKHD PGS 29511366 BLKHD PGS 29511371 BLKHD PGS 29514041 BLKHD PGS 29514042 BLKHD PGS 29514043

CONNECTOR

FOLLOWER, BACKSHELL, 24/19 GROMMET, BACKSHELL #24 CONNECTOR, REC., 31-WAY CONTACT, SOCKET #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19 NUT, PANEL O-RING CONNECTOR, PLUG, 31-WAY CONTACT, SOCKET #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19 GROMMET, BACKSHELL #24

PART NAME DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH

MANUFACTURER COMP J2 COMP J2 TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP TCM J2/COMP COMP J1 COMP J1 COMP J1 COMP J1 COMP J1 COMP J1

CONFIG

MATING P/N 29514042 — 29511855 29511369 29511371 29514041 29514042 — — 29511368 29511369 29511371 29514041 29514042 29514043 MFG. P/N

CONNECTOR, REC., 31-WAY CONTACT, PIN #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19 GROMMET, BACKSHELL, #24

CONNECTOR, PLUG, 31-WAY CONTACT, PIN #16 SEALING PLUG HOUSING, BACKSHELL, 24/19 FOLLOWER, BACKSHELL, 24/19

FOLLOWER, BACKSHELL

MATING PART NAME

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E—CONNECTOR REPAIR INFORMATION

Copyright© 2004 General Motors Corp.

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APPENDIX E—CONNECTOR REPAIR INFORMATION

NOTES

E–34

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F—TPS ADJUSTMENT A.

Description of Operation 1. To properly communicate throttle position to the TCM, the throttle position sensor must convert mechanical movement to an electrical form the TCM can understand. To accomplish this, contacts move across a resistive strip inside the sensor which translates position into voltage (Figure F–1).

THROTTLE POSITION LINKAGE CONTACTS RESISTIVE STRIP

V00656.01

Figure F–1. Throttle Position-to-Voltage Conversion 2. Each position gives a different voltage. The TCM then converts this voltage into throttle percent. Each millimeter of travel converts to approximately 0.110 volts. Figure F–2 diagrams the voltage and throttle movement relationship.

Adjust so total stroke is within 8.9 mm – 35.7 mm band 0.98 volts – 3.921 volts

0 Volt

4.750 Volts

0.550 Volts ERROR ZONE

5 Volts

0.979 Volts

3.927 Volts

ERROR ZONE

APPROX. 19 mm (0.75 in.) STROKE CLOSED THROTTLE FULLY RETRACTED (AT REST)

8.9 mm (0.35 in.) 2.5 mm (0.1 in.)

0 mm

WIDE OPEN THROTTLE

Total Stroke CT–WOT 15.2 mm–22.9 mm (0.63 in.–0.9 in.) 1.667–2.549 Volts

35.7 mm (1.4 in.)

FULLY EXTENDED

40.6 mm (1.6 in.) 45.7 mm (1.8 in.) V05746.00.01

Figure F–2. Throttle Position Determination Diagram 3. Throttle percent is proportional to the amount of travel of the throttle position sensor. Therefore a small amount of travel corresponds to a low throttle percentage, and a large amount of travel corresponds to a high throttle percentage (Table F–1, Page F–3).

Copyright© 2004 General Motors Corp.

F–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F—TPS ADJUSTMENT 4. The throttle position sensor is self-calibrating within its normal range of operation. Each time the vehicle is started and the TCM is initialized, the idle position that is stored for closed throttle is increased from its previous lowest reading. Also, the wide open throttle position is reduced from its previous highest reading. Once the new position is read from the TPS, the idle and wide open throttle set points are continuously readjusted to the lowest and highest points, respectively. This compensates for fuel control system wear or previous mechanical adjustment. One area of particular concern is when the throttle sensor extends into the error zone. This indicates a TPS misadjustment to the TCM, and 100 percent throttle is assumed until readjustment is performed. Simply clearing the DTC will not resolve the situation; use the Scan Tool to reset the TPS calibrations after a TPS adjustment. B.

Throttle Position Sensor (TPS) Adjustment When properly installed by the equipment manufacturer (Figure F–3), the TPS should not require adjustment. Confirm that the throttle sensor is installed to manufacturer specifications before adjusting the throttle position sensor. The idle position should be approximately 8.9 mm or 0.98 volts or higher, and the full throttle position should be approximately 35.7 mm or 3.921 volts or lower. The TPS is self-calibrating, meaning there is no optimum closed throttle or wide open position. As long as the travel is within the 8.5–35.7 mm range the TPS is set properly. A total stroke of 15.2–22.9 mm must be maintained. Watch the movement of the throttle sensor as the controls move it through the full stroke. Make certain the idle and full throttle positions are not in the error zones (refer to Figure F–2). The error zones occur when the idle position is less than 2.5 mm, or when the full throttle position is more than 40.6 mm. When idle or wide open throttle positions are in the error zones, the TCM will log a code. When a TPS code is logged the TCM assumes a default throttle setting which will negatively affect shift quality. NOTE:

F–2

Use Test Harness J 41339 for measuring voltages.

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F—TPS ADJUSTMENT Table F–1. Distance (mm) of Travel Versus Volts mm

Volts

mm

Volts

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

0 0.110 0.220 0.329 0.439 0.549 0.659 0.768 0.878 0.988 1.098 1.207 1.317 1.427 1.537 1.646 1.756 1.866 1.976 2.085 2.195 2.305 2.415 2.524

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

2.634 2.744 2.854 2.964 3.073 3.183 3.293 3.403 3.512 3.622 3.732 3.842 3.951 4.061 4.171 4.281 4.390 4.500 4.610 4.720 4.829 4.939 5.049

Copyright© 2004 General Motors Corp.

F–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F—TPS ADJUSTMENT

MOUNTING PROVISION: Use M6 x 1.00 or 1⁄4-20 in. series bolts 3 places Torque M6 x 1.00 bolt to 10–13 N•m (84–120 lb in.) 1 Torque ⁄4-20 in. series bolts to 13–14 N•m (108–132 lb in.) Mount to a solid frame member. Flatness of chassis mounting surface must not exceed 0.8 mm (0.03 in.).

BENDING LOAD APPLIED

UNACCEPTABLE INSTALLATION 10.0° MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS LOADING IN TENSION ONLY

ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading in tension only (no bending loads). WIRING HARNESS 55.0 mm (2.17 in.) MIN REQUIRED FOR CONNECTION REMOVAL FULLY EXTENDED FORCE REQUIRED 26.7 N (6.0 LB) MAX

Fuel control must not move the throttle sensor beyond the closed throttle position at any time.

R 152.0 mm (6.00 in.) MIN ALLOWANCE RADIUS

FULLY RETRACTED

FULL THROTTLE 118.1 mm (4.65 in.)

MOUNTING (NOTE: Mounting length LENGTH + 50.8 mm (2 inches) equals cable length)

CLOSED THROTTLE 95.2 mm (3.75 in.)

47.5 mm (1.87 in.)

OPERATING BAND 15.2 – 22.9 mm (0.6 – 0.9 in.) 118.1 mm (4.65 in.) 95.2 mm (3.75 in.)

Attach to engine or governor housing using clamp and shims as required. Clamp must positively lock in cable groove. HITCH PIN CLIP

93.45 mm (3.679 in.) 87.15 mm (3.431 in.)

30.2 mm (1.19 in.)

Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle position when sensor rod is maintained at full throttle position. Attach the throttle sensor directly to the engine fuel lever with no breakover or yield linkages between the engine fuel lever shaft and the attachment point of the throttle sensor.

The location of the clamping bracket relative to the fuel lever at closed throttle must be maintained within this range.

ENGINE FUEL LEVER

CLOSED THROTTLE

183.1 mm (7.21 in.) MAX

FULL THROTTLE 160.2 mm (6.31 in.) MIN

SAME AS WITHOUT SLIP LINK FULLY EXTENDED

38.1 mm (1.50 in.) HITCH PIN CLIP FULLY RETRACTED

OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK

Figure F–3. Throttle Position Sensor Adjustment

F–4

Copyright© 2004 General Motors Corp.

V00430.05

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE MODULE 1–1.

WELDING ON VEHICLE

When frame or other welding is required on the vehicle, take the following precautions to protect the electronic control components: 1. Disconnect the wiring harness connectors at the transmission control module (TCM). 2. Disconnect the positive and negative battery connections, and any electronic control ground wires connected to the frame or chassis. 3. Cover electronic control components and wiring to protect them from hot sparks, etc. 4. Do not connect welding cables to electronic control components.

WARNING!

Do not jump start a vehicle with arc welding equipment. Arc welding equipment’s dangerously high currents and voltages cannot be reduced to safe levels.

Copyright© 2004 General Motors Corp.

G–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE MODULE

NOTES

G–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – NEUTRAL / PARK PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

D N R

C1 MAIN PRESSURE TAP

CONV – OUT

C1 Clutch Valve

MAIN TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Exhaust Backfill Valve

TCC

CONV – IN TCC SIGNAL

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

LUBE

C5

PSE PSD

CONV – OUT

SUMP

TO COOLER

OVERAGE

Cooler Lube Regulator Valve Main Filter

PSR

Converter Flow Valve

CONV – IN TCC SIGNAL

Cooler

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Converter Flow Valve

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION A TRIM SIGNAL REVERSE SIGNAL C5 A TRIM PRESSURE V06914.04.00

Figure H–1. Hydraulic Schematic — Neutral/Park Copyright © 2004 General Motors Corp.

H–1/H–2

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – REVERSE (PRIOR TO, AND INCLUDING, NO4* SOFTWARE WITH THROTTLE APPLIED) 1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Trim Solenoid

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Added–3rd Quarter 2003 G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

D N R

C1 MAIN PRESSURE TAP

CONV – OUT

C1 Clutch Valve

MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

C5

PSE PSD

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Exhaust Backfill Valve

TCC

CONV – IN LUBE

CONV – OUT

SUMP

TCC SIGNAL

TO COOLER

OVERAGE

Cooler Lube Regulator Valve Main Filter

Converter Flow Valve

PSR

CONV – IN TCC SIGNAL

Cooler

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

*EFFECTIVE JANUARY 1, 2001

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL (EBF)

SUCTION A TRIM SIGNAL B TRIM SIGNAL REVERSE SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE

V04755.04.00

Figure H–2. Hydraulic Schematic — Reverse (Prior To Software Level N04) Copyright © 2004 General Motors Corp.

H–3/H–4

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – REVERSE – CLOSED THROTTLE (WITH NO4* SOFTWARE AND LATER) 1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

B Solenoid Filter

N/C

G Solenoid Added–3rd Quarter 2003

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

CONV – IN

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Exhaust Backfill Valve

TCC

CONV – IN LUBE

CONV – OUT

SUMP

TCC SIGNAL

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Cooler

C5

PSE PSD

Converter Flow Valve

TO COOLER

OVERAGE

PSR

Blocked At Separator Plate For Modulated Main Pressure

CONV – IN TCC SIGNAL

Main Filter Cooler

Converter Flow Valve

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

*EFFECTIVE JANUARY 1, 2001

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL (EBF)

SUCTION A TRIM SIGNAL B TRIM SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE V06874.04.00

Figure H–3. Hydraulic Schematic — Reverse (Software Level N04 And Later) Copyright © 2004 General Motors Corp.

H–5/H–6

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 1st RANGE PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown Energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1

C1 Clutch Valve

MAIN TCC SIGNAL IDLE COOLING MAIN TO OVERAGE VALVE LEAKAGE EXHAUST

MAIN

C2 Control Main Filter

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

CONV – IN

LUBE

Lube Regulator Valve

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

TCC SIGNAL

C5

PSE PSD

Exhaust Backfill Valve

TCC SUMP CONV – OUT

Converter Flow Valve

TO COOLER PSR

OVERAGE

Cooler

CONV – IN TCC SIGNAL

Main Filter Cooler

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Converter Flow Valve

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C5 A TRIM PRESSURE V06915.04.00

Figure H–4. Hydraulic Schematic — 1st Range Copyright © 2004 General Motors Corp.

H–7/H–8

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 2nd RANGE

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES

PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

Exhaust Backfill Valve

TCC CONV – IN TCC SIGNAL

CONV – OUT

SUMP

Cooler Lube Regulator Valve Main Filter

E Shift Valve D Shift Valve

OVERAGE

Charging Pump LUBE

C5

PSE PSD

TO COOLER

OVERAGE

Converter Flow Valve

PSR CONV – IN TCC SIGNAL

Cooler

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION B TRIM SIGNAL REVERSE SIGNAL C1 C4 B TRIM PRESSURE V06916.04.00

Figure H–5. Hydraulic Schematic — 2nd Range Copyright © 2004 General Motors Corp.

H–9/H–10

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 3rd RANGE

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Exhaust Backfill Valve

TCC CONV – IN LUBE TCC SIGNAL

C5

PSE PSD

CONV – OUT

SUMP

TO COOLER

OVERAGE

Cooler Lube Regulator Valve Main Filter

PSR

Converter Flow Valve

CONV – IN TCC SIGNAL

Cooler

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C3 A TRIM PRESSURE V06917.04.00

Figure H–6. Hydraulic Schematic — 3rd Range Copyright © 2004 General Motors Corp.

H–11/H–12

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 4th RANGE

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Exhaust Backfill Valve

TCC CONV – IN LUBE TCC SIGNAL

Cooler Lube Regulator Valve Main Filter

C5

PSE PSD

CONV – OUT

SUMP

TO COOLER

OVERAGE

Converter Flow Valve

PSR CONV – IN TCC SIGNAL

Cooler

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION B TRIM SIGNAL REVERSE SIGNAL C1 C2 B TRIM PRESSURE V06918.04.00

Figure H–7. Hydraulic Schematic — 4th Range Copyright © 2004 General Motors Corp.

H–13/H–14

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 5th RANGE

G Solenoid Added–3rd Quarter 2003

1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

Control Main Valve

Main Regulator Valve

C2

Control Main Filter

EXHAUST

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

OVERAGE

C Shift Valve

TCC CONV – OUT

Converter Relief Valve

TO COOLER

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Exhaust Backfill Valve

TCC CONV – IN LUBE TCC SIGNAL

Cooler Lube Regulator Valve Main Filter

C5

PSE PSD

CONV – OUT

SUMP

TO COOLER

OVERAGE

Converter Flow Valve

PSR CONV – IN TCC SIGNAL

Cooler

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

SUMP

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION A TRIM SIGNAL B TRIM SIGNAL REVERSE SIGNAL C2 C3 A TRIM PRESSURE

V06919.04.00

Figure H–8. Hydraulic Schematic — 5th Range Copyright © 2004 General Motors Corp.

H–15/H–16

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT FORWARD (3rd RANGE "LIMP HOME") 1000 AND 2000 PRODUCT FAMILIES PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

B Trim Solenoid

A Trim Accumulator Solenoid

N/C

F Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

B Solenoid Filter

N/C

G Solenoid Added–3rd Quarter 2003

N/O

C On/Off Shift Solenoid

D On/Off Shift Solenoid

E On/Off Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C

CONTROL MAIN

CONTROL MAIN EBF

B TRIM PRESSURE

CONV – IN

MAIN

Selector Valve

A TRIM PRESSURE

MAIN PRESSURE TAP

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3 MODULATED MAIN PRESSURE (G SOLENOID)

C4

C Shift Valve

TCC

OVERAGE CONV – OUT

Converter Relief Valve

TO COOLER

E Shift Valve D Shift Valve

OVERAGE

Charging Pump

Exhaust Backfill Valve

TCC CONV – IN CONV – OUT

LUBE TCC SIGNAL

Cooler Lube Regulator Valve Main Filter

C5

PSE PSD

TO COOLER

SUMP OVERAGE

Converter Flow Valve

PSR CONV – IN TCC SIGNAL

Cooler

SUMP

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST

EXHAUST BACKFILL (EBF) SUCTION A TRIM SIGNAL REVERSE SIGNAL C1 C3 A TRIM PRESSURE V07738.04.00

Figure H–9. Hydraulic Schematic — Hydraulic Default Forward Copyright © 2004 General Motors Corp.

H–17/H–18

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H—HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT REVERSE ("LIMP HOME") 1000 AND 2000 PRODUCT FAMILIES G Solenoid Added–3rd Quarter 2003 PRE-BLOCK 1 GAIN VALVE AND A TRIM SOLENOID W/O SPRING

A Trim Accumulator Solenoid

N/C

B Solenoid Filter

N/C

F Trim Solenoid

B Trim Solenoid

G Solenoid Lowers Main Pressure And Increases Cooler Flow When Energized (Typically at Low Throttle, Low Speed)

Accumulator

(Shown De-energized)

N/O

C Shift Solenoid

D Shift Solenoid

E Shift Solenoid

G Mod Main Solenoid

N/C

N/C

N/C

N/C

N/C CONTROL MAIN

CONTROL MAIN B TRIM PRESSURE

EBF CONV – IN

MAIN A TRIM PRESSURE

MAIN PRESSURE TAP

Selector Valve

D N R

CONV – OUT C1 MAIN

C1 Clutch Valve

TCC SIGNAL MAIN

C2 Control Main Filter

EXHAUST

Control Main Valve

Main Regulator Valve

PSC

Control Main Relief Valve

C3

MODULATED MAIN PRESSURE (G SOLENOID)

C4

OVERAGE

C Shift Valve

TCC CONV – OUT

Converter Relief Valve Charging Pump

E Shift Valve

TO COOLER

OVERAGE

C5

PSE PSD

D Shift Valve SUMP

Exhaust Backfill Valve

TCC

CONV – IN LUBE

CONV – OUT

TO COOLER

TCC SIGNAL OVERAGE

Cooler Lube Regulator Valve Main Filter

Converter Flow Valve

PSR

CONV – IN TCC SIGNAL

Cooler

SUMP

Converter Flow Valve

Blocked At Separator Plate For Modulated Main Pressure

Beginning Model Year 2004i (interim) Converter Flow Valve See SIL 03-1K/2K-04 New Hydraulic Path For TCC Signal

MAIN PRESSURE CONTROL MAIN PRESSURE CONVERTER–IN/OVERAGE CONVERTER–OUT TORQUE CONVERTER CLUTCH (TCC) LUBRICATION/COOLER EXHAUST EXHAUST BACKFILL (EBF)

SUCTION A TRIM SIGNAL B TRIM SIGNAL C3 C5 A TRIM PRESSURE B TRIM PRESSURE V07739.04.00

Figure H–10. Hydraulic Schematic — Hydraulic Default Reverse Copyright © 2004 General Motors Corp.

H–19/H–20

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J — WIRING SCHEMATICS

1000 AND 2000 PRODUCT FAMILIES WIRING SCHEMATIC SWITCHED POWER CHECK TRANS OUTPUT FUNCTION 1 OUTPUT FUNCTION 2 OUTPUT FUNCTION 3 OUTPUT FUNCTION 4 RANGE INHIBIT INDICATOR OUTPUT FUNCTION 6 SIGNAL RETURN INPUT FUNCTION 9 INPUT FUNCTION 8 INPUT FUNCTION 7 INPUT FUNCTION 6 INPUT FUNCTION 5 INPUT FUNCTION 4 INPUT FUNCTION 3

ALLISON RECOMMENDED COLOR

ALLISON RECOMMENDED WIRE NO.

GREEN

125

TAN

119

ORANGE

120

WHITE

121

BLUE

122

PINK

123

WHITE

124

YELLOW

128

ORANGE

114

PINK

113

BLUE

112

GREEN

111

YELLOW

110

WHITE

109

GREEN

108

ORANGE

107

BLUE

106

IGNITION POWER

YELLOW

102

IGNITION POWER

YELLOW

104

PINK

103

INPUT FUNCTION 2 INPUT FUNCTION 1

BATTERY POWER TCM GROUND

DIAGNOSTIC TOOL/ENGINE INTERFACE

GRAY

105

BLUE

130

GREEN

131

RED

129

PWM THROTTLE IGN

SPEEDO 2 (ZERO CROSSING) PULSES/REV SAME AS WIRE 126 SPEEDO 1 (NON ZERO CROSSING) 8, 16, 20 OR 40 PULSES/REV

BLACK

132

WHITE

116

PINK

127

TAN

126

A

21 L

22

A

24

L

28 D

14

BAT

13 L

12

YELLOW

No HIGH

16

216

GREEN

No LOW

13

213

ORANGE

NT HIGH

14

214

BLUE

NT LOW

17

217

TAN

N E HIGH

18

218

ORANGE

N E LOW

23

223

WHITE

M

22

222

YELLOW

L

24

224

PINK

N

25

225

ORANGE

P

31

231

12V or 24V (A)

TAN

C

226

GREEN

SOL C ON/OFF

GRAY

29

229

WHITE

J

230

BLUE

R

232

GREEN

S

21

221

YELLOW

T

1

201

BLUE

D

A

2

202

PINK

F

B

3

203

WHITE

E

C

30 12V or 24V (B)

32

2

12V or 24V (A) AND (B)

4 3

POWER SUPPLY

1 A

5

D

L

31

32

ANALOG INTERFACE

5V

HARDWARE DIVIDE

27 26

TPU CALC/ SYNTHESIS

5V

A

TRANS OUTPUT SPEED

DIGITAL INTERFACE

ANALOG INTERFACE

18

6 4 5

MODULATED MAIN SOLENOID

7

1 12 10

G

E

19

219

PINK

H

F

9

209

BLUE

MAIN TRANSMISSION CONNECTOR

20

220

GREEN

5

205

BLUE

6

206

YELLOW

7

207

GRAY

8

208

WHITE

D

K

P

YELLOW

206

B

BLUE

205

A

GREEN

220

11

BLUE

2

A

4C 4B 4D 4A 7D

10 AWG

WHITE

YELLOW BLUE

7G 7E 7F 7C 7B

THROTTLE POSITION SENSOR

ORANGE

STARTER SOLENOID/STARTER RELAY

YELLOW

PARK AND NEUTRAL START FEED

PINK

REVERSE LAMPS

BLUE

REVERSE AND PARK ACCESSORY FEED

GRAY

GREEN

TAN

7A

10 AWG

B

10 AWG

C

PINK

SUMP TEMP

C

207

YELLOW

E R

10

208

10 AWG

D

PRESSURE SWITCH MANIFOLD

GRAY

ORANGE

C

TAN

WHITE

9

= DIGITAL GROUND

SOL G ON/OFF

210

NSBU SWITCH P/N 29540193 (P/N 29540479 KIT)

NSBU SWITCH P/N 29541852

= ANALOG GROUND

SOL F (PWM) LOCKUP

GREEN

A

= LOGIC GROUND

SOL E ON/OFF W

12

16

LEGEND

SOL D ON/OFF B

11

CAN 2.08 J1939 DATA LINK

29

A

204

4

CLASS II: J1850 DATA LINK or ISO 9141 DATA LINK

30

D

SOL B (PCS)

228

6

A

ENGINE SPEED SENSOR SOL A (PCS)

B

28

7

L

A

BLUE

8

TURBINE SPEED SENSOR

B

227

L

OUTPUT SPEED SENSOR

A

27 DIGITAL INTERFACE

A B

10

8

SAE STD 9-PIN DIAGNOSTIC CONNECTOR

215

26

9

118

ALLISON RECOMMENDED COLOR

11

SAE J1939 BACKBONE REFERENCE: FIG. J-2

ENGINE INTERFACE

NE

23

15

12V or 24V

A

ALLISON RECOMMENDED WIRE NO.

15

NT

20

17 GREEN OPTIONAL SPEEDO SIGNAL RETURN

No

19

10A

IGNITION SWITCH

TRANSMISSION CONTROL MODULE (TCM)

25

101

GRAY

10A

TCM CONNECTOR "J2" (RED)

TCM CONNECTOR "J1" (GRAY)

ORANGE

PARK ACCESSORY

YELLOW PINK BLUE TAN

3

NSBU WITH 12-PIN CONNECTOR

NSBU WITH 4 AND 7-PIN CONNECTORS

V07485.01.02

Figure J–1. 1000 and 2000 Product Families Wiring Schematic Copyright © 2004 General Motors Corp.

J–1/J–2

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J—WIRING SCHEMATICS

ENGINE (ECM)

9-PIN DDL CONNECTOR

TRANS (TCM)

J1939 Data Link

J1939 Data Link

D E F

C A

B J

G

SHIELD

PIN E PIN C (+) SHIELD PIN D (–)

TERMINATION RESISTOR

131 GREEN 129

120Ω RESISTOR

Should not exceed 1 meter

SHIELD

SHIELD SHIELD

Attached to ECM via Deutsch/P triangle 3-pin connector

PIN 31 PIN 29 PIN 32

H

Pin ID determined by Engine OEM

132

RED SHIELD

BLACK

SHIELD

120Ω RESISTOR

CONTROLLER AREA NETWORK (CAN) Should not exceed 40 meters

SAE J1939-11

V06460.01.00

Figure J–2. J1939 Backbone (CAN Bus)

Copyright© 2004 General Motors Corp.

J–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J—WIRING SCHEMATICS

NOTES

J–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K—RESISTANCE VS. TEMPERATURE 1000 AND 2000 PRODUCT FAMILIES SOLENOID RESISTANCE MAXIMUM / NOMINAL / MINIMUM

SOLENOID RESISTANCE: Ohms

42

MAX NOM MIN

37 32

C, D, E, and G Solenoids

27 22 17 F Solenoid

12

A and B Solenoids

7 2 0

40 80 TEMPERATURE (°C)

120

32

104 176 TEMPERATURE (°F)

248 V06484.01.01

Figure K–1. Solenoid Resistance vs. Temperature Graph

Table K–1. Solenoid Resistance vs. Temperature Sump Temperature

Solenoid A, B Resistance

Solenoid C, D, E, G Resistance

Solenoid F Resistance

(°C)

(°F)

(Ω)

(Ω)

(Ω)

0

32

4.5

20.0

9.5

20

68

5.5

22.0

10.5

40

104

6.5

24.5

11.5

80

176

7.5

27.0

12.5

120

248

8.5

29.5

13.5

Copyright© 2004 General Motors Corp.

K–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K—RESISTANCE VS. TEMPERATURE

RESISTANCE – TEMPERATURE CHARACTERISTIC CHART

Trans Fluid Temp Sensor Resistance (Ohms)

1000000

100000

10000

1000

Nominal Resistance 100

10

1 -45

-30

-15

0

15

30

45

60

75

90

105

120

135

150

194

221

248

275

302

Temperature (C) -22

-49

5

32

59

86

113

140

167

Temperature (F) V05749

Figure K–2. Transmission Fluid Temperature Sensor Resistance vs. Sump Temperature Graph NOTE:

Look carefully at the graph. The scale for the resistance (on the left side) is not constant (linear). It is logarithmic which means it can display a great range of values within a small space. Each section of the graph is ten units, but the units vary from 1 to 100 000 Ohms.

Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature Temperature (°C)

Temperature (°F)

Minimum Resistance (Ω)

–45

–49

128 565

141 951

155 338

–40

–40

95 826

100 735

105 644

–35

–31

68 952

72 315

75 679

–30

–22

50 153

52 480

54 807

–25

–13

36 854

38 478

40 103

–20

–4

27 345

28 488

29 631

–15

5

20 476

21 286

22 097

–10

14

15 467

16 045

16 624

–5

23

11 781

12 197

12 612

0

32

9045

9345

9646

5

41

6998

7219

7441

K–2

Nominal Resistance Maximum Resistance (Ω) (Ω)

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K—RESISTANCE VS. TEMPERATURE Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature (cont’d) Temperature (°C)

Temperature (°F)

Minimum Resistance (Ω)

Nominal Resistance Maximum Resistance (Ω) (Ω)

10

50

5458

5623

5787

15

59

4291

4413

4536

20

68

3398

3490

3582

25

77

2710

2779

2849

30

86

2173

2228

2282

35

95

1754

1797

1840

40

104

1424

1459

1493

45

113

1163

1191

1218

50

122

955.0

977.1

999.2

55

131

788.6

806.5

824.5

60

140

654.7

669.3

683.9

65

149

546.3

558.3

570.2

70

158

458.1

467.9

477.8

75

167

385.9

394.1

402.2

80

176

326.6

333.3

340.1

85

185

277.5

283.2

288.9

90

194

236.5

241.6

246.7

95

203

202.4

206.9

211.5

100

212

173.8

177.9

182.0

105

221

149.8

153.6

157.3

110

230

129.7

133.0

136.4

115

239

112.6

115.6

118.7

120

248

98.17

100.88

103.6

125

257

85.87

88.29

90.71

130

266

75.35

77.52

79.69

135

275

66.34

68.27

70.21

140

284

58.58

60.31

62.04

145

293

51.88

53.42

54.97

150

302

46.08

47.46

48.84

155

311

41.04

42.27

43.50

160

320

36.65

37.74

38.84

Copyright© 2004 General Motors Corp.

K–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K—RESISTANCE VS. TEMPERATURE

1000 AND 2000 PRODUCT FAMILIES TRANSMISSION SPEED SENSOR RESISTANCE VALUES 4500 4000

OHMS

3500 3000 2500 Max Ohms Nominal Ohms Min Ohms

2000 1500 –25

0

25

50 75 TEMPERATURE (°C)

100

125

150

–13

32

77

122 167 TEMPERATURE (°F)

212

257

302 V06096.00.01

Figure K–3. Speed Sensor Resistance vs. Temperature Graph

Table K–3. Speed Sensor Resistance vs. Temperature

K–4

Temperature (°C) –25

Temperature (°F) –13

Minimum Resistance (Ω) 1929

Nominal Resistance Maximum Resistance (Ω) (Ω) 2143 2358

0

32

2157

2397

2637

25

77

2340

2600

2860

50

122

2614

2904

3195

75

167

2842

3158

3474

100

212

3071

3412

3753

125

257

3299

3666

4032

150

302

3483

3870

4257

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX L—ELECTRONIC INTERFERENCE 1–1.

ELECTROMAGNETIC INTERFERENCE (EMI)/RADIO FREQUENCY INTERFERENCE (RFI)

All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic systems. Allison Transmission electronic transmission controls comply with Federal Communications Commission (FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation electronics. The position of Allison Transmission Division of General Motors is that manufacturers and installers of Electromagnetic Interference (EMI)/Radio Frequency Interference (RFI) emitting equipment are responsible for adhering to FCC regulations and other guidelines concerning emitted radio frequency interference for transportation electronics. Some radio-telephone or two-way communication radios (land-mobile radio), or the manner in which they are installed, can adversely affect vehicle operation or be affected by other vehicle components. Expenses incurred to protect vehicle-related systems from EMI/RFI emissions by radio-telephone or two-way communications radios (land-mobile radio) or to integrate such devices into vehicles are not the responsibility of Allison Transmission.

1–2.

GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION

The following general guidelines for installing radio-telephone or two-way communications radios (land-mobile radio) in a vehicle supplement, but DO NOT replace, detailed instructions provided by the radio equipment manufacturer. Detailed installation instructions are the sole responsibility of the radio equipment manufacturer. Experience has shown that most EMI/RFI problems can be prevented or eliminated by following the guidelines. If EMI/RFI problems persist after following the guidelines and after ensuring the installation conforms to the guidelines, contact the vehicle and radio equipment manufacturers for additional installation or equipment operation instructions. A.

Transmitter Installation 1. Locate remote radio transmitters as far away from other electronic devices and as near to the side of the vehicle body as possible. 2. Mount transceivers (transmitter and receiver in one box) under the dash so as not to interfere with vehicle controls or passenger movement.

B.

Antenna Installation Each vehicle and body style reacts differently to radio frequency energy. When dealing with an unfamiliar vehicle, test various antenna locations by using a magnetic mount antenna and checking for adverse effects. Antenna location is a major factor in EMI/RFI problems.

C.

Antenna Cable Routing 1. Use high quality, 95 percent shield coverage, coaxial (coax) cable. Route the coax well away from any electronic components. 2. Route antenna cables as far away from vehicle wiring as possible to reduce the likelihood of the vehicle wiring acting as an antenna for interference.

D.

Radio Wiring and Connector Location 1. Connect transmitter power leads directly to the battery. 2. For transceivers (transmitter and receiver in one box) with ignition control, place a 12V power contactor at the vehicle battery. Drive the contactor coil, through an appropriate in-line fuse, from an ignition circuit not powered during engine cranking. 3. Any negative lead from a handset or control unit must return to battery negative. 4. Connect the positive lead from a handset or control unit directly to battery. 5. Fuse handset or control unit positive and negative leads separately from the transceiver negative and positive leads. Use correctly rated fuses.

Copyright© 2004 General Motors Corp.

L–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX L—ELECTRONIC INTERFERENCE E.

Power and Ground Wire Routing Route radio power and ground wires as far away as possible from electronic control modules.

F.

Troubleshooting The following are common causes of EMI/RFI problems: • • • •

1–3.

Power leads connected to points other than the battery Improper antenna location Poor shielding or connections to antenna cable Transmitter or transceiver wiring too close to vehicle electronics

EXTERNALLY-GENERATED SPEED SENSOR SIGNALS A.

Checking for Externally-Generated Speed Sensor Signals Use the following procedures to determine if speed sensor signals generated by a source external to the transmission or wiring harness are present: 1. Turn the ignition ON. 2. Keep the engine OFF. 3. If the TCM is ON, connect the Allison DOC™ For PC diagnostic tool.

NOTE:

If false speed signals were present at the previous shutdown, the TCM might still be “ON” even though the ignition is “OFF”. The Allison DOC™ For PC diagnostic tool is powered by ignition power so the ignition must be “ON” to use the Allison DOC™ For PC to read the speed signals. 4. Read the speed sensor signals. 5. If a speed sensor signal is other than one (1), then there is a short to another circuit that is carrying an AC or PWM signal. 6. Check resistance of the sensor. 7. Check for shorts to other circuits within the harness or transmission connector. 8. Check to ensure there is no conductive material inside the connector. 9. Check to be sure the speed sensor circuit wires are a twisted pair. 10. Check to ensure a properly grounded drain wire. 11. Check for the presence of a strong external AC signal. 12. Repair or replace parts as required.

L–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL NOTE:

1.

Instructions for using the Allison DOC™ Diagnostic Tool when performing 1000 and 2000 Product Families On-Highway transmission electronic controls diagnostics, are included in Appendix M. Refer to the Allison DOC™ For PC User Guide GN3433EN for complete Allison DOC™ For PC instructions.

INTRODUCTION

The Allison Diagnostic Optimized Connection For PC™ tool (Allison DOC™ For PC) is a diagnostic system designed for use with Allison’s 1000 and 2000 Product Families transmissions. This PC-based diagnostic program is capable of reading from a 1000 and 2000 Product Families Transmission Control Module (TCM) using J1939/ J1850 communication protocols. Allison DOC™ For PC performs the following: • Monitors 1000 and 2000 Product Families Transmission Control Module (TCM) data • Displays multiple transmission parameters. • Displays a graphical instrument panel with analog and digital gauges. • Displays a graphical strip chart. • Records and plays back diagnostic sessions. • Prints diagnostic reports. • Reprograms selected TCM settings (requires completion of Allison Transmission training). Allison DOC™ For PC provides the following features: • A Microsoft Windows®/PC look and feel. • Security measures to control reprogramming TCM parameters. • Integrated Help. • Diagnostic Trouble Code information with a direct link to the 1000 and 2000 Product Families Troubleshooting Manual. • A demo mode using prerecorded data. • SmartConnect for detecting the PC-to-vehicle translation device. • Allison DOC™ For PC is compliant with applicable TMC Recommended Practices, GM Online Standards, SAE Standards, and CE Standards. • Allison DOC™ For PC is RP1210A compliant.

2.

WARNINGS AND NOTES

WARNING!

To avoid personal injury, the vehicle operator must not use or read the diagnostic tool while the vehicle is moving. Doing so may result in loss of vehicle control, which may cause personal injury and vehicle damage.

WARNING!

Personnel other than the vehicle operator must use the diagnostic tool.

WARNING!

The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations.

NOTE:

Allison DOC™ For PC users are assumed to have a basic working knowledge of the Microsoft Windows 95®/98®/NT/XP® Operating System(s) and Adobe® Acrobat ® Reader®. Copyright© 2004 General Motors Corp.

M–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Trademark Information •

Windows 95®, Windows 98®, Windows ME®, Windows 2000®, Windows NT®, Windows Explorer®, XP® Professional and Windows Media Player® are registered trademarks of Microsoft Corporation

•

Adobe® Acrobat® is a registered trademark of Adobe Corporation

•

Pentium® and Pentium II® are registered trademarks of Intel Corporation

•

MPSI MagiKey® and MPSI PDM® are registered trademarks of NEXIQ Technologies Incorporated

•

Dearborn Group Dearborn Protocol Adapter (DPA) II® and Dearborn In-line Adapter II® are registered trademarks of Dearborn Group Technology

•

Allison Diagnostic Optimized Connection™ and Allison DOC™ For PC are trademarks of General Motors Corporation

•

SPX J1850® is a registered trademark of SPX Corporation

•

InstallShield® is a registered trademark of InstallShield Software Corporation

3.

TEXT CONVENTIONS USED IN THIS GUIDE

The following text conventions are used in this Guide to more clearly describe using Allison DOC™ For PC: •

Screen button and keyboard key names are in bold capitals—OK, RETURN.

•

Menu names are presented as displayed—File, Edit, etc.

•

Menu items are presented as displayed—Exit.

•

File names that may change with use are in lowercase italics—snapshot.log.

•

Filenames, usually system files, that do not change are in initial capitals—Acrobat.pdf.

•

Titles of windows are as they appear in the window.

6.

ALLISON DOC™ FOR PC OVERVIEW

Allison DOC™ For PC has been designed to aid you, the technician, in troubleshooting and maintaining 1000 and 2000 Product Families Allison transmissions. Allison DOC™ For PC can be used with a desktop PC or a laptop PC in the cab of a vehicle.

WARNING!

To avoid personal injury, the vehicle operator must not use or read the diagnostic tool while the vehicle is moving. Doing so may result in loss of vehicle control, which may cause personal injury and property damage.

Allison DOC™ For PC aids you by providing: •

Displays of real-time and saved transmission operating data that include: — — — —

Trouble codes Sump temperature Retarder temperature, if applicable Percent of retarder application, if applicable — Shift inhibit indicator

M–2

— — — — — —

Range selected/attained Configuration data TPS percentage Input speed Turbine speed Output speed

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL •

The ability to clear active and inactive trouble codes

•

Access to TCM configuration data

•

With Allison Transmission approved training, the ability to change TCM configuration

•

A graphic data display

•

Strip chart data graphing

•

A variety of reports such as: — 1000 and 2000 Product Families Failure Records — Shift Inhibits — Allison Transmission I/O Wires

NOTE:

6–1.

— — — —

Diagnostic Data Customer Modifiable Constants Trouble Codes DTC Test

Contact your nearest Allison Distributor for additional Allison DOC™ For PC training. Allison distributors are listed on the Allison website at www.allisontransmission.com.

ALLISON DOC™ FOR PC NAVIGATION, CONTROLS, AND STATUS INFORMATION

Allison DOC™ For PC displays the following navigation, control, and status information items regardless of what is displayed in the main Allison DOC™ For PC window.

a.

Status Bar

The status bar provides information about the connection between Allison DOC™ For PC and the TCM. It is located in the upper portion of the main Allison DOC™ For PC window. The fields in the primary status bar are not labeled, but their content adequately indicates their purpose.

(Transmission and CIN) Transmission Control System and Calibration Identification Number. Example: WTEC III 00T12352300

(Connection) Describes the connection between Allison DOC™ For PC and an TCM. Descriptions are: •

Connected—Allison DOC™ For PC is actively connected to an TCM and receiving live data.

•

Off-Line—The connection between Allison DOC™ For PC and TCM is not live and no data is being received.

•

Playback—The displayed data is part of a snapshot and is not current.

•

Demo—Displayed data is part of the demo program.

(Active Code) Indicates the presence of an active Trouble Code. Indicators are: •

Active Codes

•

No Active Codes Copyright© 2004 General Motors Corp.

M–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL b.

Menus

The menu bar at the top of the Allison DOC™ For PC window, above the Primary Status bar, displays the following drop-down menus:

File •

Run

•

Print—displays the Print Report window

•

Exit—exits the Allison DOC™ For PC program

TCM Interface •

Connect/Disconnect—displays the Connect/Disconnect window

Diagnostic •

Trouble Code—displays the Trouble Code window

•

Performance Complaint—displays the Performance Complaint window

•

Data Monitor—displays the Data Monitor window

•

TCM/Calibration Information—displays the TCM/Calibration Information window

•

Custom Data Monitor—displays the Custom Data Monitor data selection window

•

Graphics Monitor—displays the Graphics Monitor window

•

Strip Chart—displays the Select the Data to Graph on the Strip Chart window

•

Data Bus Viewer—displays the data stream being sent to Allison DOC™ For PC from the TCM.

Action Request •

Clutch Test Enabled—enables the Clutch Test

•

C Solenoid Test

•

Reset Adapted Shifts

•

Reset Throttle Calibrations—resets TPS calibration

•

Engineering Calculations—provides means to calculate converter speed ratio, vehicle speed, and acceleration in g’s

Snapshots •

Record

•

Record Options—displays the recording options window

•

Stop Recording—halts recording

•

Add Bookmark—displays the bookmark window

Playback •

Open Playback File—displays the Open window and the content of the Log folder.

•

Play—plays a recorded data file.

•

Rewind—starts the playback at the beginning.

•

Stop—stops a playback.

•

Fast Forward—plays a recorded data file at four times the normal speed.

•

Continuous—plays a recorded data file continuously, a looped playback.

•

Email—displays the Compose Email window.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Options •

Application Configuration—displays the Application Configuration tabs.

Help •

Help Topics—displays the Help Topics window.

•

Demo—displays the Choose Demo window.

•

1000 and 2000 Product Families Troubleshooting Manual—activates the Adobe® Acrobat reader to display the 1000 and 2000 Product Families Troubleshooting Manual.

•

Access to Allison Transmission Website —connects to the Allison Transmission website, www.allisontransmission.com. Requires Internet connection and login ID and Password to access the extranet.

•

Video-based Training Materials — — — — — — —

1K2K NSBU Switch 1K2K Internal Wiring Harness 1K2K Electronic Controls 1K2K Breakout Box Circuit Checks Circuit Basics Allison DOC™ Training Videos

•

Hydro Schematics—displays hydraulic schematics

•

ATD Calc—displays the Application Engineering Installation Design Calculations window — — — — —

•

c.

Multiple-Joint Driveline Analysis Oil-to-Water (OTW) Cooling Analysis Oil-to-Air (OTA) Cooing Analysis OTW and OTA Combination Cooling Analysis Hose and Fitting Pressure Drop Analysis

About Allison Transmission Diagnostic (Scan) Tool

Button and Keyboard Shortcuts

The following buttons are always available in the primary Allison DOC™ For PC window. Clicking the button or pressing the associated function key displays the listed menu.

F1–Help Accesses the Help system

F2–File •

Print

•

Exit

F3–Diagnostic •

Trouble Code

•

Performance Complaints

•

Data Monitor

•

TCM/Calibration Information

•

Custom Data Monitor

•

Graphics Monitor Copyright© 2004 General Motors Corp.

M–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL • •

Strip Chart Data Bus Viewer

F4–Snapshot Start or stop recording snapshots.

F5–Connect Establish or break the connection between Allison DOC™ For PC and the TCM.

F6–Fire Trigger Inserts a “bookmark” in the data stream during a recording session. Bookmarks are sequentially numbered by the system when F6–Fire Trigger is used.

F7–Stop Recording Stops a snapshot recording Accelerator keys—On screen buttons have shortcuts known as accelerator keys. An underlined character in the button text identifies the button’s accelerator keyboard key. Pressing the accelerator key activates the function associated with the button. For example, on the button below, the P keyboard key is the accelerator key. Dropdown menu items accelerator keys require pressing ALT before pressing the accelerator key. After pressing the ALT/ACCELERATOR KEY combination that menu displays.

When this button is visible, and you press the P key, you activate a print function.\

M–6

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 8.

STARTING ALLISON DOC™ FOR PC

8–1.

STARTING THE PROGRAM

There are two ways to start Allison DOC™ For PC: • Double-click the Allison DOC™ For PC tool icon on your PC desktop, or, • From your PC’s Start menu, select Programs_ Allison Transmission_ Allison DOC. If you stored Allison DOC™ For PC in another location, follow the path to that location and select Allison DOC.

8–2.

30-DAY TRIAL

A 30-Day trial is included as part of Allison DOC™ For PC. The 30-day trial window appears each time Allison DOC™ For PC is started, unless the activation password has been entered. The 30-day trial window displays the number of days remaining in the trial period. At any time before the trial period ends you may enter the activation password. The Allison DOC™ For PC application will not function after 30 days if a valid activation password has not been entered. Contact your Allison Support Representative to obtain the product activation password. • Once you have the password, enter it into the Password field of the 30-Day Trial window and press OK. • During the 30-day trial period, press CANCEL to run the Allison DOC™ For PC program.

Copyright© 2004 General Motors Corp.

M–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 8–3.

AT START-UP

When you start Allison DOC™ For PC, a brief animation sequence plays (stop the 13 seconds sequence by pressing the SPACEBAR). When the animation sequence ends, the Warning window displays (if the activation password has been entered, otherwise the 30-Day Trial window displays). The Warning window lists basic transmission troubleshooting tasks and outlines basic safety considerations (see Warnings and Notes). The CONNECT TO VEHICLE button initiates the software connection to a vehicle and the DEMO button starts Allison DOC™ For PC Demos.

10.

USING THE ALLISON DOC™ FOR PC

10–1. CONNECTING/DISCONNECTING a.

Connecting

NOTE:

Allison DOC™ For PC supports only RP1210A compliant devices.

The Connect/Disconnect window establishes the software connection between Allison DOC™ For PC and the TCM through a PC-to- TCM data translator. In order for Allison DOC™ For PC to read information from the TCM, both the vehicle ignition and the PC-to-vehicle translator must be powered on. Upon successful connection, the Trouble Code window automatically displays. Any logged Diagnostic Trouble Code information is displayed in the Trouble Code window. To establish a connection between Allison DOC™ For PC and TCM: 1. From the Warnings window of Allison DOC™ For PC, click the button or select Connect/Disconnect from the TCM Interface drop-down menu, or click the F5–Connect button, or press the F5 key—The Connect/Disconnect window appears. M–8

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

2. To have Allison DOC™ For PC automatically select the translation device: • Click the SmartConnect check box. • Select a transmission series from the Transmission drop down menu. • Click the button. Upon successful connection, a Trouble Code window displays.

Copyright© 2004 General Motors Corp.

M–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 3. To select the translation device manually: •

If SmartConnect is selected, click the SmartConnect checkbox to deselect SmartConnect.

• Select the TCM Vendor from the drop-down Vendor list. If the Vendor line is blank, verify that the PC-to-vehicle translator’s driver software has been installed on your PC. •

Select the translator device connecting the PC to the TCM from the drop-down Device list.

If a connection is not established, the Connect Failure window displays.

b.

Disconnecting

NOTE:

Disconnection breaks the Allison DOC™ For PC to TCM connection; it does not deactivate the Allison DOC™ For PC software.

To break the connection between Allison DOC™ For PC and TCM: 1. Select Connect/Disconnect from the TCM Interface drop-down menu, click the ton, or press the F5 key—the Transmission Connect/ Disconnect window appears.

2. Click the

but-

button—Allison DOC™ For PC/vehicle communications stop.

10–2. VIEWING DIAGNOSTIC DATA Diagnostic data can be displayed in any of seven different formats. Each transmission type displays data differently. The same seven formats are available to all transmission types. The seven formats appear in the Diagnostic Options window. Access a format by clicking on the format name or typing the first letter of the format name. The transmission type selected during the Connect process determines what data is displayed. M–10

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

c.

1000 and 2000 Product Families Diagnostic Trouble Codes

A 1000 and 2000 Product Families Diagnostic Trouble Code consists of the letter “P” or “U” followed by four or five numbers. A “P” indicates a transmission internal problem, while a “U” indicates a problem in a vehicle system or the transmission-to-vehicle interface.

1000 and 2000 Product Families Diagnostic Trouble Code View

DTC The 1000 and 2000 Product Families uses a five character, a letter and four numbers, diagnostic trouble code. Any DTC that is unknown to the system generates a message stating that the DTC is unsupported and to call Allison Transmission.

Active Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing the code still exists, that code is said to be active; otherwise the trouble code is inactive.

Historic Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing the code still exists, that code is said to be active, otherwise the trouble code is historic.

Check Trans A “Y” indicates the CHECK TRANS light is illuminated. Copyright© 2004 General Motors Corp.

M–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Failure Record A “Y” indicates that a failure record has been generated for the DTC.

Description Describes the DTC.

Clear DTC information Clears DTC information for a selected DTC row.

Cal ID Calibration Identification.

Software Level Software version loaded into the TCM.

Serial Number The TCM’s serial number. If a nonprintable character is encountered, the character is represented by *. The TCM serial number consists of the following components: • • • • • • •

Product Code Broadcast code Supplier Code Supplier Manufacturing Code Last Digit of the calendar year Julian day of the year Serial Number

HCN Hardware Compatibility Number.

Sump Temp Temperature in the transmission sump.

PRNDL A Status of NSBU switch A.

PRNDL B Status of NSBU switch B.

PRNDL C Status of NSBU switch C.

PRNDL P Status of NSBU switch P.

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Gear Select/Attain The range selected at the shift selector and the actual range attained by the transmission.

TCM Input Volts The TCM input voltage.

c–1.

Viewing Troubleshooting Manual Information for a Trouble Code

In the Trouble Code window of Allison DOC™ For PC, double-click the DTC or DTC Description for which more information is needed. Adobe Acrobat® displays the 1000 and 2000 Product Families Troubleshooting Manual page appropriate for the DTC.

c–2.

Clearing Active Codes 1. In the Trouble Code window, click the

button.

A window appears displaying the message, “Clear Active Codes Request Completed Successfully!” 2. Click the OK button. Active Trouble Codes and associated information are cleared from the Allison DOC™ For PC window. If the cause of the Trouble Code is not corrected, the Trouble Code may immediately reappear. NOTE:

To clear active Trouble Codes, the vehicle must be stopped and in Neutral. If these conditions are not met. A message “Request Denied. Output Speed not less than maximum allowable value.” or “Neutral not attained.” displays.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL d.

Displaying Failure Records

You can view the last five DTC failure records by double clicking on a DTC row in the Failure Record Available column of the DTC grid or by selecting the Failure Record item from the Diagnostic main menu. A message displays if Failure Records cannot be displayed.

Failure Record Display

e.

Performance Complaint

The Performance Complaint function assists you in diagnosing a problem by selecting a symptom. 1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key. 2. Select Performance Complaint—The Performance Complaint window displays.

3. Select the appropriate Vehicle Complaint from the drop-down list. 4. Click OK—the appropriate Troubleshooting Manual pages display information relevant to the selected Vehicle Complaint.

M–14

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL f.

Diagnostic Data Monitor

f–1.

Displaying the Diagnostic Data Monitor

The Data Monitor allows you to view TCM information in a table format. The data displayed is dynamic. Speed and other data changes are displayed as they occur. To display the Data Monitor: 1. Click the press the F3 key.

button, or select Data Monitor from the Diagnostics drop-down menu, or

The diagnostic options window appears.

2. Click Data Monitor—the appropriate Diagnostic Data Monitor appears.

h.

1000 and 2000 Product Families Data Monitor

The 1000 and 2000 Product Families Data Monitor can display diagnostic data for TCMs with Configuration Identification Numbers (CIN) starting with 11, 12, and 13 in four different vocations. These vocations are: • Standard—displays data for standard North American vocations • Euro Bus—displays data for European bus vocations • Euro Truck—displays data for European truck vocations • Medium Duty Gas—displays data for medium-duty gasoline engine vocations A vocation menu displays to allow selecting a vocation. NOTE:

Be sure to select the appropriate vocation to display the correct data.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 1000 and 2000 Product Families Standard Data Monitor

The 1000 and 2000 Product Families Data Monitor displays data in two sections: • Diagnostic Data • ATD Wire Data

h–1. Diagnostic Data • Diagnostic Data—A brief description of the diagnostic data being measured. • Value—The value of the associated diagnostic data. • Units—units of measure for the value.

h–2. ATD Wire Data • ATD Wire #—The wire circuit number of the programmed function. • Input/Output Function. • State—On/Off.

i.

TCM Calibration Information

To display current TCM and Calibration information: 1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key. 2. Select TCM/Calibration Information.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 1000 and 2000 Product Families TCM Calibration Information

j.

The Custom Data Monitor

You may select the information to be displayed in the Custom Data Monitor window by adding or removing data types to the display. Data types are added or removed in the Custom Data Monitor data selection window. The Custom Data Monitor window is the same as the Data Monitor window, except that only the selected data is displayed. Selected data types must be re-selected each time the Custom Data Monitor is displayed unless a Custom Data List is saved. To select Custom Data Monitor data types: 1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key. 2. Select Custom Data Monitor—the Custom Data Monitor data selection window displays.

Copyright© 2004 General Motors Corp.

M–17

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 3. Select the desired Diagnostic Data type(s); up to eight data types may be selected from the lefthand column. 4. Click the hand column.

button or double click the selection—the selected data types appear in the right-

5. Click the OK button—the selected data types appear in the Custom Data Monitor window.

1000 and 2000 Product Families Custom Data Monitor

To remove Customer Data Monitor data types: 1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key. 2. Select Custom Data Monitor—the Select Diagnostic Data to Track window displays. 3. Select the desired Diagnostic Data types from the right-hand column. 4. Click the

button—the selected data types are restored to the left-hand column.

5. Click the OK button—the deleted data types no longer appear in the Custom Data Monitor window and the window closes.

j–1.

Custom Data List

You can save a list of data to display in the Custom Data Monitor by using the Custom Data List feature. 1. Move data to track into the right-hand window. 2. Click the SAVE button—the Custom Data Monitor List Save window displays

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Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 3. Type a name for the list 4. Click the OK button—the list is saved under the name you entered. To use the saved data list: 1. Click on the Select One drop-down arrow in the data select window. 2. Highlight a list name—the Load and Delete buttons become active. 3. Click either Load, to load the list, or Delete, to delete the list.

k.

The Graphics Monitor

The Graphics Monitor displays diagnostic data using gauges, thermometers, indicator lights, text boxes, and a scrollable ATD Wire # data display.

k–1.

Displaying the Graphics Monitor

To display the Graphics Monitor: 1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key. 2. Select Graphics Monitor—the Graphics Monitor window displays.

1000 and 2000 Product Families Graphics Monitor

The following information is included in the Graphics Monitor: NOTE:

A gauge can be expanded to a full-screen display by double-clicking on the gauge. Return the display to normal by pressing the ESC key or double clicking in the expanded display.

Engine Speed RPM indicated by needle gauge and digital readout. Copyright© 2004 General Motors Corp.

M–19

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Output Speed RPM indicated by needle gauge and digital readout.

Turbine Speed RPM indicated by needle gauge and digital readout.

TPS % The TPS Percentage is indicated by needle gauge.

Gear Selected The selected range displays.

Gear Attained The attained range displays.

PRNDL Switch States On/off position of the PRNDL switches.

Sump Oil Temperature Temperature indicated by Fahrenheit thermometer and Fahrenheit/Celsius readout.

Shift Inhibits A brief description of the shift inhibit and the associated value.

ATD Wire information • •

ATD Wire # - The wire circuit number of the programmed function. State – On/Off

l.

The Strip Chart

l–1.

Displaying the Strip Chart

The Strip Chart is a graph that tracks, over time, changes in selected data as the changes occur. The data-againsttime data stream is continuous regardless of the Strip Chart mode selected.

M–20

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL To display the Strip Chart: 1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key. 2. Select Strip Chart—the Select the Data to Graph on the Strip Chart window displays.

3. Select up to eight Diagnostic Data types from the left-hand column. 4. Choose a color for the trace of the data selected or allow the default color. NOTE:

Contrasting colors are easier to see on the strip chart. 5. Click OK.

The selected data types appear in the Strip Chart window.

1000 and 2000 Product Families Strip Chart

l–2.

Data Trace Identification

The selected data is assigned a color on the graph. The name of the data and its corresponding color is displayed in the upper-right corner of the Strip Chart display. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL l–3.

X-axis Scaling

The passage of time in seconds is indicated on the X-axis, horizontal bottom of the graph. As time passes, data lines on the graph move to the right. The Strip Chart displays 10 seconds of data at a time. If playing back recorded data, the VCR Control window displays the Total File Time and the Current File Time, in minutes. Total File Time is the total length of the recording. Current File Time is the time elapsed since you started the playback.

l–4.

Y-axis Scaling

The Y-axis, vertical left side of the Strip Chart, displays a range of values based upon the data selected for display. If you select data having different types of measurements such as input rpm and engine cooling temperature, a divisor, preceded by a slash (/), displays next to the data that requires calculation to determine the correct value. For example: input speed and engine cooling temperature. RPM is displayed on the Y-axis, from 0 to 4000. To determine the engine cooling temperature, divide the value of the engine cooling temperature trace by 15.7. An easier method is to use the Strip Chart Cursor mode, which calculates the adjustment and displays the correct value.

l–5.

Strip Chart Modes

Several data display modes are selectable from the tool bar in the upper left portion of the Strip Chart window. These modes, or commands, allow you to control the data display on the Strip Chart. To change to a particular mode, simply click the desired mode icon. When a mode other than Plot is selected, the data display at that time is frozen; but the data-against-time stream continues in the background. When Plot is re-selected, the data-againsttime stream is re-entered at the time Plot was re-selected. The control modes are:

Plot Plot is the default Strip Chart mode, where data lines move from left to right across the Strip Chart graph.

Pause Pauses the plot. Data continues to be collected, but not displayed in the graph. Click the PLOT button to resume normal plotting.

Zoom Out All Axes Each click on the Zoom Out All Axes button increases the values displayed to the left of the graph, which increases the area displayed and provides a less detailed display than the standard plot mode. Click the PLOT button to resume normal plotting.

Zoom In All Axes Each click on the Zoom In All Axes button decreases the values displayed to the left of the graph, which decreases the area displayed and provides a more detailed display than the standard plot mode. Click the PLOT button to resume normal plotting.

Cursor Cursor mode allows you to place a vertical line at any point in the graph. A widow containing the Y, vertical, value of the selected trace displays next to the cursor. Use drag and drop to position the cursor line. The Y value is for the data selected from the list relating a line color to data. The cursor line color is the same as the selected data line. M–22

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Print Sends the Strip Chart data display to your printer.

Data Bus Traffic View The data flowing between the TCM and Allison DOC™ For PC is viewable in the Data Bus Traffic View. The 1000 and 2000 Product Families data is on the J1850 bus. You can view Data Bus Messages in either decimal, base 10, or hexadecimal, base 16, number systems. The data bus traffic can also be saved to a file for later retrieval.

To view Data Bus Traffic: 1. Select the Diagnostics drop-down menu. 2. Click on the Data Bus Viewer menu item—the Data Bus Traffic Viewer window displays.

Data Bus Messages The numeric representations of the data flow on the data bus.

MID/SA Message Identifier/Source Address code— the message type/source/destination.

Component ID Manufacturer of a controller.

Model A controller’s model number.

Software ID Identifies the software used by the controller. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Hexadecimal Toggles the Data Bus Message display between decimal and hexadecimal number systems.

Pause/Continue Button Pauses and continues the Data Bus Message display.

Clear Button Clears all Data Bus Message data.

Save Button Saves the data as displayed in Data Bus Viewer in a file named by data and time that is located in the Allison DOC™ For PC Saved DataBusViewerFiles folder. Use Windows Explorer to navigate to the hard drive on which Allison DOC™ For PC is located, then to the following path—…\Program Files\Allison Transmission\Allison DOC For PC\Saved DataBusViewer Files. The saved data can be viewed with NotePad® or WordPad™.

Exit Button Closes the Data Bus Traffic viewer.

10–3. CLUTCH TESTS b.

1000 and 2000 Product Families Clutch Test

The 1000 and 2000 Product Families Clutch Test uses a software tool bar to command a particular range. Fourth and Fifth range are inhibited if the engine speed is above 1400 rpm. When clutch test is enabled, a appears next to the Clutch Test item in the Action Request menu. Enable the 1000 and 2000 Product Families Clutch Test by: 1.

Selecting the Action Request drop-down menu.

2.

Selecting Clutch Test—the Clutch Test Tool Bar displays with the current range highlighted.

To select a range from the Clutch Test Tool Bar, click on the desired range. When the shift or range change is accomplished, the selected number is highlighted. A successful clutch test is indicated by a message display. Disable the 1000 and 2000 Product Families Clutch Test by: 1. Selecting the Action Request drop-down menu. 2. Selecting Clutch Test—the Clutch Test Tool Bar display and the Clutch Test are removed. M–24

Copyright© 2004 General Motors Corp.

in the Action Request menu

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 10–4. 1000 AND 2000 PRODUCT FAMILIES SOLENOID TEST 1000 and 2000 Product Families Solenoid Test provides a means of troubleshooting a particular solenoid’s performance. To enable the Solenoid Test function: 1. Select the Diagnostics drop-down menu. 2. Click on the Solenoid Test menu item—the Solenoid Data window displays.

To test a particular solenoid: 1. Select the solenoid from the Select a Solenoid To Test drop-down list 2. Click the TEST SOLENOID button—test data appears in the Solenoid Data window.

Sensor Name The name of the device for which data is being reported

Value The data being reported for each sensor—duty cycle for solenoids A, B, and F, On/Off state for solenoids C, D, and E. To disable the Solenoid Test function, click the CLOSE button.

10–6. 1000 AND 2000 PRODUCT FAMILIES RESET ADAPTIVE SHIFT PARAMETERS Reset Adaptive Shift Parameters replaces all adaptive clutch control parameters with the factory calibration values and invokes fast adaptive algorithms to adapt clutch control parameters. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL To reset Adaptive Shift Parameters: 1. Select the Action Request drop-down menu 2. Click on the Reset Fast Adaptive menu item—the Reset Fast Adapt window displays.

The Reset Fast Adapt window contains 10 tabs; one for each shift that can be reset to fast adaptive. The following information displays in the Reset Fast Adapt window:

Item Name The name of a parameter

Value The numerical value of the parameter

UOM Unit Of Measure for the parameter value—cc (cubic centimeter), kPa (kilopascal), sec (second) The fast adaptive parameters are reset when you click on the RESET FAST ADAPTIVE button—the Rest Fast Adaptive Successful window displays. Click the OK button.

Reset Fast Adaptive Garage Resets N (Neutral) to D (Drive) or N (Neutral) to R (Reverse) shifts to fast adaptive.

10–9. 1000 AND 2000 PRODUCT FAMILIES THROTTLE CALIBRATION Throttle Calibration re-initializes the values of throttle sensor input that indicates closed throttle and wide open throttle. Reset throttle calibration if the throttle sensor experienced over-travel or under-travel outside of normal operational limits and within failure limits. M–26

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL To reset open throttle calibration: 1. Select the Action Request drop-down menu. 2. Select Reset Open Throttle Calibration. The Throttle Action window displays.

3. Fully depress the throttle. 4. Click OK. 5. The Reset Open Throttle Calibration Successful window displays. To reset closed throttle calibration: 1. Select the Action Request drop-down menu. 2. Select Reset Closed Throttle Calibration. The Throttle Action window displays.

3. DO NOT depress the n throttle. 4. Click OK. 5. The Reset Closed Throttle Calibration Successful window displays. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 10–11. ENGINEERING CALCULATIONS The Engineering Calculations function allows you to calculate Converter Speed Ratio, Vehicle Speed, and Acceleration in g’s.

Enter the required data and press the OK button. The calculated data is added to the transmission information displayed in the Data Monitor and Custom Data Monitors windows.

10–12.RECORDING SNAPSHOTS Snapshots record all data being tracked by the TCM, allowing you to save the data for playback. At start up the Allison DOC™ For PC automatically begins receiving data. Data is not saved unless a save method is selected in the Record Options window. If no data bus traffic is detected for 6 seconds, Allison DOC™ For PC assumes the vehicle ignition has been turned off, recording is halted, and the Ignition Off window displays.

•

Click NO to not save the recording.

•

Click YES to save the recording—the Save As window displays.

If you close Allison DOC™ For PC during a recording session the following window displays—

•

Click SAVE to save the recording

•

Click CANCEL to return to Allison DOC™ For PC

NOTE:

Data is recorded in 30-minute blocks. If a session lasts more than 30 minutes, data recorded at the beginning of the session is lost. This function is similar to adding a ball to a tube filled with balls. The new ball pushes the oldest ball out of the end of the tube.

To record a snapshot: 1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key. M–28

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 2. Select Record. 3. Select Recording Options—the Record Options window displays.

NOTE:

The Sub Code field is disabled for 1000 and 2000 Product Families transmissions. 4. Select one of the following trigger conditions to start recording data:

•

When this Trouble Code appears, remember this session. You must enter a Trouble Code or select one from the drop-down list. If the Trouble Code entered occurs, the session is recorded.

•

When any Trouble Code appears, remember this session. The session is recorded if any Trouble Code occurs.

•

Remember this session. Recording begins immediately after you click OK. 5. Click OK.

a.

F6–FIRE TRIGGER

F6 –FIRE TRIGGER is a feature that allows you to bookmark a position for future reference in the TCM data recording. Bookmarks are assigned a sequential number in the order in which they were inserted into the playback file. In addition to their bookmark number, bookmarks are associated with a time relative to the length of the recording. To insert a bookmark while recording data either press the F6 keyboard key or click on the F6–FIRE TRIGGER BUTTON. NOTE:

If a recording has not been started and a bookmark is inserted, recording starts immediately and ignores all record options. Bookmark #1 and a time stamp are set to the beginning of the file.

NOTE:

The FIRE TRIGGER button text changes to display the next Bookmark #.

Example: Bookmark number 4 has been inserted in the recording.

10–13. STOPPING/SAVING PLAYBACK FILES 1. Press the F7—Stop Recording button or press the F7 key. 2. Select record. 3. Click YES. The Save As window displays. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

4. Type a log file filename. Do not type a filename extension. (Example – Alpha5, NOT alpha5.log). NOTE:

To save a recording in a folder other than the Logs folder, navigate to the desired folder before clicking the SAVE button. 5. Click the

button.

10–14. PLAYING BACK SNAPSHOTS Snapshot playback provides data to any of the diagnostic views. 1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key. 2. Select Playback. 3. Select Open Playback File. NOTE:

Allison DOC™ For PC breaks any live connection to an TCM and the Open File window displays. 4. Navigate to the appropriate directory. 5. Select the playback file to be played (example – playback1). 6. Click OK—the Trouble Code window and the Playback VCR control window display.

Playback indicators and VCR controls are: •

Meter bar—the percentage of the playback file played.

•

Total File Time—the length of the playback file in minutes and seconds

•

Current File Time—the elapsed time in minutes and seconds since the beginning of the file, based on the current location of the meter bar.

Using your mouse pointer, you may click and drag the meter bar to any point within the file and play the file from that point. Other controls include: • M–30

Open file—displays the Open File window Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

•

Rewind to beginning of file

•

Play

•

Stop

•

Play at four times normal speed

•

Loop—continuous play

•

Jump to trigger—displays data starting at the trigger condition selected when the data was recorded.

•

Jump to Bookmark—displays the bookmark window

•

Email Playback as Attachment—displays the Compose E-mail window

NOTE:

A playback file that is not loaded can also be e-mailed. Click on the e-mail menu item in the snapshot menu.

If you have not configured your PC for sending Email, click the CONFIGURATION button. The Email Configuration window displays. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

Contact your E-mail Administrator for the correct values to enter for your configuration.

11.

REPROGRAMMING TCM

11–1. REPROGRAMMING THE TCM NOTE:

You must have obtained and entered the proper authorization code for reprogramming the TCM.

Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Configuration window. ‘

M–32

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Reprogram TCM Window 1. Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Configuration window. 2. The Reprogram TCM window displays.

Reprogramming Status During the reprogramming function, a red, flashing status line displays at the bottom of the reprogramming window.

a–6.

b.

TCM Calibrations in the Reprogram TCM Window

Wire Number

The wire circuit number of the programmed function described below the wire number.

Status The enabled or disabled status of the function. Click on the Check Box to toggle between enable/disable.

Customer Modifiable Constraints Based on the assigned Current Vocation Package (see Reprogramming Package Assignments), the associated CMCs appear in display in the Reprogram TCM window. CMC information includes: •

Customer Modifiable Constants—a description of the CMC

•

Value—the current assigned value of the CMC

Reprogram TCM After all data has been entered or changed, click the REPROGRAM TCM button.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Select One Allison DOC™ For PC can save TCM configurations under a unique file name. •

To load a saved configuration, select the configuration from the drop down list and click LOAD.

•

To save a configuration, be sure the correct data is entered. Type a unique configuration name and click SAVE.

12.

REPORTS

The Allison DOC™ For PC Report function allows you to generate TCM information reports. At least one report must be selected for printing to occur. If the translator device uses the printer port on your PC, you must save the report and print it when the translation device is no longer connected to the printer port. One or all report sections may be printed at the same time. One or all report sections may be saved then printed under a single file name.

12–1. PRINTING ALLISON DOC™ FOR PC REPORTS 1. Select the File drop-down menu, or click the F2–File button, or press the F2 key. 2. Select Print—the Print Report window displays. 3. Select any or all of the available Report Sections to print. 4. Click the PRINT button.

1000 and 2000 Product Families Report Selection

•

I/O Wires

•

Diagnostic Data

•

Customer Modifiable Constants

•

Trouble Codes

•

Failure Records (1000 and 2000 Product Families)

•

Adapt Shifts (1000 and 2000 Product Families)

•

DTC Test (1000 and 2000 Product Families) 5. Select any or all of the available Report Sections to print. 6. Click the PRINT button.

M–34

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 12–2. SAVING ALLISON DOC™ FOR PC REPORTS 1. Select the File drop-down menu 2. Select Print—the Print Report window displays. 3. Select any or all of the available Report Sections to save 4. Click the SAVE button—the Report Name Dialog Box displays.

5. Type a unique name for the report. 6. Click the OK button—the report(s) is saved under the name typed in the Report Name Dialog Box. NOTE:

You do not have to exit the Print Report window to display a report on the screen.

12–3. DISPLAYING A SAVED REPORT ON THE SCREEN 1. Select the File drop-down menu 2. Select Print—the Print Report window displays. 3. Select a report from the drop-down list of saved reports 4. Click the LOAD button—the selected report displays

12–4. PRINTING A SAVED REPORT 1. Select the File drop-down menu. 2. Select Print—the Print Report window displays. 3. Select a report from the drop-down list of saved reports. 4. To confirm that you have the correct report, click the LOAD button—the selected report displays. 5. Click the PRINT button.

12–5. REPORT EXAMPLES The reports may be printed or saved as a file. Saved reports can be displayed on the screen. Examples of each report, as displayed on the screen, are on the following pages. All reports are configured with calibration information at the beginning of the report. Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL Failure Records Report (1000 and 2000 Product Families)

Adapt Shift Report (1000 and 2000 Product Families)

DTC Test Report (1000 and 2000 Product Families)

M–36

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL 12–6. PRINTING SCREENS The Print Screen function of Allison DOC™ For PC allows you to print the screen being displayed. To print a screen: Select Print Screen from the drop-down list above the primary status bar. The Allison DOC™ For PC screen being displayed prints at the default printer.

12–7. EXITING ALLISON DOC™ FOR PC There are three ways to Exit Allison DOC™ For PC: 1. Click the EXIT button in the top right corner of the Allison DOC™ For PC window, or, Click the button and select Exit or select the File drop-down menu and select Exit—the Allison DOC™ For PC program closes.

Copyright© 2004 General Motors Corp.

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ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

NOTES

M–38

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS intended the and specified controls featureThese which The schematics which followThis wereschematic taken fromshows the Techthe Data Book foruse theof 1000 2000 Product Families. schematics provide detail information to correctly input and output Any function connections. Forof anthis has beenneeded validated in the perform configuration shown. miswiring or use overview of Input/Output Functions, to Section 6 of this manual. feature refer which differs from that shown could result in damage to equipment or WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR This schematic shows the intended use of the specified controls feature which UNINTENDED USE OF THESE FEATURES. has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

A.

SECONDARY SHIFT SCHEDULE

USES:

Provides for operator selection of primary or secondary shift schedules. Can be used for performance/ economy, loaded/empty, or other shift schedule combinations.

VARIABLES TO SPECIFY: VOCATIONS:

None

No vocational restrictions

J1 (GRAY)

WIRE 110 (INPUT) J1-10 WIRE 128 SIGNAL RETURN

J1-28

DASH SWITCH Open: PRIMARY (usually “PERFORMANCE”) Closed: SECONDARY (usually “ECONOMY”)

OPTIONAL VIW CONNECTOR(S)

J2 (RED)

TCM

NOTE: When the TCM is turned ON, the active shift schedule is determined by the current switch position.

NOTE: All items shown, except TCM, are customer furnished. V05693.01

Figure N–1. Secondary Shift Schedule

Copyright© 2004 General Motors Corp.

N–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

C.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

PTO ENABLE

USES:

Permits the PTO to be engaged only when calibration-defined conditions are met. Also automatically disengages the PTO if specified speeds are exceeded.

VARIABLES TO SPECIFY:

VOCATIONS:

Various (with usage of PTO)

J1 (GRAY)

CAUTION:

TCM

Maximum engine speed for engagement, maximum engine speed for allowable operation, maximum output speed for engagement, maximum output speed for allowable operation, and neutral lockup ON shift speed.

When the PTO is disengaged due to overspeed, it will be automatically re-engaged at the “Max. Engine Speed for PTO Engagement” speed (a User Specified Variable), which is typically set at a relatively low speed. The resultant re-engagement shock could cause damage to a high-inertia PTO system.

OPTIONAL VIW CONNECTOR(S) J1-6

SWITCHED POWER DASH LIGHT

PTO SWITCH

J1-19

PTO PRESSURE SWITCH

WIRE 106 (INPUT) J2 (RED)

NC COM

WIRE 119 (OUTPUT)

NO

Relay shown de-energized

NOTE: All items shown, except TCM, are customer furnished.

Figure N–2. PTO Enable

N–2

PTO

Copyright© 2004 General Motors Corp.

V05694.01

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

E.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

AUXILIARY FUNCTION RANGE INHIBIT

USES:

Prevents inadvertent range selection when auxiliary equipment (e.g. wheelchair lift) is operating. May also be used to prevent neutral-to-range shifts unless the brake pedal is depressed.

VARIABLES TO SPECIFY: VOCATIONS:

Various. Not for use in emergency equipment.

Typical Uses:

WARNING!

J1 (GRAY)

None

School bus — brake pedal input Special service bus— wheelchair lift interlock Motorhome — “Door Ajar” interlock If this function is enabled in the shift calibration, the function MUST be integrated into the vehicle wiring. If the function is available in the shift calibration but will not be used in the vehicle, it MUST be disabled in the calibration.

OPTIONAL VIW CONNECTOR(S) J1-11 J1-28

WIRE 111 INPUT

WIRE 111 (INPUT)

WIRE 128 (SIGNAL RETURN)

— OR — Switch is open when auxiliary equipment is operating

BRAKE PRESSURE SWITCH

Switch closes when brakes are applied

WIRE 128 SIGNAL RETURN

J2 (RED)

TCM

NOTE: TCMs with this function activated must have wire 111 permanently connected to wire 128 if the function is not being used. NOTE: All items shown, except TCM, are customer furnished. V05695.01

Figure N–3. Auxiliary Function Range Inhibit

Copyright© 2004 General Motors Corp.

N–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

H.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE (STANDARD)

USES:

Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower transmission range when the brake is enabled, this function creates increased braking and/or maintains engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY:

J1 (GRAY)

VOCATIONS:

Preselect range (standard value is third range) “Lowered” or “Standard” preselect downshift schedule.

No vocational restrictions

EXHAUST–TYPE ENGINE BRAKE DASH SWITCH SWITCHED POWER WIRE 107 (INPUT)

OPTIONAL VIW CONNECTOR(S) J1-7

J1-20

NOTE: The engine exhaust brake must provide a low engine speed shutoff feature, set to disable the brake at a speed slightly higher than idle speed.

WIRE 120 (OUTPUT)

TCM NC J2 (RED)

NOTE: This switch is part of the engine brake system and provides an indication when the engine is at closed throttle. This switch, or an equivalent control feature, is REQUIRED for all installations.

COM

ENGINE THROTTLE SWITCH

NO

Relay shown de-energized

DASH LIGHT

BRAKE ON

ENGINE EXHAUST–TYPE BRAKE

NOTE: All items shown, except TCM, are customer furnished. V06485.01

Figure N–4. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Standard)

N–4

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

H.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE (OPTIONAL)

USES:

Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower transmission range when the brake is enabled, this function creates increased braking and/or maintains engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY: VOCATIONS:

Preselect range (standard value is third range) “Lowered” or “Standard” preselect downshift schedule.

No vocational restrictions

SWITCHED POWER J1 (GRAY)

NC

NOTE: Maximum current must not exceed engine manufacturers specification

WIRE 107 (INPUT)

J1-7

COM

NO

ENGINE ECM

J1-20 OPTIONAL VIW CONNECTOR(S)

ENGINE EXHAUST BRAKE DASH SWITCH

Relay shown de-energized

TCM

J2 (RED)

NC COM WIRE 120 (OUTPUT)

NOTE: The exhaust brake must provide a low engine speed shutoff feature, set to disable the brake at a speed slightly higher than idle rpm. NOTE: All items shown, except TCM, are customer furnished.

NO

Relay shown de-energized

DASH LIGHT (OPTIONAL)

BRAKE ON

ENGINE EXHAUST BRAKE

SWITCHED POWER V07486

Figure N–5. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Optional)

Copyright© 2004 General Motors Corp.

N–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

I.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

EXHAUST BRAKE/PRESELECT REQUEST, PLUS ENGINE BRAKE ENABLE (SPECIAL)

USES:

Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower transmission range when the brake is enabled, this function creates increased braking and/or maintains engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY:

J1 (GRAY)

VOCATIONS:

Preselect range (standard value is third range). “Lowered” or “Standard” preselect downshift schedule.

No vocational restrictions

OPTIONAL VIW CONNECTOR(S) J1-7

J1-20

WIRE 107 (INPUT)

ENGINE BRAKE DASH SWITCH SWITCHED POWER

NOTE: This switch is part of the engine brake system and provides an indication when the engine is at closed throttle. This switch, or an equivalent control feature, is recommended for all installations.

WIRE 120 (OUTPUT)

TCM

J2 (RED)

NC COM

ENGINE THROTTLE SWITCH

NO

Relay shown de-energized

DASH LIGHT

BRAKE ON

ENGINE BRAKE

NOTE: All items shown, except TCM, are customer furnished. V06487.01

Figure N–6. Exhaust Brake/Preselect Request, Plus Engine Brake Enable (Special)

N–6

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

L.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

AUTOMATIC NEUTRAL FOR PTO

USES:

Provides a means to automatically command N (Neutral) when PTO is operated. Requires the operator to re-select a range to shift out of N (Neutral). Frequently used in utility trucks or wrecker/recovery trucks.

VARIABLES TO SPECIFY: VOCATIONS:

Various. Not for use in emergency equipment.

WARNING!

J1 (GRAY)

Maximum output speed for activating this function. Range indicator = N (Neutral).

If this function is enabled in the shift calibration, the function MUST be integrated into the vehicle wiring. If the function is available in the shift calibration but will not be used in the vehicle, it MUST be disabled in the calibration.

J1-8

AUTO NEUTRAL (INPUT) WIRE 108 OR WIRE 111

J1-21

RANGE INDICATOR WIRE 121 (OUTPUT)

OPTIONAL VIW CONNECTOR(S) J2 (RED)

TCM

DASH SWITCH

SWITCHED POWER DASH LIGHT PTO PRESSURE SWITCH

NC COM

NO

Relay shown de-energized

PTO

NOTE: All items shown, except TCM, are customer furnished. V07487.00.01.eps

Figure N–7. Automatic Neutral for PTO

Copyright© 2004 General Motors Corp.

N–7

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

WARNING!

V.

REVERSE ENABLE

USES:

This function provides for a separate instrument panel-mounted switch which must be pressed simultaneously with the R (Reverse) shift selector pushbutton to achieve reverse operation.

VARIABLES TO SPECIFY: VOCATIONS:

None

European transit buses and tour buses. If this function is enabled in the shift calibration, the function MUST be integrated into the vehicle wiring. If the function is available in the shift calibration but will not be used in the vehicle, it MUST be disabled in the calibration.

WARNING!

J1 (GRAY)

MOMENTARY SWITCH

J2 (RED)

TCM

SWITCHED POWER

WIRE 106 REVERSE ENABLE

J1–06

OPTIONAL VEHICLE INTERFACE WIRING CONNECTOR

V07488

Figure N–8. Reverse Enable

N–8

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

AH.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

KICKDOWN

USES:

Permits both “Economy” and “Performance” shift schedules to be used in the same operating mode. Typically used in stop-and-go duty cycles with an emphasis on fuel economy.

VARIABLES TO SPECIFY: VOCATIONS:

None

No vocational restrictions

CLOSED THROTTLE

J1 (GRAY)

OPTIONAL VIW CONNECTOR(S) J1-9 J1-28

FULL THROTTLE KICKDOWN SHIFT POINTS

THROTTLE PEDAL MOMENTARY SWITCH

TCM

J2 (RED)

ENGINE OPERATING RANGE

FULL THROTTLE ECONOMY SHIFT POINTS

WIRE 109 (INPUT) WIRE 128 (SIGNAL RETURN)

Pedal movement beyond this point must not change engine fuel setting or transmission throttle position

NOTE: “Full throttle economy shift points” position on the pedal should coincide with full stroke of the Allison throttle position sensor (if used) and/or “full fuel” setting of the engine control. Thus, pedal movement beyond “full throttle economy shift points” must not change fuel setting of the engine or the throttle position signal to the transmission control system. NOTE: All items shown, except TCM, are customer furnished. V05702.01

Figure N–9. Kickdown

Copyright© 2004 General Motors Corp.

N–9

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

AM. REFUSE PACKER STEP SWITCH USES:

This signal can be used to denote the presence of personnel who are riding on a rear platform of the vehicle (refuse packer).

VARIABLES TO SPECIFY: VOCATIONS:

None

Refuse packer.

WARNING!

If this function is enabled in the shift calibration, the function MUST be integrated into the vehicle wiring. If the function is available in the shift calibration but will not be used in the vehicle, it MUST be disabled in the calibration.

MOMENTARY SWITCH J1 (GRAY)

WIRE 108 REFUSE PACKER STEP SWITCH

J1–08 TCM

OPTIONAL VIW CONNECTOR(S) J2 (RED)

Function is activated when switch is depressed. Function is de-activated when switch is released.

SWITCHED POWER

Switch opens to indicate presence of personnel on step. SWITCH OPENS TO INDICATE PRESENCE OF PERSONNEL ON STEP

NOTE: Transmission will shift according to preselect downshift schedule when function is activated while above 1st range. If function is activated while in Reverse, transmission will shift to Neutral.

V07489

Figure N–10. Refuse Packer Step Switch

N–10

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

WARNING!

AR. USES:

OVERDRIVE DISABLE Can be used in conjunction with a 5–3–2–1 selector configuration to permit hold selection of all forward ranges. This feature has no effect on 4-speed configurations.

VARIABLES TO SPECIFY: VOCATIONS:

None

No vocational restrictions

J1 (GRAY)

SWITCHED POWER

J1–12

OVERDRIVE DISABLE WIRE 112 (INPUT)

J1–28

SIGNAL RETURN WIRE 128

LIGHTED DASH SWITCH

CLOSED: Overdrive (5th) is disabled OPEN: Normal operation

OPTIONAL VIW CONNECTOR(S)

J2 (RED)

TCM

NOTE: All items shown, except TCM, are customer furnished. V07490

Figure N–11. Overdrive Disable

Copyright© 2004 General Motors Corp.

N–11

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

B.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

SUMP TEMPERATURE INDICATOR

USES:

Provides a means to turn on a dash indicator or other alarm when transmission sump temperature has exceeded specified limits.

VARIABLES TO SPECIFY: VOCATIONS:

None

No vocational restrictions

J1 (GRAY)

SWITCHED POWER

J1-24

WIRE 124 (OUTPUT)

TRANSMISSION TEMP

OPTIONAL VIW CONNECTOR(S)

J2 (RED)

TCM If current in lamp circuit exceeds 0.5 amp, ground lamp through a relay

NC TRANS TEMP

COM

SWITCHED POWER

NO

WIRE 124

NOTE: All items shown, except TCM, are customer furnished. V05703.01

Figure N–12. Sump Temperature Indicator

N–12

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

C.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

RANGE INDICATOR

USES:

May be used in the control system of an auxiliary vehicle system to permit its operation only when the transmission is engaged in specified gear range(s), including Neutral.

NOTE:

P (Park) can be an indicated range for a 1000 Product Family or 2000 Product Family transmission (with a park pawl). For a 2000 Product Family transmission (without a park pawl), the “P” position can be used to indicate a second NEUTRAL position.

NOTE:

This feature is not suitable for activating a customer-furnished park brake in the second NEUTRAL position (2000 Product Family transmissions), since the indicator is active only when the engine is running.

VARIABLES TO SPECIFY: VOCATIONS:

Range or ranges to be indicated.

No vocational restrictions

J1 (GRAY)

SWITCHED POWER WIRE 121 (OUTPUT)

J1-21

NC

OPTIONAL VIW CONNECTOR(S)

COM

NO

J2 (RED)

TCM Relay shown de-energized

NOTE: This signal should not be used to automatically apply the park brake or service brakes when the transmission is shifted to N (Neutral).

AUXILIARY VEHICLE SYSTEM

NOTE: All items shown, except TCM, are customer furnished. V05704.01

Figure N–13. Range Indicator

Copyright© 2004 General Motors Corp.

N–13

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N—INPUT/OUTPUT FUNCTIONS

WARNING!

D.

This schematic shows the intended use of the specified controls feature which has been validated in the configuration shown. Any miswiring or use of this feature which differs from that shown could result in damage to equipment or property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES.

OUTPUT SPEED INDICATOR

USES:

To indicate reaching a minimum or maximum operating speed to assist in the indication of and/or control of the vehicle or auxiliary equipment. Frequently used to alert the operator that output speed has exceeded a specified value.

VARIABLES TO SPECIFY: VOCATIONS:

Output speed to turn indicator ON and to turn indicator OFF (ON value must be higher than the OFF value).

No vocational restrictions

J1 (GRAY)

SWITCHED POWER

NC COM

WIRE 122 (OUTPUT)

J1-22

NO

Relay shown de-energized

OPTIONAL VIW CONNECTOR(S)

TRANSMISSION OR VEHICLE OVERSPEED INDICATOR

J2 (RED)

TCM

NOTE: All items shown, except TCM, are customer furnished. V05705.01

Figure N–14. Output Speed Indicator

N–14

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

WARNING!

For vehicles containing 1000 Product Family and 2000 Product Family (2400 models), each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Ensure that the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the P (Park) range by slowly releasing the service brake. • Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.

WARNING!

For vehicles containing 2000 Product Family transmissions without auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Ensure that the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brake and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.

WARNING!

For vehicles containing 2000 Product Family transmissions with auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Ensure that the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. • Apply the emergency brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.

Copyright© 2004 General Motors Corp.

P–1

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE NOTE:

To ensure accurate fluid level checks, be sure that the fill tube and dipstick meet Allison Transmission specifications. Requirements for the standard oil pan are shown in Figure P–1 and requirements for the shallow oil pan are shown in Figure P–2. When checking a long dipstick calibration: • •

Be sure the dipstick contacts the oil pan surface as shown in Figures P–1 and P–2. Take measurements from the end of the dipstick.

When checking a short dipstick calibration: • •

Remove the oil pan. Take measurements from the oil pan splitline.

5.0 mm (0.20 in)

TRANSMISSION CENTERLINE

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

TRANSMISSION CENTERLINE

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in) HOT RUN

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

5.0 mm (0.20 in)

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in)

TYPICAL COLD CHECK BAND

HOT RUN

TYPICAL COLD CHECK BAND

101.9 mm (4.01 in) Dipstick must contact oil pan

LONG FILL TUBE AND DIPSTICK* *Check measurements from end of dipstick

SHORT FILL TUBE AND DIPSTICK V05803

Figure P–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)

P–2

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

5.0 mm (0.20 in)

TRANSMISSION CENTERLINE

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

TRANSMISSION CENTERLINE

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in) HOT RUN

98.9 mm (3.89 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

5.0 mm (0.20 in)

Fill tube to be straight in all vertical planes for this distance

72.6 mm (2.86 in)

TYPICAL COLD CHECK BAND

HOT RUN

TYPICAL COLD CHECK BAND

88.5 mm (3.48 in) Dipstick must contact oil pan

LONG FILL TUBE AND DIPSTICK* *Check measurements from end of dipstick

SHORT FILL TUBE AND DIPSTICK V05804

Figure P–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan) A.

Manual Fluid Check Procedure Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using the following procedure and report any abnormal fluid levels to your maintenance persons.

B.

Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made.

CAUTION:

The fluid level rises as fluid temperature increases. DO NOT fill above the “COLD CHECK” band if the transmission fluid is below normal operating temperatures.

• Park vehicles containing 1000 Product Family and 2000 Product Family (2400 models) as follows:

— — — — —

Bring the vehicle to a complete stop on a level surface using the service brake. Ensure that the engine is at low idle rpm. Put the transmission in P (Park). Engage the P (Park) range by slowly releasing the service brake. Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged.

Copyright© 2004 General Motors Corp.

P–3

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE • Park vehicles containing 2000 Product Family transmissions with auto-apply parking brakes as

follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Ensure that the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged. • Park vehicles containing 2000 Product Family transmissions without auto-apply parking brakes as

follows: — — — —

Bring the vehicle to a complete stop on a level surface using the service brake. Ensure that the engine is at low idle rpm. Put the transmission in N (Neutral). Apply the emergency brake and/or parking brake and make sure they are properly engaged.

• Chock the wheels and take any other steps necessary to keep the vehicle from moving. • Run the engine for at least one minute. Apply the service brakes and shift to D (Drive), then to

N (Neutral), and then shift to R (Reverse) to fill the hydraulic system. Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly release the service brakes. • With the engine running, remove the dipstick from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check

procedure to verify the reading. • If the fluid level is within the “COLD CHECK” band, the transmission may be operated until the fluid

is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band. • Perform a hot check at the first opportunity after the normal operating sump temperature of

71ºC–93ºC (160ºF–200ºF) is reached. C.

Hot Check Procedure

CAUTION:

The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases.

• Operate the transmission in D (Drive) range until normal operating temperature is reached:

— sump temperature 71ºC–93ºC (160ºF–200ºF) — converter-out temperature 82ºC–104ºC (180ºF–220ºF) — If a transmission temperature gauge is not present, check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour. • Park vehicles containing 1000 Product Family and 2000 Product Family (2400 models) as follows:

— — — — —

P–4

Bring the vehicle to a complete stop on a level surface using the service brake. Ensure that the engine is at low idle rpm. Put the transmission in P (Park). Engage the P (Park) range by slowly releasing the service brake. Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged.

Copyright© 2004 General Motors Corp.

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE • Park vehicles containing 2000 Product Family transmissions with auto-apply parking brakes as

follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Ensure that the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged. • Park vehicles containing 2000 Product Family transmissions without auto-apply parking brakes as

follows: — — — —

Bring the vehicle to a complete stop on a level surface using the service brake. Ensure that the engine is at low idle rpm. Put the transmission in N (Neutral). Apply the emergency brake and/or parking brake and make sure they are properly engaged.

• Chock the wheels and take any other steps necessary to keep the vehicle from moving. • With the engine running, remove the dipstick from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove. Check fluid level reading. Repeat the check procedure

to verify the reading. NOTE:

Safe operating level is within the “HOT RUN” band on the dipstick. See Figures P–1 and P–2. The width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal operating sump temperature. • If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level

to within the “HOT RUN” band. D.

Consistency of Readings Always check the fluid level at least twice using the procedure described above. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distributor or dealer.

Copyright© 2004 General Motors Corp.

P–5

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

NOTES

P–6

Copyright© 2004 General Motors Corp.

TS3192EN 200304

www.allisontransmission.com

Printed in U.S.A. 200406

Mechanic’s Tips 1000 and 2000 Product Family Transmissions MT3190EN

Mechanic’s Tips

2004 MARCH 01 MT3190EN

Allison Transmission VOCATIONAL MODELS 1000 EVS 1000 HS 1000 MH 1000 PTS 1000 RDS 1000 SP B 210

2100 EVS 2100 HS 2100 MH 2100 PTS 2100 RDS 2100 SP B 220

2200 EVS 2200 HS 2200 MH 2200 PTS 2200 RDS 2200 SP

2500 EVS 2500 HS 2500 MH 2500 PTS 2500 RDS 2500 SP

1000 Series™ 2000 Series™ 2000 MH Series 2400 Series™

Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46202-0894 www.allisontransmission.com

Printed in USA

Copyright © 2004 General Motors Corporation

i

WARNINGS, CAUTIONS, AND NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems (including appropriate warnings, cautions, and notes). Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair is important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission (or the vehicle manufacturer) and described in this handbook are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. Three types of headings are used in this manual to attract your attention. These warnings and cautions advise of specific methods or actions that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. WARNING: A warning is used when an operating procedure, practice, etc., if not correctly followed, could result in personal injury or loss of life.

CAUTION: A caution is used when an operating procedure, practice, etc., if not strictly observed, could result in damage to or destruction of equipment.

NOTE: A note is used when an operating procedure, practice, etc., is essential to highlight.

TRADEMARK INFORMATION DEXRON® is a registered trademark of General Motors Corporation. Allison DOC™ is a trademark of General Motors Corporation. TranSynd™ is a trademark of Castrol Ltd.

ii

TABLE OF CONTENTS Paragraph

SECTION I 1–1 1–2 1–3 1–4 1–5 1–6 1–7 1–8 1–9

SECTION II 2–1 2–2 2–3 2–4 2–5 2–6

SECTION III 3–1 3–2 3–3 3–4 3–5

SECTION IV 4–1 4–2 4–3 4–4 4–5

Description

Page

PREVENTIVE MAINTENANCE Periodic Inspections And Care. . . . . . . . . . . . . . . . . . . . . . . Importance Of Proper Transmission Fluid Level. . . . . . . . . Transmission Fluid Check . . . . . . . . . . . . . . . . . . . . . . . . . . Keeping Fluid Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Fluid And Filter Change Intervals . . . . . . . . . Transmission Fluid Contamination . . . . . . . . . . . . . . . . . . . Transmission Fluid And Filter Change Procedure. . . . . . . . Oil Vent (Breather) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 3 3 10 10 11 13 14 16

REMOVING TRANSMISSION Draining Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uncoupling From Driveline, Engine, And Vehicle . . . . . . . Removing The Transmission . . . . . . . . . . . . . . . . . . . . . . . . Removing The Flexplate Adapter . . . . . . . . . . . . . . . . . . . . Removing Output Flange Or Yoke . . . . . . . . . . . . . . . . . . .

17 17 18 18 19 19

PREPARING THE TRANSMISSION FOR INSTALLATION Checking Input Components . . . . . . . . . . . . . . . . . . . . . . . . Installing Output Flange Or Yoke . . . . . . . . . . . . . . . . . . . . Installing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Fill Tube And Seal . . . . . . . . . . . . . . . . . . . . . . . . Checking Plugs And Openings . . . . . . . . . . . . . . . . . . . . . .

20 20 21 24 25

PREPARING VEHICLE FOR TRANSMISSION INSTALLATION Engine, Transmission Adaptation Requirements . . . . . . . . . Checking Flexplate Drive Assembly . . . . . . . . . . . . . . . . . . Chassis And Driveline Inspection . . . . . . . . . . . . . . . . . . . . Cooler, Filter, And Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

26 30 30 31 32

Paragraph

Description

SECTION V

INSTALLING TRANSMISSION INTO VEHICLE

5–1 5–2 5–3 5–4 5–5 5–6 5–7 5–8 5–9 5–10 5–11

SECTION VI 6–1 6–2

Page

Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting To Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Transmission Mounting Components . . . . . . . . . Coupling To Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Power Takeoff Controls . . . . . . . . . . . . . . . . . . Connecting Parking Brake Control . . . . . . . . . . . . . . . . . . . Connecting Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Road Test And Vehicle Operation Checklist . . . . . . . . . . . .

35 35 37 37 37 38 38 39 39 40 42

CUSTOMER SERVICE Owner Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv

44 44

PREFACE This handbook is a mechanic’s reference for maintaining, removing, or installing 1000 and 2000 Product Families transmissions. All features of the transmission and the vehicle involved in installation procedures are discussed. The information presented will help the mechanic maintain, remove, or install the transmission in a manner that assures satisfactory operation and long service life. For additional detailed information, refer to the appropriate transmission service manual and electronic controls troubleshooting manual. Unless specifically indicated otherwise, this handbook refers to all 1000 and 2000 Product Families transmissions. The differences between the various transmissions are explained as required.

v

vi

CONTROL MAIN FILTER

TORQUE CONVERTER ASSEMBLY

OUTPUT YOKE

MAIN SHAFT

MAIN HOUSING MODULE • MAIN HOUSING • C3 CLUTCH • C4 CLUTCH • C5 CLUTCH

REAR COVER MODULE • REAR COVER • OUTPUT SPEED SENSOR • OUTPUT SHAFT • P3 PLANETARY • PARK PAWL (1000/2200 ONLY) P2 PLANETARY P1 PLANETARY DEEP OIL PAN CONTROL VALVE MODULE SUCTION FILTER ROTATING CLUTCH MODULE • TONE WHEEL (IF NO PTO) OR PTO DRIVE GEAR • C2 CLUTCH • C1 CLUTCH • TURBINE SHAFT V04525.02.02

CONVERTER HOUSING/FRONT SUPPORT MODULE • CONVERTER HOUSING • INPUT SPEED SENSOR • OIL PUMP • FRONT SUPPORT TURBINE SPEED SENSOR

1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION

vii

CONVERTER HOUSING

SHALLOW PAN

with Optional Converter Housing, Rear Cover, and Shallow pan

1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION

V05719.02.02

REAR COVER

viii CONTROL MAIN OIL FILTER

AVAILABLE OIL FILL TUBE LOCATION

SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL)

SELECTOR SHAFT

NSBU SWITCH

V04779.03.02

OUTPUT SPEED SENSOR

PARKING BRAKE MOUNTING PROVISION

1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – LEFT-FRONT VIEW

OIL VENT (BREATHER) TURBINE SPEED SENSOR INPUT SPEED SENSOR

ix MAIN ELECTRICAL CONNECTOR

AVAILABLE OIL FILL TUBE LOCATION SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL)

V04780.01.05

MOUNTING PAD (SAE #3 HOUSING ONLY) COOLER PORTS

1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – RIGHT-REAR VIEW

PROVISION FOR CUSTOMER-SUPPLIED SPEED SENSOR OR TACHOGRAPH (OPRIONAL)

OUTPUT SPEED SENSOR

OIL VENT (BREATHER)

TURBINE SPEED SENSOR

INPUT SPEED SENSOR

NOTES

x

PREVENTIVE MAINTENANCE

S ECTION

I

1–1. PERIODIC INSPECTIONS AND CARE Transmission Product Families Beginning January 2004, Allison Transmission began shipping new 1000 and 2000 Product Families vocation specific transmission models for North America. 1000 and 2000 Product Families vocational models are: • Emergency Vehicle Series—1000 EVS, 2100 EVS, 2200 EVS, 2500 EVS • Highway Series—1000 HS, 2100 HS, 2200 HS, 2500 HS • Motorhome Series—1000 MH, 2100 MH, 2200 MH, 2500 MH • Pupil Transportation/Shuttle Series—1000 PTS, 2100 PTS, 2200 PTS, 2500 PTS • Rugged Duty Series—1000 RDS, 2100 RDS,·2200 RDS,·2500 RDS • Specialty Series—1000 SP, 2100 SP, 2200 SP, 2500 SP • Bus Series—B 210, B 220 The 1000 and 2000 Product Families include the 1000/2000/2400 Series transmissions. Refer to WATCH 309 for detailed descriptions of the vocational models and their correlation to the existing 1000/2000/2400 Series.

Transmission Inspection CAUTION: When cleaning the transmission, do not spray steam, water, or cleaning solution directly at the breather (oil vent). Spraying steam, water, or cleaning solution at the breather can force the water or cleaning solution into the transmission and contaminate the transmission fluid.

1

Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of these inspections. Inspect the transmission for: • loose bolts—transmission and mounting components • fluid leaks—repair immediately • loose, dirty, or improperly adjusted throttle sensor or shift selector linkage • damaged or loose hoses • worn, frayed, or improperly routed electrical harnesses • worn or frayed electrical connections • worn or out-of-phase driveline U-joints and slip fittings • clogged or dirty oil vent (breather)

Vehicle Inspection Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler.

Welding CAUTION: When welding on the vehicle: • DO NOT WELD on the vehicle without disconnecting from the TCM all control system wiring harness connectors. • DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads. • DO NOT WELD on any control components. • DO NOT CONNECT welding cables to any control components. A label describing on-vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place. A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on-vehicle welding label (SA2607).

2

1–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools, lubricates, and transmits hydraulic power. Always maintain proper fluid level. If fluid level is too low, the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats. If the level is too high, the fluid aerates—causing the transmission to shift erratically and overheat. Fluid may be expelled through the breather or dipstick tube when the fluid level is too high.

1–3.

TRANSMISSION FLUID CHECK WARNING: For vehicles containing 1000 or 2200 models, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure that the engine is at low idle rpm. • Put the transmission in P (Park). • Engage the P (Park) range by slowly releasing the service brake. • Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. WARNING: For vehicles containing 2100 or 2500 models with autoapply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure that the engine is at low idle rpm. • Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. • Apply the emergency brake, if present, and make sure it is properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. 3

WARNING: For vehicles containing 2100 or 2500 models without auto-apply parking brakes, each time you park the vehicle or leave the operator’s station with the engine running, do the following. • Bring the vehicle to a complete stop using the service brake. • Make sure that the engine is at low idle rpm. • Put the transmission in N (Neutral). • Apply the emergency brake and/or parking brake and make sure they are properly engaged. • If the operator’s station will be unoccupied with the engine running, chock the wheels and take any other steps necessary to keep the vehicle from moving. If this procedure is not followed, the vehicle can move suddenly and you or others could be injured. NOTE: For accurate fluid level checks, be sure that the fill tube and dipstick meet Allison Transmission specifications. Requirements for the standard oil pan are shown in Figure 1–1 and requirements for the shallow oil pan are shown in Figure 1–2. When checking a long dipstick calibration: • Be sure the dipstick contacts the oil pan surface as shown in Figures 1–1 and 1–2. • Take measurements from the end of the dipstick. When checking a short dipstick calibration: • Remove the oil pan. • Take measurements from the oil pan splitline.

4

Figure 1–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)

5 Dipstick must contact oil pan

TYPICAL COLD CHECK BAND

HOT RUN

TYPICAL COLD CHECK BAND

HOT RUN

Fill tube to be straight in all vertical planes for this distance

5.0 mm (0.20 in)

V05803

SHORT FILL TUBE AND DIPSTICK

72.6 mm (2.86 in)

98.9 mm (3.89 in)

TRANSMISSION CENTERLINE

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

Fill tube to be straight in all vertical planes for this distance

5.0 mm (0.20 in)

LONG FILL TUBE AND DIPSTICK*

72.6 mm (2.86 in)

*Check measurements from end of dipstick

101.9 mm (4.01 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

98.9 mm (3.89 in)

TRANSMISSION CENTERLINE

Figure 1–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)

6

72.6 mm (2.86 in)

Dipstick must contact oil pan

TYPICAL COLD CHECK BAND

HOT RUN

TYPICAL COLD CHECK BAND

HOT RUN

Fill tube to be straight in all vertical planes for this distance

5.0 mm (0.20 in)

V05804

SHORT FILL TUBE AND DIPSTICK

72.6 mm (2.86 in)

98.9 mm (3.89 in)

TRANSMISSION CENTERLINE

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE

Fill tube to be straight in all vertical planes for this distance

5.0 mm (0.20 in)

LONG FILL TUBE AND DIPSTICK* *Check measurements from end of dipstick

88.5 mm (3.48 in)

10.0 mm (0.39 in) 30.0 mm (1.18 in) OIL PAN SPLIT LINE (Ref. only)

98.9 mm (3.89 in)

TRANSMISSION CENTERLINE

a. Manual Fluid Check Procedure. Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using the following procedure and report any abnormal fluid levels to your maintenance persons. b. Cold Check Procedure. The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made.

CAUTION: The fluid level rises as fluid temperature increases. DO NOT fill above the “COLD CHECK” band if the transmission fluid is below normal operating temperatures.

• Park vehicles containing 1000 or 2200 models as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in P (Park). — Engage the P (Park) range by slowly releasing the service brake. — Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • Park vehicles containing 2100 or 2500 models with auto-apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged.

7

• Park vehicles containing 2100 or 2500 models without auto-apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in N (Neutral). — Apply the emergency brake and/or parking brake and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. • Run the engine for at least one minute. Apply the service brakes and shift to D (Drive), then to N (Neutral), and then shift to R (Reverse) to fill the hydraulic system. Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly release the service brakes. • With the engine running, remove the dipstick from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. • If the fluid level is within the “COLD CHECK” band, the transmission may be operated until the fluid is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band. • Perform a hot check at the first opportunity after the normal operating sump temperature of 71˚C–93˚C (160˚F–200˚F) is reached. c. Hot Check Procedure. CAUTION: The fluid must be hot to provide an accurate check. The fluid level rises as temperature increases.

• Operate the transmission in D (Drive) range until normal operating temperature is reached: — sump temperature 71˚C–93˚C (160˚F–200˚F) — converter-out temperature 82˚C–104˚C (180˚F–220˚F) — If a transmission temperature gauge is not present, check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour.

8

• Park vehicles containing 1000 or 2200 models as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in P (Park). — Engage the P (Park) range by slowly releasing the service brake. — Apply the emergency brake and/or parking brake, if present, and make sure it is properly engaged. • Park vehicles containing 2100 or 2500 models with auto-apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is properly engaged. — Apply the emergency brake, if present, and make sure it is properly engaged. • Park vehicles containing 2100 or 2500 models without auto-apply parking brakes as follows: — Bring the vehicle to a complete stop on a level surface using the service brake. — Make sure that the engine is at low idle rpm. — Put the transmission in N (Neutral). — Apply the emergency brake and/or parking brake and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving. • With the engine running, remove the dipstick from the tube and wipe the dipstick clean. • Insert the dipstick into the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading.

9

NOTE: Safe operating level is within the “HOT RUN” band on the dipstick. See Figures 1–1 and 1–2. The width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal operating sump temperature. • If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level to within the “HOT RUN” band. d. Consistency of Readings. Always check the fluid level at least twice using the procedure described above. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer.

1–4. KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay the dipstick in a clean place while filling the transmission. CAUTION: Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause the clutch plates to fail.

1–5. FLUID RECOMMENDATIONS Hydraulic fluids (oils) used in the transmission are important influences on transmission performance, reliability, and durability. Only fluids meeting TES-295 (TranSynd™) or DEXRON®-III specifications are acceptable for use in the 1000 and 2000 Product Families transmissions. To make sure the fluid is qualified for use in Allison transmissions, check for a TES-295 or a DEXRON®-III fluid license or approval numbers on the container, or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types. CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life. When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or geographical location must be taken into consideration. Table 1–1 lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in P (Park) 10

or PB (Auto-Apply Parking Brake), if available, or N (Neutral) for a minimum of 20 minutes before attempting range operation. Table 1–1. Transmission Fluid Operating Temperature Requirements

Ambient Temperature Below Which Preheat is Required Viscosity Grade

Celsius

Fahrenheit

DEXRON®-III TranSynd™

–27 –33

–17 –22 (Ref. SIL 13-TR-90)

1–6. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. More frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating. a. Frequency. Change the control main filter at or before the initial 8000 km (5000 miles) then follow the schedule in Table 1–2. Table 1–2 is given only as a general guide for fluid and filter change interval.

11

12

Fluid

Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid) 25,000 Miles 25,000 Miles 50,000 Miles 50,000 Miles (40 000 km) (40 000 km) (80 000 km) (80 000 km) 12 Months Overhaul 12 Months 24 Months 24 Months Overhaul

Lube/Auxiliary

GENERAL VOCATION Filters Control Main Internal 50,000 Miles (80 000 km) 24 Months

Lube/Auxiliary

25,000 Miles (40 000 km) 12 Months

Overhaul

25,000 Miles (40 000 km) 12 Months

50,000 Miles (80 000 km) 24 Months

50,000 Miles (80 000 km) 24 Months

Overhaul

50,000 Miles (80 000 km) 24 Months

50,000 Miles (80 000 km) 24 Months

Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. Filters must be changed at or before recommended intervals.

* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd™ that is required to fill the transmission to the proper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-TranSynd™ other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3. NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first. Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and MH models. General Vocation: All other vocations.

25,000 Miles (40 000 km) 12 Months

Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid) 50,000 Miles 50,000 Miles 100,000 Miles 50,000 Miles (80 000 km) (80 000 km) (160 000 km) (80 000 km) 24 Months Overhaul 24 Months 48 Months 24 Months Overhaul Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd™ and Non-TranSynd™ Fluids

Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of 100 percent of the used fluid. Recommendations in Schedule 2 are based upon standard Allison fluid change procedures.

The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd™ fluid. For transmissions that contain a mixture of TranSynd™ and non-TranSynd™ fluids, refer to Schedule 3.

50,000 Miles (80 000 km) 24 Months

NOTE:

25,000 Miles (40 000 km) 12 Months

Fluid

SEVERE VOCATION Filters Control Main Internal

Table 1–2. 1000 and 2000 Product Families Transmission Fluid and Filter Change

b. Abnormal Conditions. Transmissions used in high cycle rate applications should use fluid analysis to be certain that a proper fluid change interval is established. Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor, or by fluid analysis. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. c. Fluid Analysis. Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 1–3. Consult your Distributor/Dealer for an Oil Analysis Kit (refer to SIL 17-TR-96, Rev A). To be sure of consistent and accurate fluid analysis, use only one fluid analysis firm. Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information. Table 1–3. Fluid Oxidation Measurement Limits

Test Viscosity Total Acid Number

Limit ±25% change from new fluid +3.0 change from new fluid

1–7. TRANSMISSION FLUID CONTAMINATION a. Fluid Examination. At each fluid change, examine the drained fluid for evidence of dirt or water. A normal amount of condensation will appear in the fluid during operation. b. Water. Obvious water contamination of the transmission fluid or transmission fluid in the heat exchanger coolant indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. NOTE: Coolant can also be contaminated by engine oil; be sure to locate the correct source of coolant contamination.

c. Engine Coolant. CAUTION: Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious damage. Completely disassemble, inspect, and clean the transmission. Remove all traces of the coolant, and varnish deposits resulting from engine coolant contamination. Refer to SIL 18-TR-98 for more information. 13

d. Metal. Metal particles in the fluid (except for the minute particles normally trapped in the oil filter) indicate internal transmission damage. If these particles are found in the sump, the transmission must be disassembled and closely inspected to find their source. Metal contamination requires complete transmission disassembly. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. CAUTION: After flushing the cooler with Kwik-Flush Cart J 46550, be sure to check the external cooler circuit restriction. If circuit pressure drop is above specification, the cooler has excessive trapped particles and must be replaced. NOTE: When equipment to flush the oil cooler is not available, install a filter in the cooler line between the oil cooler and the transmission “from cooler” port. The cooler circuit pressure drop specifications must still be met (see AS64–071 or AS 64–072 in the Allison Sales Tech Data book). Frequent initial changes of this filter element may be required as debris is flushed out of the oil cooler circuit. Closely monitoring change in cooler circuit pressure drop will indicate when a filter change is needed.

1–8. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE a. Drain Fluid.

NOTE: Do not drain the transmission fluid if changing the control main filter only. • Drain the fluid when the transmission is at normal operating sump temperature—71˚C–93˚C (160˚F–200˚F). Hot fluid flows quicker and drains more completely. • Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container. • Examine the fluid as described in Paragraph 1–7. b. Replace Control-Main Filter. (Figure 1–3) 1. Using J 45023 filter wrench or a strap filter wrench, remove the control-main filter by rotating it in the counterclockwise direction. Use a standard straptype filter wrench. 14

MAGNET FILTER

V05805

Figure 1–3.

2. Remove the magnet from the filter attachment tube or from the top of the filter element. 3. Clean any metal debris from the magnet. Report any metal pieces larger than dust to your maintenance personnel. 4. Reinstall the magnet onto the filter attachment tube. 5. Lubricate the gasket on the control-main filter with transmission fluid. 6. Install, by hand, the control-main filter until the gasket on the control-main filter touches the converter housing or cooler manifold. CAUTION: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter.

7. Turn the filter ONE FULL TURN ONLY after gasket contact. 8. Reinstall the drain plug and sealing washer. Tighten the drain plug to 30–40 N·m (22–30 lb ft). 15

c. Refill Transmission. The amount of refill fluid is less than the amount used for the initial fill. Fluid remains in the external circuits and transmission cavities after draining the transmission. After refill, check the fluid level using the procedure described in Paragraph 1–3. Table 1–4. Transmission Fluid Capacity

Initial Fill*

Refill*

Sump

Liters

Quarts

Liters

Quarts

Standard Shallow

14 12

14.8 12.7

10 7

10.6 7.4

* Approximate quantities, do not include external lines and cooler hose.

1–9. OIL VENT (BREATHER) a. Location and Purpose. The breather is located at the top left-rear of the transmission main housing. The breather prevents air pressure buildup within the transmission and its passage must be kept clean and open. b. Maintenance. The amount of dust and dirt encountered will determine the frequency of breather cleaning. Use care when cleaning the transmission. CAUTION: When cleaning the transmission, do not spray steam, water, or cleaning solution directly at the breather (oil vent). Spraying steam, water, or cleaning solution at the breather can force the water or cleaning solution into the transmission and contaminate the transmission fluid.

16

S ECTION

II

REMOVING TRANSMISSION

2–1. DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle. • Remove the drain plug from the oil pan. Examine the drained fluid for evidence of contamination—refer to Paragraph 1–7. Reinstall the drain plug. • Remove the transmission fill tube if it interferes with transmission removal. Plug the fill tube hole in the main housing to keep dirt from entering the transmission. NOTE: A significant amount of fluid may drain from the hydraulic lines when they are disconnected from the transmission. • Disconnect all hydraulic lines from the transmission. Remove the lines from the vehicle if they interfere with transmission removal. Plug all openings to keep dirt from entering the hydraulic system.

2–2. DISCONNECTING CONTROLS • Disconnect the external wiring harness from the main electrical connector, three speed sensors and the NSBU switch (refer to Pages viii and ix). Prevent dirt or moisture from entering a disconnected connector. Position the wiring harness so it does not interfere with transmission removal. • Disconnect linkage from the customer-furnished transmission shift lever. Position the disconnected linkage so it does not interfere with transmission removal. Leave the shift lever and NSBU switch on the transmission. • If PTO(s) is (are) used, disconnect the PTO(s) wiring harness(es). • If parking brake is present, disconnect linkage.

17

2–3. UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE WARNING: Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary if vehicle is on a lift or jackstands. • Disconnect the vehicle drive shaft from the transmission output flange or yoke. Position the disconnected shaft to avoid interference when removing the transmission. • If PTO equipped, disconnect PTO connections such as: — PTO hydraulic hoses — PTO-powered equipment drive shaft • If transmission mountings support the rear of the engine, place a jack or other support under the engine. • Securely support the transmission with a hoist, jack, or other suitable removal equipment. • Remove all bolts, nuts, washers, spacers, and supports that attach the transmission to the vehicle and the engine. NOTE: It may be necessary to remove an engine flywheel housing access cover to remove flexplate or flexplate adapter bolts. This is the engine to transmission connection.

2–4. REMOVING THE TRANSMISSION CAUTION: Do not pull the transmission away from the torque converter assembly. The torque converter drive cover must be entirely free of any restraint by the flexplate drive or crankshaft pilot when the transmission separates from the engine. WARNING: Be sure the torque converter is moving rearward with the transmission as it is removed. Do not allow the torque converter to become disengaged from the oil pump or to fall and injure yourself or others. • Move the transmission away from the engine, approximately 34.6 mm (1.36 inch) for a number 2 flywheel housing or 44.2 mm (1.74 inch) for a number 3 flywheel housing, until it is completely clear of the engine. If used, remove the adapter ring and/or gasket. • Raise or lower the transmission as necessary to remove it from the vehicle. 18

2–5. REMOVING THE FLEXPLATE ADAPTER • Remove the flexplate adapter, if present, from the front of the torque converter. This part will be needed for transfer if a replacement transmission is being installed. WARNING: Handle the transmission carefully whenever the torque converter retaining bracket is not present. NEVER tilt the converter end down or the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing damage and/or personal injury. • Attach a torque converter retaining bracket at the earliest opportunity. The bracket keeps the torque converter from sliding out of engagement with the oil pump or from falling off completely and being damaged or causing personal injury.

2–6. REMOVING OUTPUT FLANGE OR YOKE If replacing the transmission, you may need to transfer the output flange or yoke to the replacement transmission. The output flange or yoke is retained by one 1⁄2-20 x 23⁄4 inch flanged-head bolt.

19

PREPARING THE TRANSMISSION FOR INSTALLATION

S ECTION

III

3–1. CHECKING INPUT COMPONENTS a. Bolt Holes. Check all bolt holes on the front of the transmission and rear of the engine that are used in connecting the transmission to the engine. The threads must be undamaged and the holes free of chips or foreign material. b. Pilot Boss. Check the pilot boss (at the center of the torque converter) for damage or raised metal that prevents free entry into the crankshaft hub (or adapter). c. Starter Ring Gear. Check the starter ring gear for excessive wear or damage. d. Transmission Mounting Flange. Check the transmission mounting flange for raised metal, dirt, or if used, pieces of gasket material. e. Transmission-to-Engine Mounting Flange. Inspect the transmission-to-engine mounting flange for raised metal, burrs, or pieces of gasket material (if used). Remove any of these defects. Inspect the threaded holes for damaged threads.

3–2. INSTALLING OUTPUT FLANGE OR YOKE a. Output Oil Seal. Check the output oil seal for leaks or damage. Refer to JA3664EN, In-Chassis Maintenance, for replacement instructions. If not replacing the oil seal, lubricate it with high-temperature grease or transmission fluid. b. Check Flange or Yoke. CAUTION: DO NOT attempt to polish the oil seal contact surface on the flange or yoke. Scratches or machine-type lead can cause the seal to leak. Replace the output flange/yoke if light scoring cannot be removed using crocus cloth. Check each flange or yoke for damage or wear. The oil seal contact surface must be smooth and regular to prevent oil leaking past the seal. Rotate the flange after installation to check for binding. 20

c. Install Output Flange or Yoke. CAUTION: Be sure that the flange, output shaft and retaining hardware are clean. Care must be exercised to avoid transmission output seal or journal damage. Check to be sure that the seal is free of tears and cuts. Nicks and scratches must not exist on the lead-in chamfer or seal journal section of the output flange or yoke. Lubricate the splines of the output shaft and the oil seal assembly with transmission fluid or oil-soluble grease. CAUTION: Do not use a hammer or other similar tool to force the flange/yoke onto the shaft. Forcing the flange/yoke onto the shaft may result in transmission damage. Start the yoke/flange assembly onto the output shaft, being sure that the splines are properly engaged and slide freely. Push the yoke/flange assembly into the rear cover module. Install a new output shaft sealing washer and the output shaft bolt. CAUTION: Use of an impact wrench requires the retention of the yoke/flange to prevent internal transmission damage. Tighten the output shaft bolt to 110–135 N·m (80–100 lb ft). Rotate the yoke/flange assembly by hand to check for binding, interference, and runout.

3–3. INSTALLING PTO Access to the PTO mounting pads and the space available to maneuver the transmission determine whether the PTO should be installed before or after the transmission is installed. CAUTION: DO NOT use cork or other soft gaskets to install the PTO. Use only the shims/gaskets listed in the 1000 and 2000 Product Families Tech Data Book. NOTE: DO NOT use sealing compounds—they are usually incompatible with automatic transmission fluid.

21

a. Install Guide Pins—included in the PTO manufacturers installation kit. Determine the required position of the guide pins in relation to the mounted position of the PTO. Install two headless guide pins into the converter-housing PTO pad. Tighten the pins. b. Install Gasket. Install the special gasket over the guide pins—ribbed surface away from the transmission. c. Mount the PTO. CAUTION: M10 bolts MUST be used to attach the PTO to the transmission. Inch series threads (.375-16 UNC) will damage the transmission main housing. Mount the PTO on the guide pins or studs provided in PTO kit. Mesh the PTO driven gear with the transmission PTO drive gear. Retain the PTO by installing a bolt in the top bolt hole. Install the remaining bolts and nuts, if used. When nuts are not used, two bolts replace the guide pins. Tighten all bolts to 57–68 N·m (42–50 lb ft). Tighten nuts to manufacturers specifications. Be sure that the PTO backlash meets manufacturers requirements. d. Connect PTO Lube, if required. Some PTOs require pressure lubrication. When needed, tap into the cooler return fitting or line at the transmission converter housing (see Figure 3–1). An orifice of 0.81 mm (0.031 inch) must be present in the line to control the amount of fluid diverted from the transmission. Some PTO assemblies contain internal restrictions equivalent to the required orifice (check the PTO manufacturer for lubrication needs and the orifice installation). This connection can be made later if the lube line will interfere with transmission installation. See Figure 3–2 which shows this connection schematically. MAIN PRESSURE TAP

“TO COOLER” PORT “FROM COOLER” PORT

BOTTOM VIEW

V05742.01

Figure 3–1. Cooler Port and Main Pressure Tap Location 22

“FROM COOLER” PORT PTO LUBE LINE (with 0.81 mm (0.032 in.) orifice)

COOLER RETURN OIL LINE

ENLARGED DETAIL V05816

Figure 3–2. PTO Lube Plumbing Schematic

e. Connect PTO Clutch Feed, if required. Some PTOs are clutch-applied. Use transmission main pressure from the main pressure tap for applying the PTO clutch. See Figure 3–1 for the location of the main pressure tap and Figure 3–3 for a typical plumbing schematic when this feature is needed. This connection can be made later if the clutch apply line will interfere with transmission installation.

23

EXHAUST TO TRANSMISSION THROUGH PTO

TRANSMISSION MAIN PRESSURE

MANUAL HYDRAULIC VALVE OR SOLENOID VALVE

“FROM COOLER” PORT PTO LUBE LINE (with 0.81 mm (0.032 in.) orifice) V05817

Figure 3–3. PTO Clutch Pressure Plumbing Schematic

3–4.

INSTALLING FILL TUBE AND SEAL

a. Location. The fill tube may be mounted on either the right or left side. The unused fill tube provision must have a plug in the fill tube opening. CAUTION: Install a fill tube bracket using the correct length M8 self-tapping screw which is 24.0 mm (0.95 inch). A screw that is too long may cause cracks and leaks in the main housing. Refer to AS64-065 in the Allison Sales Tech Data book for the correct screw specifications. b. Installation. If the fill tube will interfere with the installation of the transmission, delay this step until after the transmission is in the vehicle. Install the fill tube seal into the main housing. Insert the fill tube through the seal until the shoulder at the bottom of the fill tube contacts the seal. Align the tube bracket with its bolt location. Install the fill tube bolt and tighten until it is firmly seated against the bracket. 24

3–5. CHECKING PLUGS AND OPENINGS Carefully check all sides and the bottom of the transmission for loose or missing plugs. a. Main Pressure Tap Plug. Check that 0.4375–20 UNF-2A pressure plug is tightened to 10–13 N·m (7–10 lb ft). b. Fluid Drain Plug. Check that the drain plug is tightened to 25–32 N·m (18–24 lb ft). c. Tachograph Plug. If present, tighten to 60–67 N·m (44–49 lb ft). d. Cleanliness. Check the openings into which the cooler lines connect for deformities or obstructions. Check the transmission electrical connectors for cleanliness. Clean electrical connections with an LPS cleaner only (refer to Service Information Letter 17-TR-94).

25

PREPARING VEHICLE FOR TRANSMISSION INSTALLATION

S ECTION

IV

4–1. ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS You must make sure a new transmission installation can be adapted to the vehicle’s engine. Using the measurements described in this section assures correct transmission-to-engine adaptation. Refer to Figure 4–1, 4–2, or installation drawings AS64-022 and/or AS64-023 in the Allison Sales Tech Data book. Typical arrangement of adaptation components is shown in Figure 4–3. a. Measuring Equipment. The following measuring equipment is required: • 600 mm (24 inch) precision caliper • 50–100 mm (2–4 inch) telescoping gauge • 25–76 mm (1–3 inch) outside micrometer • Dial indicator and mounting attachments—base, posts, and clamps • 0–150 mm (0–6 inch) depth micrometer b. Flywheel Housing Pilot Bore Diameter. The flywheel housing pilot bore diameter must measure: • No. 3 Housing—409.58–409.70 mm (16.125–16.130 inch) • No. 2 Housing—447.68–447.80 mm (17.625–17.630 inch) c. Flywheel Housing Bore Runout. Flywheel housing bore runout cannot exceed 0.51 mm (0.020 inch) TIR. d. Flywheel Housing Face Squareness. The flywheel housing face cannot be out-of-square more than 0.51 mm (0.020 inch) TIR. e. Crankshaft Hub Pilot or Adapter Diameter. The crankshaft hub pilot or hub adapter pilot diameter must measure between 43.26–43.31 mm (1.703–1.705 inch). f. Crankshaft Hub Pilot or Adapter Squareness. The crankshaft hub or hub adapter cannot be out-of-square more than 0.013 mm (0.0005 inch) TIR per inch of diameter. g. Crankshaft Hub Pilot or Adapter Concentricity. The crankshaft hub pilot or the hub adapter pilot concentricity cannot exceed 0.25 mm (0.010 inch) TIR. 26

Figure 4–1. 1000 and 2000 Product Families Engine Adaptation (No. 3 Housing)

27

CRANKSHAFT 43.26–43.31 mm CENTERLINE (1.703–1.705 in.) I.D. PILOT ON CRANKSHAFT HUB ADAPTER

* CRANKSHAFT HUB ADAPTER

* SCUFFPLATE

* FLEXPLATE BLANK – 23045169 (No crankshaft bolt holes)

292.1 mm (11.50 in.) DIA BOLT CIRCLE

* FLEXPLATE ADAPTER 23045170

BOLT (12), M10 x 1.5 x 15 General Motors P/N 23049056 Torque to 57–68 N•m (42–50 lb-ft)

Must be maintained when installed

)

4.05 mm (0.159 in.) MIN CLEARANCE

V05821

See Drawing AS64-023 in Allison Sales Tech Data book for more information.

Converter space claim exceeds that of AT500 outside 120.4 mm (4.70 in.) diameter. When using existing AT500 flexplate adaptations, this area must be checked to ensure proper clearance.

Torques shown are for plain (non-plated) customer furnished components. Torque requirements should be reviewed if plated fasteners will be used. Consult with your fastener supplier.

Parts with asterisk ( *) are not supplied with transmission assembly

NOTES: Opening must be provided in flywheel housing for access to attach flexplates bolts

409.5 mm DIA (16.12 in.)

* MOUNTING BOLT Thread grade and torque to be compatible with engine flywheel housing. A minimum of 10 bolts is required, including the top two.

Society of Automotive Engineers (SAE) J617 standard number 3 engine flywheel housing mounting face (cast iron or aluminum) Hardened flat washer recommended (Lockwasher permissible)

49.95–50.00 mm (1.967–1.969 in.) HUB PILOT O.D. 2.54 mm (0.100 in.) MIN PILOT 4.05 mm (0.159 in.) MIN CLEARANCE

(

44.21 mm 40.15 mm 1.741 in. 1.581 in.

Figure 4–2. 1000 and 2000 Product Families Engine Adaptation (No. 2 Housing)

28

(

CRANKSHAFT 43.26–43.31 mm CENTERLINE (1.703–1.705 in.) I.D. PILOT ON CRANKSHAFT HUB ADAPTER

* CRANKSHAFT HUB ADAPTER

* SCUFFPLATE

* FLEXPLATE BLANK – 23045169 (No crankshaft bolt holes)

292.1 mm (11.50 in.) DIA BOLT CIRCLE

* FLEXPLATE ADAPTER 23045170

)

34.56 mm 30.50 mm 1.361 in. 1.201 in.

BOLT (12), M10 x 1.5 x 15 General Motors P/N 23049056 Torque to 57–68 N•m (42–50 lb-ft)

Must be maintained when installed

49.95–50.00 mm (1.967–1.969 in.) HUB PILOT O.D. 2.54 mm (0.100 in.) MIN PILOT 4.05 mm (0.159 in.) MIN CLEARANCE

V05822

See Drawing AS64-022 in Allison Sales Tech Data book for more information.

Converter space claim exceeds that of AT500 outside 120.4 mm (4.70 in.) diameter. When using existing AT500 flexplate adaptations, this area must be checked to ensure proper clearance.

Torques shown are for plain (non-plated) customer furnished components. Torque requirements should be reviewed if plated fasteners will be used. Consult with your fastener supplier.

Parts with asterisk ( *) are not supplied with transmission assembly

NOTES: Opening must be provided in flywheel housing for access to attach flexplates bolts

4.05 mm (0.159 in.) MIN CLEARANCE

447.6 mm DIA (17.62 in.)

Society of Automotive Engineers (SAE) J617 standard number 2 engine flywheel housing mounting face (cast iron or aluminum) * MOUNTING BOLT Thread grade and torque to be compatible with engine flywheel housing. A minimum of 10 bolts is required, including the top two. Hardened flat washer recommended (Lockwasher permissible)

Figure 4–3. Typical Arrangement Of Adaptation Components

29

FLYWHEEL-MOUNTED STARTER RING GEAR V05823

CONVERTER PILOT

CRANKSHAFT HUB ADAPTER

CONVERTER PILOT

CONVERTER DRIVE COVER

FLEXPLATE ADAPTER FLEXPLATE

WEARPLATE

CRANKSHAFT

FLYWHEEL/STARTER RING GEAR ASS'Y

TRANSMISSION MAIN HOUSING

CONVERTER DRIVE COVER WEARPLATE CRANKSHAFT HUB ADAPTER

FLEXPLATE ADAPTER

FLEXPLATE-MOUNTED STARTER RING GEAR

CRANKSHAFT

FLEXPLATE

STARTER RING GEAR

TRANSMISSION MAIN HOUSING

SAE # 2 OR # 3 FLYWHEEL HOUSING

SAE # 2 OR # 3 FLYWHEEL HOUSING

h. Flexplate Flatness. Flexplate flatness must be 0.76 mm (0.030 inch) TIR, or less, when measured at 292 mm (11.5 inch) diameter. i. Torque Converter Axial Location. This is controlled by the engine physical adaptation. Using a depth gauge, measure from the face of the engine flywheel housing to the face at the 292.1 mm (11.50 inch) diameter. The torque converter axial location should measure: • No. 3 Housing—40.15–44.21 mm (1.581–1.741 inch) • No. 2 Housing—30.50–34.56 mm (1.201–1.361 inch)

4–2. CHECKING FLEXPLATE DRIVE ASSEMBLY a. Flexplate Inspection. Check the flexplate for cracks, distortion, or elongated bolt holes. Replace a worn or damaged flexplate. b. Engine Crankshaft End Play. Make sure engine crankshaft end play is within the engine manufacturer’s specifications. NOTE: When assembling the flexplate to the crankshaft hub or hub adapter, make sure the outer flexplate bolt holes are aligned.

c. Flexplate Assembly Installation. Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine. Refer to Figure 4–1 or 4–2 for the proper position of an installed flexplate.

4–3. CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following conditions, and correct them as appropriate. • Transmission mounts—broken or worn-out • Bolts and other hardware—damaged, missing, or incorrect • Isolators (rubber mounts)—damaged or missing • Driveline angles—runout, or balance which does not conform to the manufacturer’s recommendations • Driveline yoke slip joints: — — — —

freedom of movement damaged or worn-out correctly lubricated correctly indexed 30

• Driveline midship or hanger bearings—damaged or misaligned • Universal joints: — freedom of movement — damaged or worn-out — correctly lubricated — correctly indexed • Vehicle differential backlash—manufacturer’s specification • Universal joint coupling—alignment and differential damage • Cross-frame members and rear support members—condition and location • PTO-driven equipment shafts and couplings—damaged or misaligned • Auxiliary transmission: — shaft alignment — alignment of yoke or flange — backlash — fluid leaks

4–4. COOLER, FILTER, AND LINES a. Inspection. Perform the following and correct any faulty conditions: • Transmission fluid cooler and related coolant lines: — Check for contamination—clean and flush as necessary — Inspect for deterioration — Inspect for faulty connectors or kinks — Clean and flush transmission fluid cooler, both coolant and oil sides. Pressure check both sides using a 276 kPa (40 psi) air supply. • Hydraulic lines: — Check for contamination—clean and flush as necessary — Inspect for deterioration — Inspect for faulty connectors or kinks

31

b. After Overhaul. A complete cleanup of the transmission system after an overhaul cannot be assumed. See JA3664EN, In-Chassis Maintenance, for cooler flushing procedure. NOTE: When equipment to flush the oil cooler is not available, install a filter in the cooler line between the oil cooler and the transmission “from cooler” port. The cooler circuit pressure drop specifications must still be met (see AS64–071 or AS 64–072 in the Allison Sales Tech Data book). Frequent initial changes of this filter element may be required as debris is flushed out of the oil cooler circuit. Closely monitoring change in cooler circuit pressure drop will indicate when a filter change is needed.

4–5. CHECKING CONTROLS a. Inspection. Inspect the following and correct any faulty conditions: • Shift selector: — improper operation — improper cable routing • Cab and chassis wiring harness: — poor connections — frayed insulation — wiring damage • Throttle sensor components, if present: — freedom of movement — improper routing — bellows damage — improper or loose cable mounting • PTO controls, if present: — damage — wear — improper operation — lubrication — electrical harness connections and wiring damage • Temperature gauge: — capillary tube damage (if used) — sensor damage 32

• Fluid pressure gauge tubing: — damage — kinks — improper routing b. Throttle Position Sensor (TPS) Adjustment. When properly installed by the equipment manufacturer, the TPS, if used, should not need adjustment. If TPS adjustment is necessary, confirm that it has been installed to ATD specification (refer to Figure 4–4). The TPS is self-calibrating and therefore has no optimum closed throttle or full throttle value. Be sure there is no misalignment or obstruction to smooth movement through the full stroke of the TPS. The Allison DOC™ for PC diagnostic tool can be used to check the TPS adjustment. See the users manual that comes with the diagnostic tool for details. Also, be sure to check for diagnostic codes (DTCs) associated with TPS function. c. Hitch-Pin Throttle Position Sensor Installation. • Install the throttle sensor body as follows: — Clamp cable end using clamp and shims (refer to Figure 4–4). — Secure the sensor body using the mounting holes provided. — Install a heat shield if any part of the throttle sensor is near the exhaust manifold, turbochargers, or any other heat source. • Adjust the throttle sensor as follows: — The engine fuel lever must be at the closed throttle position. — Install the hitch pin cable end of the sensor to the engine fuel lever with brackets so that at the idle position the cable end is 11–17 mm (0.44–0.67 inch) from its fully retracted position, and at wide open throttle the cable end is pulled an additional 15–22.9 mm (0.60–0.90 inch) from the idle position. — Recheck the stroke distance of the throttle sensor, from closed to wide open after installation is completed. Stroke distance must be from 15.2–22.9 mm (0.60–0.90 inch). — Recheck for zero clearance at the fuel lever. Make sure that the 15.2–22.9 mm (0.60–0.90 inch) dimension has not changed. — Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance bands throughout its operating life.

33

BENDING LOAD APPLIED

UNACCEPTABLE INSTALLATION MOUNTING PROVISION: Use M6 x 1.00 or 1⁄4-20 in. series bolts 3 places Torque M6 x 1.00 bolt to 10–13 N•m (84–120 lb in.) 1 Torque ⁄4-20 in. series bolts to 13–14 N•m (108–132 lb in.) Mount to a solid frame member. Flatness of chassis mounting surface must not exceed 0.8 mm (0.03 in.).

10.0° MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS LOADING IN TENSION ONLY

ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading in tension only (no bending loads).

WIRING HARNESS 55.0 mm (2.17 in.) MIN REQUIRED FOR CONNECTION REMOVAL

Fuel control must not move the throttle sensor beyond the closed throttle position at any time.

FULLY EXTENDED FORCE REQUIRED 26.7 N (6.0 LB) MAX

R 152.0 mm (6.00 in.) MIN ALLOWANCE RADIUS

FULLY RETRACTED

CLOSED THROTTLE 95.2 mm (3.75 in.)

47.5 mm (1.87 in.) FULL THROTTLE 118.1 mm (4.65 in.)

MOUNTING LENGTH (NOTE: Mounting length + 50.8 mm (2 inches) equals cable length)

OPERATING BAND 15.2 – 22.9 mm (0.6 – 0.9 in.)

118.1 mm (4.65 in.) 95.2 mm (3.75 in.)

The location of the clamping bracket relative to the fuel lever at closed throttle must be maintained within this range.

93.45 mm (3.679 in.) 87.15 mm (3.431 in.)

30.2 mm (1.19 in.)

Attach to engine or governor housing using clamp and shims as required. Clamp must positively lock in cable groove.

HITCH PIN CLIP

Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle position when sensor rod is maintained at full throttle position. Attach the throttle sensor directly to the engine fuel lever with no breakover or yield linkages between the engine fuel lever shaft and the attachment point of the throttle sensor.

ENGINE FUEL LEVER

CLOSED THROTTLE

183.1 mm (7.21 in.) MAX

FULL THROTTLE 160.2 mm (6.31 in.) MIN

SAME AS WITHOUT SLIP LINK FULLY EXTENDED

38.1 mm (1.50 in.)

HITCH PIN CLIP FULLY RETRACTED

OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430.06

Figure 4–4. Hitch-Pin Throttle Position Sensor Installation Diagram

34

S ECTION

V

INSTALLING TRANSMISSION INTO VEHICLE

5–1. HANDLING a. Preventing Damage. Carefully handle the transmission to prevent damage to components in the installation path. b. Control of Transmission Movements. Use a hoist or transmission jack that allows precise control of transmission movements during installation.

5–2. MOUNTING TO ENGINE Use the following procedure to mount the transmission to the engine: WARNING: Handle the transmission carefully whenever the torque converter retaining bracket is not present. NEVER tilt the converter end down or the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing damage and/or personal injury. • Inspect the flexplate adapter, if used, for cracks or other damage and replace it when these conditions are found. • Remove the torque converter retaining bracket just before the transmission is ready to be installed in the vehicle. • Attach the flexplate adapter to the front of the torque converter or to the flexplate using six new adhesive-coated M10 x 1.5 x 15 bolts. Tighten each bolt to 57–68 N·m (42–50 lb ft). • Align one of the flexplate’s bolt holes with the access opening in the engine flywheel housing. • Lubricate the center pilot boss with molybdenum disulfide grease (Molycote G, or equivalent). • Install an M10 x 1.5 headless guide bolt into one of the flexplate bolt holes in the flexplate adapter or torque converter mounting lug (see Figure 5–1). Align the guide bolt with the flexplate hole at the access opening. 35

FLYWHEEL HOUSING GUIDE BOLT

Make from M10 x 1.5" bolt

TAPER Screwdriver slot to aid removal

V05824

Figure 5–1. Pilot Tool For Transmission-To-Engine Alignment

• Push the transmission toward the engine while guiding the pilot boss on the torque converter into the flexplate hub adapter or flywheel, and the guide bolt into the hole on the flexplate (a headless guide bolt in the engine flywheel housing may also aid in the transmission installation). • Seat the transmission squarely against the engine flywheel housing—no force is required. If interference is encountered, move the transmission away from the engine and investigate the cause. • Align the bolts holes in the converter housing with those in the engine flywheel housing. • Install all transmission-to-engine bolts and washers finger tight (a minimum of 10 bolts is required and must include the top two). CAUTION: The entire converter housing circumference must be flush against the engine flywheel housing before tightening any bolts. DO NOT use the bolts to seat the housing. • Tighten four bolts at equally-spaced intervals around the converter housing bolt circle. Use the torque specified by the engine or vehicle manufacturer. • Remove the flexplate guide bolt through the engine flywheel housing access opening. Replace it with a self-locking bolt. Tighten the bolt finger tight. 36

NOTE: DO NOT tighten any flexplate-to-flexplate adapter bolts until all of the bolts have been installed and tightened finger tight.

• Rotate the engine crankshaft to install the remaining new adhesive-coated bolts into the flexplate adapter. After all bolts have been installed finger tight, tighten the bolts to 57–68 N·m (42–50 lb ft). • Install the flywheel housing access cover, if used.

5–3. INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION: Use the type and grade of mounting bolts recommended by the vehicle manufacturer. • Install all bolts, washers, spacer, isolators, or supports required to support the transmission in the vehicle frame. • Tighten the bolts to the torque values recommended by the vehicle manufacturer.

5–4. COUPLING TO DRIVELINE • Couple the driveline companion flange or universal joint yoke to the flange or yoke on the transmission. Use the bolts and torque values recommended by the vehicle manufacturer. • Check the universal joint angularity of all U-joints in the driveline. Determine if they are within specification.

5–5. CONNECTING POWER TAKEOFF CONTROLS If not already mounted, mount the PTO(s) onto the transmission—refer to Paragraph 4–3. • Check the PTO harness routing for kinks and sharp bends. Avoid routing the cable close to exhaust pipes or manifold. The PTO harness must not rub or interfere with adjacent parts. • Connect controls to the PTO. • Check for proper PTO control operation. 37

CAUTION: PTO units using transmission main pressure to engage the PTO gear must have a positive main pressure shut-off at the solenoid valve when the PTO is not engaged. Failure to provide this feature may cause inadvertent clutch apply and PTO damage. • Couple the PTO output to its driven equipment. Check couplings or universal joints for correct assembly and alignment. If the driven component is not a direct mount arrangement, check the PTO drivelines for angularity, phasing, and offsets.

5–6. CONNECTING PARKING BRAKE CONTROL • Connect and properly adjust the parking brake. • If present, adjust the brake shoe-to-drum clearance as specified by the manufacturer.

5–7. CONNECTING COOLER Figure 5–2 shows typical cooler port locations on the transmission. Consult AS64-071 (in Allison Sales Tech Data book) for cooler fitting torque values. \

MAIN PRESSURE TAP

“TO COOLER” PORT “FROM COOLER” PORT

BOTTOM VIEW

V05742.01

Figure 5–2. Cooler Port Location

• Remove the cover from the main transmission electrical connector and carefully connect the transmission external wiring harness. Keep dirt and debris out of the connector. 38

• Connect the external wiring harness to the engine, turbine, and output speed sensors. • If used, connect the PTO(s) connector(s). The PTO connector is NOT part of the Allison Transmission external wiring harness. • If used, connect wire(s) to electric tachograph. • Make sure the speed sensors, the PTO connector, and all other connectors are securely seated and latched. A connector can be heard or felt to latch, but confirm the latching by pulling on the connector—NOT THE WIRES. • The transmission has a sump fluid thermistor on the pressure switch manifold. Actual temperature readings may be made using the PC-based diagnostic tool. Consult the users manual furnished with the Allison DOC™ diagnostic tool. • A temperature gauge may be installed in the “To Cooler” line. If equipped for them, install a temperature probe—capillary tube and bulb or a thermocouple. If equipped with a capillary tube and bulb: — Tighten the adapter tight enough to prevent leakage. — Install the bulb into the adapter and tighten the nut. — Check the capillary tube for interference with other parts that might chafe or damage the tube. Long tubes may require support clips or brackets. If equipped with a thermocouple: — Install the thermocouple and connect the leads.

5–8. CONNECTING CONTROLS • Remove any protective covering from the wiring harness connectors. Connect the external wiring harness to the main electrical connector, the three speed sensors and the NSBU switch (refer to Pages viii and ix). • Connect linkage to the transmission shift lever. For information on adjusting the NSBU switch or the shift linkage, see JA3664EN, In-Chassis Maintenance. • If PTO(s) is (are) used, connect the PTO(s) wiring harness(es). • If parking brake is present, connect linkage.

5–9. FILLING HYDRAULIC SYSTEM • Check that all unused hydraulic openings are plugged. • Fill the transmission with the required amount of Allison-approved DEXRON®-III fluid—refer to Paragraph 1–5 and 1–8. • Run the engine for about one minute and check the fluid level—refer to Paragraph 1–3. 39

5–10. INSTALLATION CHECKLIST Use this list after transmission installation. As items are checked, mark them off this list.

• Torque Values:

❑ All oil pan bolts—24–29 N·m (18–21 lb ft) ❑ Main pressure tap—10–13 N·m (7–10 lb ft) ❑ Cooler fittings — ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑

0.750-16 (inch series), 20–30 N·m (15–22 lb ft) 1.0625-12 (inch series), 34–47 N·m (25–35 lb ft) Cooler manifold bolts—20–34 N·m (15–25 lb ft) Flexplate adapter-to-converter cover bolts—57–68 N·m (42–50 lb ft) Flexplate-to-crankshaft hub bolts—Consult Engine Manufacturer Specifications Flexplate-to-flexplate adapter bolts—57–68 N·m (42–50 lb ft) Fluid drain plug—30–40 N·m (22–30 lb ft) Fluid fill tube bracket bolt—Firmly seated against bracket Speed sensor bolts—10–13 N·m (7–10 lb ft) Output flange bolt—108–136 N·m (80–100 lb ft) PTO cover bolts—51–61 N·m (38–45 lb ft) PTO mounting bolts—51–61 N·m (38–45 lb ft) NSBU switch to main housing—24–29 N·m (18–21 lb ft) Selector lever nut (customer-supplied)—20–27 N·m (15–20 lb ft) PTO pressure hose to transmission—10–13 N·m (7–10 lb ft) Rear cover bolts—51–61 N·m (38–45 lb ft) TPS to engine bracket (M6 bolts)—10–13 N·m (7–10 lb ft) (0.250-20 bolts)—12–15 N·m (9–11 lb ft)

• Cooler Fluid Lines and Air Hose for:

❑ No leaks ❑ Connection tightness ❑ Correct routing • Throttle Sensor for:

❑ Proper adjustment ❑ Correct routing of cable and harness 40

• Driveline for: ❑ Proper indexing of universal joints

❑ Proper drive shaft angles ❑ Driveline backlash ❑ Lubricated universals and slip-joints • Hydraulic System for: ❑ Recommended fluid—TranSynd™

❑ ❑ ❑ ❑ ❑ ❑

Correct fluid level in transmission Dipstick correctly calibrated—refer to Figure 1–1 Fill tube tight Fill tube cap tight Breather clean and free of restrictions No fluid leaks during operation

• Instruments and Electrical Equipment for: ❑ Proper wiring and electrical connections

❑ Instruments, gauges, and lights work correctly ❑ Shift selector display is on and CHECK TRANS light is off ❑ Fluid temperature gauge • Power Takeoff—if installed—for: ❑ Controls connected and operative

❑ Correctly coupled to driven equipment ❑ Lubrication line correctly installed and routed—if used ❑ Clutch apply line correctly installed and routed—if used

41

5–11. ROAD TEST AND VEHICLE OPERATION CHECKLIST NOTE: Refer to the latest edition of the 1000 and 2000 Product Families transmission Operator’s Handbook for operating instructions. Refer to Section VI for the latest publication number.

a. Driveability Drive-away checks are performed to verify proper transmission and support equipment installation and operation. The following steps outline drive-away check procedures: • Check Fluid—fill the transmission with appropriate fluid. • Start the Vehicle—check for proper system response during start-up — Turn on the vehicle’s master/ignition switch. — The CHECK TRANS light should come on. — Start the engine. — The CHECK TRANS light should go off. • Clear Trouble Codes—during installation, it is common for “false” codes to be stored in the electronic control’s TCM. These codes must be cleared prior to road testing the vehicle. Refer to Allison DOC™ users manual for details. • Road Test the Vehicle—allow the electronic control time to “converge” shifts. • Check for Proper Operation—check all components for proper mounting and operation, and check for transmission fluid leaks at gasket surfaces, lines, and hoses. • Re-check for Trouble Codes—use the Allison DOC™ diagnostic tool to determine if codes were set during the road test. See Allison DOC™ users manual for details. • Troubleshoot—if codes exist after the road test, problems must be found and corrected. Refer to TS3192EN, 1000 and 2000 Product Families Electronic Troubleshooting Manual. b. Service and Maintenance. Following an initial unit-exchange program, refer to the 1000 and 2000 Product Families Service Manual (SM3191EN) for detailed transmission service and maintenance instructions (available late 1999). 42

c. Road Test Checklist. Complete the following check list. • Neutral Start Circuit:

❑ Starts only in N (Neutral) or P (Park) • Instruments:

❑ ❑ ❑ ❑ ❑

CHECK TRANS light Transmission fluid pressure gauge—if used Speedometer Temperature gauge—if used Reverse warning system—if used

• Transmission Fluid:

❑ Fluid level meets specifications—cold, neutral, level ❑ No leaks ❑ Warm-up and check fluid level—hot, neutral, level • No-Load Governed Engine Speed:

❑ No-load governed speed of engine ❑ Adjust governor as necessary—refer to the manufacturer’s specifications for the engine-transmission being tested. • PTO—if installed:

❑ PTO operation—Refer to the 1000 or 2000 vocational model specific operator’s manual (see Section VI for the latest publication number). • Shift Sequence:

❑ Transmission upshifts and downshifts smoothly through all ranges • Other Checks:

❑ Stall test (must only be performed by qualified service technician) ❑ Shift quality • Comments: _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ 43

S ECTION

CUSTOMER SERVICE

VI

6–1. OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product. Any situation that arises in connection with the sale, operation, or service of your transmission will be handled by the distributor or dealer in your area. Technical support is available from the Technical Assistance Center (TAC) by telephone at 1-800-252-5283. Refer to the Allison Transmission website www.allisontransmission.com or to the Worldwide Sales and Service Directory SA2229EN for a current listing of Allison Transmission authorized distributors and service dealers.

6–2. SERVICE LITERATURE This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. For maximum performance and service life from your unit, see your dealer or distributor for the following publications. Check the telephone directory for the Allison Transmission service outlet nearest you. Table 6–1. 1000 and 2000 Product Families Service Literature

Service Manual *Parts Catalog Electronic Troubleshooting Manual Principles of Operation *EVS Operator’s Manual *HS Operator’s Manual *RDS Operator’s Manual *MHS Operator’s Manual *PTS Operator’s Manual *BUS Operator’s Manual *In-Chassis Maintenance *1000, 2000, 2400 Operator’s Manual

SM3191EN PC3062EN CD3062EN TS3192EN PO3065EN OM3761EN OM3757EN OM3759EN OM3364EN OM3758EN OM3765EN JA3664EN OM3063EN

* Also Available On The Internet At www.allisontransmission.com

44

NOTES

45

NOTES

46

MT3190EN 200403

www.allisontransmission.com

Printed in USA 200405

Halvorsen Section 4. Axles and Steering

KESSLER & CO., OFF-HIGHWAY AXLE DIVISION SERVICE MANUAL - JBT ML 42K4P (41.3485.3) Drive and Steer Axle DANFOSS HYDRAULICS SERVICE MANUAL (HN.21.AD.02) Hydrostatic Steering Unit OSPB/OSPC SPARE PARTS (HN.21.UA.52) Danfoss Steering Units OSPB/OSPC/OSPL/OSPD/OSPQ/OSPF

AXLES AND STEERING

5-4 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Service-Manual JBT ML 42K4P (41.3485.3)

Version 04/2012 Original

Service Manual                                    

© Kessler & Co. GmbH & Co.KG  All rights reserved   

 

                                                                                       

Copyright © Firma Kessler & Co. GmbH &Co.KG

Reproduction and dissemination of this documentation in any form (photocopying, printing or electronic dissemination) is prohibited without the written permission of Kessler & Co. GmbH & Co.KG.

   

This documentation is not subject to revision. We reserve the right to make modifications without prior notice.

   

© Kessler & Co. GmbH & Co.KG  All rights reserved   

08.06.2011 

Service Manual                                    

© Kessler & Co. GmbH & Co.KG  All rights reserved   

 

Table of contents

1

Important remarks

2

Lubrication intervals and maintenance instructions

3

General instructions for correct assembly and disassembly Service tools

4

Assembly drive assembly

5

Assembly hub assembly

6

Assembly panetary gear drive

7

Assembly service brake

8

Assembly parking brake

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

Important remarks

Service Revised 01.09.2007

Section

Important remarks

1.1

For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as:

•

Wheel nuts

•

Nuts of axle mounting bolts

•

Bolts on the steering components and the brake system parts; if the screws are tightable, the Loctite contact breaks loose and remounting is necessary.

•

Corrosion and cracks on the carrier elements (such as the axle spindle) are not acceptable for operational safety reasons.

•

Verify seals, oil levels and lubrication at regular intervals.

Brakes

•

Inspect brake lining and brake drum / brake disc regulary as well as wear of brake system parts.

•

Inspect the free movement of brake system rods.

•

In case of signs of excessive heating, consult a brake specialist or the manufacturer.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 31.05.2010

Section

Instructions for ordering spare parts

1.3

We only accept liability for the original spare parts supplied by ourselves. We express clearly that the utilisation of other parts than the form us prescribed original spare parts, can change infavourably the characteristics of the axle prescribed by the construction and that thereby the safety can be affected. For damage caused by the utilisation of not original spare parts and accessories, any liability of the Kessler & Co. GmbH & Co.KG is excluded. Please bear in mind that special manufacturing and delivery specifications apply to own as well as to foreign parts and that we always offer spare parts to the up - dated technical conditions and the up - dated legal prescriptions.

When ordering Kessler spare parts, please furnish the following information: 1. Order number (installation drawing no.) → see identification plate 2. Fabrication number → see identification plate 3. Vehicle producer 4. Description of the spare part 5. Spare part number (drawing - resp. DIN no.) 6. Number of pieces 7. Kind of delivery

In case of doubt, consult Kessler & Co. GmbH & Co.KG.

For major repairs or overhaul, it is recommendet that the complete axle assembly be returned to Kessler & Co. GmbH & Co.KG.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 31.05.2010

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

Lubrication intervals and maintenance instructions

Service Revised 28.03.2011

Section

General lubrication instructions

2.1

Lubrication points

see sheet 2.2 resp. installation drawing.

Lubricants

see sheet 2.3

Fill levels

Are checked at the level control plugs.

Oil change

Place the vehicle in a horizontal position. Draining of the oil is to be accomplished only in warm condition. Clean all lubrication points before opening them. Open the drain holes on the carrier assembly, on the wheel assemblies, and if present, on the interaxle differential and drop gear housing. On the hub assemblies, the drain plug should be turned downward. Oil draining Replacement of the oil draining plugs. Remove the oil filler plug as well as the oil level control plug on the carrier assembly, on the wheel assembly, and, if present, on the interaxle differential and drop gear housing. (See sheet 2.2 → lubrication points). Oil filling Check the oil level at the oil level plug hole (Overflow control). Wait a few minutes. If the oil level falls, add oil until the level remains constant. Clean the grease nipples before lubrication.

Lubrication intervals

see sheet 2.3

Important! On the axles with self locking differentials, a noise is produced if normal oils are used. In case of abnormal noises and in case of a jerky roll off of the tyres, use gear oil EP with additives of the “Limited Slip” type conforming to specification M 2C - 104 A. In case of prolonged non - operation of the vehicle, it is recommended to start - up and operate all of the parts of the gear train every 6 months. For this purpose, maintain the proper oil level which also protects the axle against water intrusion.

The surfaces of the brake areas are to be preserved in humid locations. On start - up, a break - in of the braking system by intermittent operation is indispensable.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 09.06.2010

Section

Lubrication points

2.2.1

The binding lubrication points have to be taken from the according installation drawing of the axle.

Single drive assembly

*The position is dependent from the respective axle version.

Drive assembly with throughdrive

*Version with interaxle differential. Fill 1,5 litre oil at *I for first - time filling and for refilling!

Drop gear D51 / D108

*II – only at version with separately oil space.

Cardan shaft intermediate bearing

I = Oil fill plug II = Oil level control plug

© Kessler & Co. GmbH & Co.KG All rights reserved

III = Oil drain plug IV = Grease nipple

Service Revised 31.05.2010

Section

Lubrication points

2.2.2

Hub assembly with planetary gear drive

Lubrication points at universal joint and brake shaft. (If not maintenance - free)

Hub assembly with wet disc brake

Tumbler bearing

I = Oil fill plug II = Oil level control plug

© Kessler & Co. GmbH & Co.KG All rights reserved

III = Oil drain plug IV = Grease nipple

Service Revised 01.09.2007

Section

Lubricants and lubrication intervals

2.3

Lubrication point

Drive assembly Wheel hub planetary gear drive Interaxle differential Drop gear/ Gear boxes Wheel bearing oil lubricated Multi disk parking brake

Lubricant

Hypoid – gear oil per MIL-L – 2105 B / API GL 5 Hypoid – gear oil in multi – range characteristic per MIL-L – 2105 C / D / API GL 5 SAE 90 or multi grade oils for normal external temperature SAE 75 W – 90; SAE 75 W – 85 for external temperature lower – 10°C

Remarks

Lubrication intervals 1.)

Oilchange

Check oil level at control points monthly

SAE 140 or multi grade oils for external temperature over + 30°C

Hydraulicoil ISO VG 32

Oilchange wet running

Cardan shaft intermediate bearing Steering knuckle bearing

Fuchs Renolit LX-NHU 2

if provided for

Steering knuckle bearing

Multi – use grease lithium saponified groove penetration per NLGI 2

Universal joint Track rod Steering cylinder -ball head/ -spherical plain bearing

every

every

min.

min.

500Bh

1000Bh

1x

1x in

1000Km

5000Km

10000Km

Year

2 Years

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

f. e. Fuchs Renolit MP 150

pinion bearing

if provided for

⊕

⊕

if provided for

⊕

⊕

if provided for

⊕

⊕

if grease lubricated

⊕

Attention!

2.)

Brake shoe bearing

Attention!

2.)

if grease lubricated

Wheel bearing see chapter -7-

⊕

maintenance reduced

Brake shaft bearing

Wet disc brake

after 100Bh

external cooled

oilchange not external cooled

oilchange

⊕

⊕

Lightly greased at brake shoe new assembly Change grease at wheel hub disassembly

⊕

dependent on tank volume / cooling system / operation conditions

⊕

⊕

⊕

(Bh = Hours of operation) 1.) Whichever occurs first. 2.) The bearing point is to be lightly lubricated only, to avoid the penetration of grease in the interior of the brake (use only hand operated grease gun and remove surplus grease!). Check regularly the brake shafts and if need correct the lubrication intervals (danger of overheating!) © Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 31.05.2010

Section

Recommendable hypoid gear oils corresponding MIL-L 2105 B/API GL 5 resp. MIL-L 2105 C/D/API GL 5

2.3.1

ARAL - Gearoil Hyp 90

AVIA - Gearoil Hypoid 90 EP

BP - Multiuse - Gearoil EP SAE 90

ELF - Tranself Typ B 90 / Tranself Typ B 80 W - 90

ESSO - Gearoil GX - D 90

FINA - Pontonic MP SAE 85 W - 90

FUCHS - Renogear Hypoid 90

MOBIL - HD 90 - A

SHELL - Spirax MB 90 / HD 90

TEXACO - Multigear EP SAE 85 W / 90

AGIP - Rotra MP / Rotra MP DB

On no account use “normal” gear oils!

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 28.03.2011

Section

General maintenance instructions

2.4

Check - and maintenance points

Remarks

Maintenance intervals 1.) after

after

every

every

min.

50Bh

100Bh

500Bh

1000Bh

1x

500Km

1000Km

5000Km

10000Km

Year

Wheel bearing

Inspect, if necessary readjust wheel bearing

Wheel nuts

Check and tighten with a torque wrench (after tire change after 50km and 200km)







Castle nuts/track rod Screws/drive flange Nuts/axle mounting bolts

Check and retighten (Verify the adjustment)







Brakes (see also chapter 7)

Check lining wear, if necessary readjust, control the proper operation of the brake shafts



Wet disc brake

Check lining wear

Wet disc brake spring load design

Check lining wear

Steering - and trackrod lever

Check and retighten mounting bolts )

Bolted connections

Check from time to time

(for example drive assembly)







monthly

  

 

Ring gear support bolt on drive assembly

Readjust (if necessary)

Seals

Check from time to time

monthly

Differential lock

Check function and the automatic return in original position

monthly



(Bh = Hours of operation) *) If the bolts are moving (Loctite brakes loose), the lever has to be mounted once more. 1.) Whichever occurs first.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 28.03.2011

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

 General assembly /disassembly instructions  service tools

Service Revised 08.03.2012

Section

General instructions for correct assembly and disassembly

3.1

• The assembly is to be accomplished only by trained personnel. • The disassembly can be made reverse to the respective assembly instruction. • Drain oil before removing, check for presence of metal particles. • Mark the parts to each other before dismantle. • Never use a hard objekt to separate tightly fitted assemblies. To remove bearings, drive flanges and similair parts, use the proper pullers. • It is recommended that the special tools according 3.6 used for disassembly. • Do not place parts on a dirty surface. • Systematically replace used seals, O - rings and if need bearings on disassembly. • Clean parts before reassembly. • Replace or clean corroded parts. • Replace carrier elements with cracks! • The cages of bearings rotating in oil are to be coated with oil at reassembly. • Seal ring treads on flanges, shafts etc. must be preserved with Castrol Rustilo DWX 32 before mounting. • Oil seal rings and particularly the anti - dust lip seals must be filled with grease. • The universal joint shafts and the axle shafts must not be force mounted (they must slide). • At mounting of radial seal rings pay attention that there is suffice overlap to the housing bores. Pay attention for a plain alignment of the radial seal ring. The seal lips always must not be contacted with Loctite! • The bolted or keyed assemblies safeties are to be checked according to instructions; in case of doubt, consult Kessler & Co. • Refill the oil after assembly! • Repair weldment is only allowed after consultation with Kessler & Co!

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.06.2010

Section

Using of Loctite and operating supplies

3.2.1

1. LOCTITE

2. EPPLE

Type

Colour

Application

243

blue

Lightly locked screws

262

red

Middle locked screws

270

green

Highly locked screws

270

green

Increased coefficient of friction in contact surfaces

510

orange

Surface gasket

572

white

Special gasket

638

light-green

Glueing with big width of slit

5926 and 209 125

blue

Surface gasket

33

grey

Surface gasket

grey

Elastic gasket

3. DIRKO

Remarks for working up Loctite and operating supplies • Threads and surfaces have to be cleaned and free from colour, oil and grease before applying Loctite. • Loctite will harden under following conditions: - Exclusion of air - Metal contact - Increased temperature • Pre - assembly and control tightening has to be made in a short time (5 to 10 min.). • The time between glueing and mounting of the parts should be shorter than 1h. Exception: parts made from nonferrous metal have to be glued within one minute. • Assembled parts must remain unloaded for at least 24 hours. • Loctite quantity at screws:

1 bead

At contact surfaces: Pay attention for a sufficient Loctite application

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.06.2010

Section

Use of Loctite and operating supplies

3.2.2

Hub assembly Safety blocked parts

Joint

Spacer ring

Contact surface

572

-

Axle spindle

Screws

262

-

Axle spindle

Contact surface

270

-

Grommet

in planetary housing

270

-

Disc

in axle spindle

270

-

Adjusting screw with nut

in planetary housing

270

-

Support

Screw

262

-

Ring gear retainer

Screws

270

-

Pol wheel

Contact surface

638

-

Steering lever Track rod lever

Screws

262

-

Steering lever Track rod lever

Contact surface

270

-

Wheel hub cover

Thread

572

-

Contact surface

572

-

Contact surface

270

-

Radial seal rings Rubber casing Radial seal rings Steel casing

Loctite Operating supplies

Wheel safety nut → see chapter 5 → Adjustment of wheel bearings

© Kessler & Co. GmbH & Co.KG all rights reserved

Service Revised 01:09:2007

Section

Use of Loctite and operating supplies

3.2.3

Drive assembly Safety blocked parts

Joint

Loctite

Operating supplies

Drive flange

Nut surface

-

Epple 33 alternative Dirko grey

Diff-housing

Screws

262

-

Contact surface

572

-

Contact surface

510

-

Drop gear housing

Contact surface

510

-

Diff.carrier

Contact surface

-

Epple 33 alternative Loctite 5926 and 209125

Through drive cover

Contact surface

510

-

Differential strap

Screws

262

-

Adjustment nut screw

Screw

270

-

Ring gear

Screws

262

-

Ring gear

Contact surface

270

-

Ring gear support

Cap

270

-

Ring gear support

Thread

-

Epple 33 alternative Dirko grey

Shifter cylinder (Diff-lock) Diff.carrier (Through drive)

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.06.2010

Kapitel

Tightening torques (Nm)

3.3

General instructions for tightening torques

 = 0,14

All tightening torques are rated in Nm.

Tolerance of the tightening torques is

±5%

(assuming a manually operated torque spanner is used)

Tightening torque of metric coarse-pitch thread

Thread M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30

© Kessler & Co. GmbH & Co.KG All rights reserved

Screw

Nut

Screw

Nut

Screw

Nut

8.8

8

10.9

10

12.9

12

3,0 5,9 10 25 49 85 135 210 300 425 580 730 1100 1450

4,4 8,7 15 36 72 125 200 310 430 610 830 1050 1550 2100

5,1 10 18 43 84 145 235 365 500 710 970 1220 1800 2450

Service Revised 05/03/2012

Kapitel

Tightening torques (Nm)

3.3

Tightening torque of metric fine pitch thread Thread M8x1 M 10 x 1 M 10 x 1,25 M 12 x 1,25 M 12 x 1,5 M 14 x 1,5 M 16 x 1,5 M 18 x 1,5 M 20 x 1,5 M 22 x 1,5

Screw

Nut

Screw

Nut

Screw

Nut

8.8

8

10.9

10

12.9

12

27 55 52 93 89 145 225 340 475 650

39 81 76 135 130 215 330 485 680 920

46 95 90 160 155 255 390 570 790 1050

Thigtening torque for galvanized bolts and nuts! Regard reduced thightening torque for galvanized bolts and nuts!

Tightening torque for brake caliper dowel screws (greased !) M 20 x 1,5 M 27 x 2

400 + 100 900 + 100

Tightening torque of the nut for steering stop 300

Approximate value for the thigthening torque for screw plug Thread M14x1,5

© Kessler & Co. GmbH & Co.KG All rights reserved

Tightening torque

Tightening torque

(Approximate value) ca. 45

(Screw plugs with O-Ring) 45

M16x1,5

ca. 60

-

M22x1,5

ca. 100

100

M24x1,5

ca. 120

-

M30x1,5

ca. 160

-

M42x1,5

ca. 260

-

M45x1,5

ca. 280

-

Service Revised 05/03/2012

Section

Tightening torques of wheel nuts

3.4

Wheel nut with spring lock

Wheel nut with clamp

Wheel nut with thrust collar

washer

(for clamp fixation)

(for rims with centerring)

Wheel nut with spring lock washer

Dimensions

Phosphourus darkened

Galvanized

M 18 x 1,5

270 Nm

250 Nm

M 22 x 1,5

450 Nm

350 Nm

Wheel nut with thrust collar

Dimensions

Phosphourus darkened

M 22 x 1,5

650 Nm

Wheel nut with clamp

Dimensions

Galvanized

M 18 x 2

350 Nm

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Tightening torques for castle nuts and adjusting nuts

3.5

Tightening torques for castle nuts on ball joints for track rods and ram cylinders

Cone size

Thread

Torque

d1 (mm)

d2 (mm)

(Nm)

26

M 20 x 1,5

200 - 220

30

M 24 x 1,5

280 - 300

32

M 27 x 1,5

290 - 320

38

M 30 x 1,5

340 - 360

45

M 39 x 1,5

410 - 430

The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality S6.

Tightening torque of the adjusting nut resp. slotted nut at flanges resp. gearwheels ect.

© Kessler & Co. GmbH & Co.KG All rights reserved

Thread

Torque

d1 (mm)

(Nm)

M 24 x 1,5

360

M 30 x 1,5

450

M 36 x 1,5

540

M 42 x 1,5

850

M 45 x 1,5

850

M 48 x 1,5

850

M 52 x 1,5

950

M 64 x 1,5

1050 - 1100

Service Revised 01.09.2007

Section

Service tools

3.6.1

When ordering service tools please provide order number (installation drawing no.), resp. fabrication number → see identification plate. (The illustrations are not binding for the design).

Spanner for wheel safety nut

Spanner for splined nut (hub assembly)

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Service tools

3.6.2

Seal ring sleeve driver

Spanner for thread rings (Differential bearing)

Spanner for counter nut (Planetary gear drive)

Assembly cone for o - ring (Differential lock)

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Service tools

3.6.3

Assembly sleeve for piston (Differential lock)

Assembly sleeve for piston (Differential lock)

Sleeve driver for universal joint bearing (Needle bearing / bearing bushing)

Sleeve driver for bearing bushings (Steering knuckle bearing)

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Service tools

3.6.4

Puller for universal joint bearing (Needle bearing / bearing bushing)

Device to press in king pins

Hydraulic device to press in king pins

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Service tools

3.6.5

Mechanical puller for king pins

Hydraulic puller for king pins

Screw spindle for king pin pullers

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

Assembly of drive assembly

Service Revised 01.09.2007

Section

Adjustment of gear meshing of Gleason gears

4.0.1

It is only possible to achieve a perfect gear meshing, if the fabrication number of the drive pinion (marked on the end face) and the ring gear (marked on the circumference) are corresponding.

Perfect marking.

The following figures show improper gear meshing marks of the ring gear. The text alongside gives the corrections to obtain correct gear meshing. The dark colored arrows in the sketch of the drive pinion and ring gear indicate the direction towards which the drive pinion has to be moved. The clear arrows indicate the direction towards which the ring gear has to be moved, to get further more a correct backlash. Gear meshing too deep. Increase the drive pinion distance by correction of the adjustment disc thickness. Regulate the backlash by inwards moving of the ring gear.

Gear meshing too high. Decrease the drive pinion distance by correction of the adjustment disc thickness. Regulate the backlash by outwards moving of the ring gear.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Securing of the striking nut

4.0.2

The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bended on the slot ground.

Use of Loctite and other operating supplies

1. Striking nut at drive flange •

In thread: assembly paste with MoS2 (exception: through drive pinion see point 2).

•

Front side contact surface: sealing compound (Epple 33 or equivalent).

2. Striking nut at through drive pinion •

In thread: Loctite 262.

3. Striking nut at gear wheels, bearings etc. •

In thread: assembly paste with MoS2.

Removing of the striking nut

Bend away the nose and screw the nut off.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Drive assembly D 41 Hy

4.2

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Adjustment of drive pinion distance

4.2.1

To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disc. The necessary thickness of the adjustment disc for first time assembly can be obtained by measurement (see calculation example).

The final thickness of the adjustment disc can be fixed during the checking of gear meshing at the assembled drive assembly (see page “Adjustment of gear meshing of Gleason gears”) (S theor. = 3 mm). *) A = Set value for correct pinion support. This dimension is writed on the end face of the pinion in millimetre. It indicates the deviation from the theoretic distance (set point dimension). **) B = Measured width of the taper roller bearing (B theor. = 27,25 mm). Calculation example to ascertain the thickness S from the adjustment disc: A = + 0,10; B = 27,20 S=

3,00 mm (theor.) + 0,05 mm → B = 0,05 mm smaller than B theor. = 3,05 mm - 0,10 mm → drive pinion value A = 2,95 mm → necessary thickness of the adjustment disc

Fit corresponding disc and outer rings of the taper roller bearings. *) Hint: if value A is positive (e.g. + 0,1) the adjustment disk has to be 0,1 mm thinner than theor. S. If value A is negative (e.g. – 0,1) the adjustment disc has to be 0,1 mm thicker than theor. S. **) Hint: if value B is positive (e.g. 27,30) the adjustment disc has to be 0,05 mm thinner than theor. S. If value B is negative (e.g. 27,20) the adjustment disc has to be 0,05 mm thicker than theor. S.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the drive pinion bearing

4.2.2

1. Insert the two outer rings of the taper roller bearings into the differential carrier. 2. Calculate the thickness C of the spacer disc. a. Place the two inner rings of the taper roller bearings in their outer rings. Measure A. b. Measure the dimension B of the roller bearing. c. Measure the dimension D of the spacer bushing. d. Thickness of the spacer disk C = A - B - D. 3. Heat the drive pinion side taper roller bearing to about 100°C and install it on the drive pinion shaft. (Drive on completely after it cools). 4. Install the spacer bushing and the spacer disc on the pinion shaft. 5. Install the drive pinion into the differential carrier. Heat the taper roller bearing inner ring at undersize to about 100°C and install it with a tube onto the drive pinion shaft. 6. Install the drive flange onto the drive pinion shaft. Tighten the safety nut according sheet 3.5. For tightening fix the differential carrier and block the drive flange. 7. Measure the roll resistance of the bearings by using a torque wrench. If the measured value is not the prescribed 0,8 to 1,5 Nm, adjust the resistance by modification of the thickness of the spacer disc. After arriving at the adjustment of the bearing, back - off the safety nut and draw off the drive flange. 8. Install the radial seal ring with Loctite 572 applied. Fill the radial seal ring with bearing grease. Slip on the drive flange, screw on the safety nut with sealing compound between the contact surfaces. Tighten the safety nut according sheet 3.5. Lock the nut by striking the nut brim into the slot of the pinion.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the Differential

4.1.3

Before assembly all of the bevel gears and the thrust rings should be well oiled. 1. Place one differential side gear with the side gear thrust washer in the differential case. 2. Install the spider with differential gears and differential pinion thrust washers in the differential case. 3. Install the other differential side gear and side gear thrust washer. (At variants with Nospin differential install the Nospin diff. instead of the differential gears) 4. Install the other half of the differential case over the assembly and observe the alignment marks, tighten the differential case bolts. Secure with Loctite 262. 5. Check that all differential pinions can rotate easily. 6. Coat the contact surface of the ring gear with Loctite 270 and install the ring gear on the differential case by tapping lightly on the circumference. Tighten the ring gear bolts. Secure with Loctite 262. 7. Heat the two taper roller bearings to about 100°C and install them by using a sleeve.

© Kessler & Co. GmbH & Co.KG Al rights reserved

Service Revised 01.09.2007

Section

Assembly of drive assembly

4.1.4

Place the differential with the outer rings of the taper roller bearings on the differential carrier which is in a vertical position, with mounted drive pinion. Mount the differential straps and align them with the thread rings. During this operation be careful of the alignment marks on the differential straps with respect to the differential carrier. (Do not interchange the differential straps.) Tighten the differential strap bolts by hand. By a counter rotation of the two thread rings, move the differential until the backlash is correct. (The smallest admissible value at the closest place is marked on the ring gear). Therefore hold the drive pinion at the drive flange. Check the backlash by careful forwards and rearwards rotating the ring gear. Use a dial indicator. Measure the backlash during a few times turns of the ring gear and if need correct the backlash, because of the smallest admissible value at the closest place must not be fall short of. Adjust gear meshing according to sheet “Adjustment of gear meshing of Gleason gears”. Tighten screws of the differential straps and lock them with Loctite 262. Adjust the bearing roll resistance trough tightening of the thread rings. Set value: 2,0 to 3,0 Nm. Check the value with a torque wrench. If measuring at the drive pinion / drive flange, take the ratio of the bevel wheel set into account. Screw the lock plates for the thread rings and secure with Loctite 270, if need bend the lock plates.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the ring gear support bolt

4.2.3

1. Glue the cap with Loctite 270 onto the support bolt. 2. Coat the support bolt with Epple 33. 3. Screw the support bolt with cap by hand to contact to the ring gear, without exerting pressure. 4. Screw the counter nut onto the support bolt. 5. Turn back the support bolt max. 15°. 6. Tighten the counter nut, during this operation the support bolt must not move. In tightened condition the clearance between the ring gear surface and the contact surface of the support bolt amounts about 0,1 mm. Attention: The support bolt has to be sealed again when adjusting timely.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Limited-slip differential

4.2.4

 Pay attention about the arrangement of the disks.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 24/04/2011

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

Assembly of the hub assembly

Service Revised 01.09.2007

Section

Hub assembly steer drive axle

5.1

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 24.04.2012

Section

Assembly bearing of steering knuckle and bearing of universal joint

5.1.1

Prepare the steering knuckle: •

Assembly of the spacer ring (if present) see sheet 5.1.6.

•

Introduce the bearing bushing (4) into the lower bore of the steering knuckle and press in, by using a sleeve. Press in the upper bearing bushing (5), by using a sleeve, into the upper bore of the steering knuckle. (At version with spring support the upper bearing bushing (5) has to be mounted after installation of the king pin).

•

Press the bearing (6) into the steering knuckle and secure it with the circlip (7). Install the seal rings (8) with Loctite 572 resp. 270, place the support disc (10) (if present) between the seal rings. Fill the seal rings with bearing grease.

Prepare the axle housing: •

Insert the inner cliclip (7) into the axle housing. Press the bearing (6) into the axle housing and secure it with the second circlip (7). Install the seal rings (8) with Loctite 572 resp. 270, place the support disc (10) (if present) between the seal rings. Fill the seal rings with bearing grease.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the drive assembly onto the axle housing

5.1.2

Coat the contact surface of the axle housing with Epple 33 (at version through drive with Loctite 510), and mount the complete drive assembly. The axle housing being placed in a horizontal position, secure the screws with Loctite 262. Mount the pol wheel (if present) onto the universal joint (see 5.1.7). Very carefully engage the long shaft of the universal joint into the axle housing. The universal joint shaft should be able to be moved easily (by hand) in the toothing of the differential side gear. At version with differential lock on the outside (D 71/ D 109) the differential lock must always be actuated when assemble or disassemble the universal joint. Direction: Actuating of the differential lock is necessary to prevent the sliding sleeve to drop out of the shifter fork into the axle housing when pulling out or sliding in the universal joint. This would entail disassembly of the axle.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the steering knuckle onto the axle housing

5.1.3

At version with maintenance reduced steering knuckle bearing install the o-rings according to the respective version. Fit the steering knuckle (1) onto the axle fork. Caution: Be very careful and do not damage the seal rings in the steering knuckle with the universal joint shaft! Introduce the thrust discs (9) according the respective version. Before mounting the king pins apply Molykote – powder or – paste on the pins and in the bores (danger of gripping). Press in the king pins (11 + 12). Disassembly king pin: Draw off the lower king pin to the bottom, and the upper king pin to the top.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of steering- resp. track rod lever

5.1.4

Important:

threads and surfaces have to be cleaned and free from colour, oil and grease before applying Loctite. Note further remarks for working up Loctite (see sheet 3.2).

Coat the contact surface between lever (6 resp. 13) and steering knuckle at the contact area with Loctite 270 and install the lever by screws onto the steering knuckle, secure the screws with Loctite 262. Time needed for Loctite 270 to harden = 24 hours.

Coat the contact surface between cover (7 resp. 14) and steering knuckle with Loctite 510 and install the cover by screws onto the steering knuckle.

Screw the grease nipples into the lever resp. cover and grease the steering knuckle bearing with bearing grease according to the lubrication plan 2.3.

At version with dowel pins for increased torque, the dowel pins have to be knocked in before tightening the screws, note the position of the slits in the dowel pins (180° turned to one another).

Steer drive axle

© Kessler & Co. GmbH & Co.KG All rights reserved

Steer axle

Service Revised 01.09.2007

Section

Assembly of the hub assembly

5.1.5.1

• Assembly of the spacer ring (if present) see sheet 5.1.6. • Install the brake onto the steering knuckle, be careful of the brake control position and bolt it. At version with disc brake install the brake carrier (if present), then mount the wheel hub with the brake disc, and after this operation install the brake. • Prepare and mount the wheel hub see chapter 5.5. Attention: Hold the wheel hub with a hoist till the outer bearing with ring gear carrier is mounted. • Assembly of the planetary gear drive see chapter 6. • At version with drum brake mount the brake drum. • Assembly of the ABS - sensor installation (if present) see 5.1.7.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 15.07.2008

Section

Prepare and mount wheel hub

5.5.93

Prepare wheel hub Press the radial seal ring (5) with Loctite 572 (rubber cage) resp. Loctite 270 (steel cage) applied into the wheel hub (1). Fill the radial seal ring with bearing grease. Press in outer rings of taper roller bearings (2 + 3), do not hammer them. Install inner ring of taper roller bearing (3). Fill the taper roller bearing with bearing grease. Press the radial seal ring (4) with Loctite 572 (rubber cage) resp. Loctite 270 (steel cage) applied into the wheel hub. Fill the radial seal ring with bearing grease. At version with cassette seal ring observe the mounting instruction 5.6.

Mount wheel hub Push the pre - assembled wheel hub (1) parallel onto the axle spindle resp. steering knuckle.

Attention: Be careful not to damage the seal rings (4 + 5). At version with cassette seal ring observe the mounting instruction 5.6.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 24.04.2012

Section

Adjustment of wheel bearings

5.7.1

Tightening torque of the wheel safety nut

series

Nm

41 51 61 71/ 72 81/ 82 91 109 116 L101 L102 D/ LT 101/ 102 106 111 112

300 350 400 400 450 500 500 500 500 550 600-650 650-700 750 1000

Adjusting of wheel bearings The temperature of the axle parts should be between 0 and + 20°C at the bearing adjustment. Screw on the wheel safety nut (Loctite- resp. Molykote- using see page 5.7.2) and adjust and secure as following described: Screw on the wheel safety nut and tighten it with a 1,5 - 2 times higher tightening torque than the finish tightening torque. During the tightening, turn the wheel hub a few times and knock it with a plastic hammer. Untighten the wheel safety nut (about 180° back rotation), then tighten the wheel safety nut to the tightening torque according to the table. At this tightening turn the wheel hub also a few times, if there is no possibility for securing, the wheel safety nut has to be turned back to next securing possibility.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Wheel safety nut

5.7.2

Designation

Version

Security/ Remarks

Shaft nut with cheese head screw

Cheese head screw & Loctite 270

Shaft nut with cheese head screw and bushing

Cheese head screw & Loctite 270

Shaft nut with set screw

Set screw & Loctite 243/ 262 Back off set screw ½

Shaft nut with counter nut

Security spline & counter nut & Loctite 243

© Kessler & Co. GmbH & Co.KG All rights reserved

rotation after tightening

Service Revised 01.09.2007

Section

Assembly steering cylinder assembly

5.9.4

• Push in the steering cylinder into the steering cylinder brackets. • Install the bolt. • Attach the shim and screwon the nut. • Tighten the nut by hand and further tightening to next safety possibility and install the split pin. • Screw in the grease nipple and lubricate the bearing with bearing grease.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Mount wheel studs

5.12

Mount wheel studs 1) Place the disk (1) on the planetary gear (2) until the contact surface. 2) Apply the thread from the cap screw (3) with Loctite. Loctite 262 3) Bolt the disk (1) with the cap screw (3). 4) Thigthen the cap screw (3). Tightening torque 610 Nm 5) Apply the wheel studs (4) with Loctite. Loctite 262 6) Screw in the wheel studs (4). 7) Standout (A) according to the axle installation drawing.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 25.04.2012

© Kessler & Co. GmbH & Co.KG All rights reserved

Section

Assembly of planetary gear drive

Service Revised 01.09.2007

Section

Planetary gear drive

6.2

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the ring gear and ring gear carrier Assembly of the sun gear

6.1.1

Prepare the ring gear and the ring gear carrier Heat the taper roller bearing inner ring with cage (1) to about 100°C and install it onto the ring gear carrier (2). Place the ring gear (3) onto the ring gear carrier. Bolt the retainer (5) with the screws (4), secure the screws with Loctite 270.

Assembly of the ring gear carrier Install the ring gear carrier (2) with ring gear (3) into the wheel hub resp. onto the steering knuckle resp. axle spindle. The oil compensating hole in the ring gear carrier must be on the bottom. Subsequent adjust wheel bearings (see chapter 5.7).

Assembly of the thrust ring Press the thrust ring (6) into the steering knuckle resp. axle spindle. Secure with Loctite 270.

Assembly of the sun gear Slip the sun gear (7) onto the universal joint resp. axle shaft, install the circlip (9) and push the universal joint resp. axle shaft towards the inside until the circlip contacts to the sun gear and the sun gear contacts to the thrust ring.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of planetary gear

6.1.2

Prepare planetary gear: Install the needle bearing (10 resp. 11) into the planetary gear (12 resp. 13).

Insert the preassembled planetary gears (12 resp. 13) with needle bearings (10 resp. 11), rings (16) (if present) and thrust discs (14 resp. 15) into the planetary housing (22 resp. 23) (planetary housing in horizontal position).

Place o - ring (19) into the slot of the planetary housing (22). Because of the difference of diameter of 0,1 mm press the planetary pin (17 resp. 18) in direction of arrow. Be sure, that the bore hole of the locking pin in the planetary pin and planetary housing are aligned. After inserting, secure the planetary pin with the locking pin (20 resp. 21).

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly of the planetary housing Adjustment of the axial clearance

6.2.1

Assembly of the planetary housing Place o - ring (30) into the slot of the planetary housing. Install the planetary housing and bolt it.

Adjustment of the axial clearance

The axial clearance between axle shaft resp. universal joint and adjusting screw must be 0,3 - 0,7 mm. The adjustment has to be made by screwing in the adjusting screw until it touches the axle shaft resp. universal joint. Back - off the adjusting screw 72° - 170° from the tightened position (this corresponds to about 0,3 - 0,7 mm axial clearance). Secure the adjusting screw and the counter nut with Loctite 270.

Attention: When tightening the counter nut (29), hold the adjusting screw unconditional in order to prevent turning of the adjusting screw.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Disassembly of planetary gear

6.1.4

Knock the locking pin (20 resp. 21) completely to the inner side of the planetary pin.

Press the planetary pin in direction of arrow out of the planetary housing.

Attention: Because of the difference of diameter of 0,1 mm do not press the planetary pin against the direction of arrow out of the planetary housing, to prevent damaging the bore.

Remove the planetary gears with the thrust discs and needle bearings.

© Kessler & Co. GmbH & Co.KG All rights reserved

Service Revised 01.09.2007

Section

Assembly/ disassembly of cageless needle bearing (planetary gear bearing)

6.1.5

Assembly: Version 1:

Install the needle bearing with mounting bushings into the planetary gear, thereby the outer mounting bushing will be stripping. Insert the planetary gear with thrust discs into the planetary housing. Press in the planetary pin, thereby the inner mounting bushing will remove.

Version 2:

Place one thrust disc on the work bench, place on the planetary gear and insert the mounting bushing. Insert the cylindrical rollers/ needles alternately with the rings (according to the design). Insert the planetary gear with thrust discs into the planetary housing. Press in the planetary pin, thereby the mounting bushing will remove.

Hint:

Note the passage “Assembly of the planetary gear”!

Disassembly: At the disassembly of the planetary pin the cageless needle bearing will fall asunder, if not a mounting bushing will be pushing inwards at planetary pin removing.

Hint:

© Kessler & Co. GmbH & Co.KG All rights reserved

Note the passage “Disassembly of the planetary gear”!

Service Revised 01.09.2007

Service Manual                                    

© Kessler & Co. GmbH & Co.KG  All rights reserved   

 

Kessler & Co. GmbH & Co. KG Huettlinger Straße 18-20 D-73453 Abtsgmuend Germany

Phone +49 (0) 73 66/81-32 Fax +49 (0) 73 66/81-69 [email protected] www.kessler-axles.com

Service Manual

Hydrostatic Steering OSPB/OSPC

Unit

HN.21 .AD.02 replaces HN.21 .AC.02

Page

Table of contents

8

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

14

Reassembling

Max. tightening torque and hydraulic connections ...................... Service shops ................. . ............................................................ Exploded view: OSPB / OSPC / OSPC LS ..................................

,b 104989

2 2

Cost-free repairs ........................................................................ Tools .......................................................................................... Dismantling ................................................................................

HN.21 .AD.02

28 29 29-30 1

We would point out that cost-free repairs as mentionedw in Danfoss General Conditions of Sale, are carried out only at Danfoss Nordborg or at service shops authorized by Danfoss (page 29).

Cost-free repairs

!rooLs A Holding

.;

'.

;. ,_

tool.

B Assembly tool Code no. SJ

Code no.:

for

o-ring

150-9000-11.

SJ

and kin-ring.

C Assembly tool for lip seal. Code no. SJ 150-9000-17.

2

150-9000-2.

D Assembly tool Code no. SJ

for

cardan

150-9000-3.

shaft.

E Assembly tool for dust seal. Code no. SJ 150-9000-22.

F Torque wrench O-7 daNm. 13 mm socket spanner. 6, 8 and 12 mm hexagon sockets. 12 mm screwdriver. 2 mm screwdriver. 13 mm ring spanner. 6, 8 and 12 mm hexagon socket spanners. Plastic hammer. Tweezers. The tools available

named under point from Danfoss.

F are not

b 3

DISMAN!L'LING 1 Dismantle steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover (6-off plus one special screw).

2 Remove the end cover,

3 Lift

sideways.

the gearwheel set (with spacer if fitted) off the unit. Take out the two o-rings.

4 Remove cardan

shaft.

5 Remove distributor

plate.

6 Screw out the threaded valve.

7 Remove o-ring.

bush over

the check

8 OSPB; OSPB LS; OSPBX LS: Shake out the check valve

ball

(0 8 mm).

OSPC; OSPC LS; OSPC LSR: Shake out the check valve valve pins and balls.

ball

and suction

Note: On some pins in the OSPC there are two springs (see page 30, pos. 28). See also spare parts list for OSPC HN.21.CA.52.

9 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and needle bearing will be pushed out of the housing together.

10 Take ring, bearing races and needle bearing from sleeve and spool. The outer (thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out.

6

lla

OSPB CN and OSPC CN A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the neutral position springs (see drawing). If the mark is not visible, remember to leave a mark of your own on sleeve and spool before the neutral position springs are dismantled.

12

Carefully

13

Press

14

Remove dust

their

press

the spool

the neutral position slots in the spool.

seal

out

of the sleeve.

springs

out

of

and -o-ring/kin-ring.

7

Dismantling

the dual

shock valves

for

OSPC/OSPC LS

15 Remove plugs from shock valves hexagon socket spanner.

16 Remove seal

washers

a 6 mm

(2-off).

17 Unscrew the setting screws hexagon socket spanner.

8

using

using

a 6 mm

18

Shake out the two springs and two valve balls into your hand. The valve seats are bonded into the housing and cannot be removed.

19 The dual .. w

‘:.

shock valves

are now dismantled.

x

”

. .

Dismantling

the pressure

relief

valve

(cartridge)

for

OSPC

20 Screw out the plug using an 8 mm hexagon socket spanner. Remove seal washers.

9

21 Unscrew the setting screw using hexagon socket spanner.

an 8 mm

22 Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed.

23 The pressure

10

relief

valve

is now dismantled.

b

Dismantling

the pressure

relief

valve

(cartridge)

for

OSPC LS/OSPC LSR

24 Screw out the pressure relief valve using an 8 mm hexagon socket spanner. Remove the seal ring* If the valve is defective it must be replaced (see OSPC spare parts list, HN.21.CA.52).

.,. ..,.

25 The pressure

relief

26 The steering dismantled.

unit

valve

is now dismantled.

; ., ‘.

..,

.,

.’ . A , i’ .. .:.. .,, :.’

OSPB is now completely

11

Cleaning

Clean all Inspection

Replace all replacements Lubrication

Before

12

parts

carefully

and replacement

27 The steering dismantled.

unit

OSPB LS is now completely

28 The steering dismantled.

unit

OSPC is now completely

29 The steering dismantled.

unit

OSPC LS is now completely

in Shellsol

seals and washers. necessary.

assembly,

lubricate

all

K or the like.

Check all parts

with

parts

carefully

hydraulic

oil.

and make any

u

Assembly pattern and colour OSP-steering units

code for

neutral

position

springs

STANDARDSPRINGS (GREY) 2-off 4-off

flat, grey: curved, grey:

GREY SET Spare set:

code no.

code no. code no.

150-0720 150-0721

150-4209

WEAK SPRINGS (BLUE) 2-off 2-off

flat, blue: curved, blue:

BLUE SET Spare set:

code no.

code no. code no.

150-0748 150-0749

150-4265

STRONGSPRINGS (GREY AND BLUE) a-off 4-off

x

flat, grey: curved, blue:

GREY/BLUE SET Spare set: code no.

code no. code no.

150-0720 150-0749

150-4207

STIFF SPRINGS (YELLOW) 2-off 2-off

flat, yellow: curved, yellow:

YELLOW SET Spare set: code no.

code no. code no.

150-4269

150N0602 150N0603

for

30

I

Assemble

spool

and sleeve.

Note

OSPB LS, OSPBX LS, OSPC LS and OSPC LSR When assembling spool and sleeve only one of two possible ways of positioning the-spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve opposite to the end with spring slots. Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool. OSPB CN and OSPC CN Assemble the spool/sleeve and make sure the marks on spool and sleeve are opposite each other (see drawing page 7).

31

Place the two flat in the slot.

neutral

Place the curved springs ones and press them into pattern, page 13).

32

14

Line

up the spring

set.

position

springs

between the flat place (see assembly

33

Guide the spool into the sleeve. Make sure that spool and sleeve for OSPB LS, OSPBX LS, OSPC LS and OSPC LSR are placed correctly in relation to each other (see page 14).

34 Press the springs togehter and push the neutral position springs into place in the sleeve.

35 Line

up the springs

and centre

them.

kd

. :‘:A:.‘,::..: ._ ,..* .i.n

.. . .

‘.

,..n;v. .._ .<.>,,. ::j,yy:

36 Guide the ring Note:

/

.:

b

.,::..,

,,,

.. ,.,”

.;

,:

down over

the sleeve.

The ring should be able free of the springs.

to rotate

-

.,

,,

...“’

15

37 Fit

the cross

38 Fit

pin

bearing races on below drawing.

Assembly

pattern

1

2 3

4 5

16

for

Outer bearing Needlebearing Inner bearing Spool Sleeve

standard

race race

bearings

into

the spool/sleeve.

and needle

bearing

as shown

‘w

Assembly pattern

1

2 3 4 5 6 7

double

bearings

Washer for axial bearing Outer needlebearing Outer bearing race Spool Sleeve Inner needlebearing Inner bearing race

The inside spool.

Installation

for

chamfer

on the

instructions

for 39

inner

bearing

o-ring/kin-ring

race

must face

the

inner

(standard)

Turn the steering unit until the bore is Guide the outer part of the horizontal. assembly tool into the bore for the spool/sleeve.

17

40 Grease o-ring and kin-ring and place them on the tool.

with

hydraulic

oil

41 Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.

42 Press and turn the o-ring/kin-ring position in the housing.

into

43 Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore.

18

w

Imstallation

in8tructioa8

for

lip

44 Lubricate place it

ma1 the lip seal with hydraulic on the assembly tool.

45 Guide the assembly

: ,::::: ..’ .: ..

tool

right

oil

and

to the bottom.

,,

46 Press and turn housing.

the lip

seal

into

place

in the

19

47

With a light turning movement, guide spool and sleeve into the bore. Note:

48

Fit pin

the spool horizontal.

set holding

the

the cross

The spool set will push out the assembly tool and kin-ring are now in guide. The o-ring position.

49 Turn the stearing unit until the bore is vertical again. Put the check valve ball the hole indicated by the arrow.

into

50 Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing.

Assembly of the two suction

valves

for

51 Place a ball the arrows.

52 Place

a pin

OSPC/OSPC LS/OSPC LSR in the two holes

indicated

by

in the same two holes.

53 In some cases a spring has to be fitted page 30, pos. 28) on the pin before it placed in the housing. (See OSPC spare list, HN.21.CA.52).

(see is parts

54 Grease the o-ring with mineral viscosity 500 cSt at 200C.

-..

j.

..

.:.

oil

approx.

55 Place the distributor plate so that the channel holes match the holes in the housing.

56 Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange.

57 Place the cardan shaft as shown - so that is held in position by the mounting fork.

it

58

Grease the two o-rings with mineral oil approx. viscosity 500 cSt at 200C and place them in the two grooves in the gear rim. Fit the gearwheel and rim on the cardan shaft.

59 Important:

60 Fit

61

Fit the gearwheel (rotor) and cardan shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gear rim so that the seven through holes match the holes in the housing

the spacer,

Place

if

the end cover

any.

in position.

23

62 Fit the special it in the hole

24

screw shown.

with

washer

and place

63

Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin with a torque of 3.0 +/-0.6 daNm. The OSPB, OSPB LS and OSPBX LS can now be function tested.

64

Place the dust seal ring in the housing. With the OSPC, PSPC LS and OSPC LSR the dust seal ring must be placed only after the pressure relief valve and shock vamhave been fitted.

66 Press ports.

Assembly

of

the

pressure

relief

the plastic plugs into Do not use a hammer!

valve

for

67 Fit

the piston.

68 Fit

the spring.

the connection

OSPC

25

69 Screw in the setting screw with an 8 mm hexagon socket spanner. Make the pressure setting on a panel or the vehicle. 0 1.7 spring for 50 - 70 bar. 0 1.9 spring for 70 - 105 bar. 0 2.1 spring for 110 - 155 bar. (See OSPC spare parts list HN.21.CA.52).

70 Screw plug with dust seal into the housing using an 8 mm hexagon socket spanner. Tightening

Assembly

of

the

pressure

relief 71

26

valve

torque:

(cartridge)

5 +/-1

for

daNm.

OSPC LS/OSPC

LSR

Place the seal ring on the cartridge and screw the cartridge into the housing using a 12 mm hexagon socket spanner. Tightening torque: 5 +/-1 daNm. Make the pressure setting on a panel or the vehicle. The cartridge is factory-set at 175 bar. Use a 4 mm hexagon socket spanner. (See OSPC spare parts list HN.21.CA.52 for setting range).

72 Screw plug with seal ring using an 8 mm Allen key. Tightening

Assembly of the dual

shock valves

for

73 Put a ball arrows.

74 Place balls. Note:

torque:

into

5 +/-1

the housing

daNm.

OSPC/OSPC LS/OSPC LSR in the two holes

springs

and valve

indicated

cones over

by the

the two

The blue spring applies to setting range 90480 bar. The untreated spring applies to setting range 190-260 bar. (See OSPC spare parts list

HN.21.CA.52).

27

75 Screw in the two setting screws using a 6 mm hexagon socket spanner. Make the pressure setting on a panel or the vehicle. (See OSPC spare parts list HN.21.Ll.52).

76 Screw plug with seal ring into the two shock valves and tighten them with a torque of 3 +/-0 daNm using a 6 mm hexagon socket spanner. Steering unit type OSPB, OSPB LS, OSPBX LS, OSPC, OSPC LS or OSPC LSR is now assembled.

tightening

Max.

torque

Max.

and hydraulic

tightening daNm

connections

torque

(lbf

in)

Screwed connection

I-1/4

BSP.F

3/8

BSP.F

I

M 18 x 1,s

28

With

With

cutting

copper

aluniniun

with

edse

washer

washer

With O-ring

7 (620)

2 (180)

5 (440)

5 (440)

10 (900)

13 t270,/

8 (700)

/ 7 (620)

1

L:

Left

R:

Right

T:

Tank

P:

Pump

port port

bd

Authorized

service

shops:

Asean : : Australia : Austria .. Belgium : Canada : Denmark : Finland : France FRG (W. Germany): Great Britain : Iceland : : Italy : Japan Netherlands : New Zealand : : Norway .. Spain : Sweden : Switzerland : U.S.A.

Danfoss Industries Pte. Ltd., Singapore Danfoss (Australia) Pty. Ltd., Melbourne Gesellschaft m.b.H, Linz Hainzl Industriesysteme, N.V. Danfoss S.A., Bruxelles Danfoss Mfg. Co. Ltd., Mississauga H. Sondergaard A/S, Malov OY Danfoss AB, Espoo Danfoss S.a.r.l., Trappes (Paris) Danfoss GmbH, Offenbach/Main Danfoss Limited, Greenford Velsmidjan Hedinn, Reykjavik Sordella & C. Oleodinamica s.r.l., Torino Danfoss (Japan) Manufacturing Co., Ltd., Gotemba ITHO B.V., Schiedam Danfoss (New Zealand) Limited, Auckland Danfoss Norge A/S, Skui Danfoss S.A., Madrid Transventor Hydraulik AB, Molndal, Goteborg Werner Kuster AG, Frenkendorf Danfoss Inc., Rockford, Illinois

Service Greece Norway

A. Skoura & Co. E.E., Athens Servi Produksjon A.S., Trondheim

Item

shops:

Spare

Parts

1 2

Dust Housing

3

Ball

4

Thread

5

O-ring

seal

ring

spool B 8,5 mn +

+ sleeve

bushing 25,

used 6

: :

12x1,78

with

m-t,

kin-ring

is

(item

6)

Kin-ring

6a

Lip

7

Bearing

8

Bearing

10

Ring

11

Cross

12

Neutral

13

Cardan

14

Spacer

seal

assembly assembly I/D

position

O-ring

16

Distributor

17

Gearwheel O-ring

19

End

06x41

m mn spring

shaft

15

18

39,6x0,7x4,5

pin

080,5x1,5

mn

plate 0,92x1,78

mn

cover

20

Washer

22

Special

23

Screw

24

Rating

25

Drive

26

Spacer

88,2x11,9x1,0

m

screw plate screw OSPB

tern Spare i Bust 2

Parts seal

ring

busing, spool and sleeve :heck valve and the seats

for relief malves are 3

all

4 5

hrcad

08,s

b-ring

mn used

with

kin-ring

6)

6

:in-ring

7

learing

8

ling

assembly

iross

pin

10

ipacer

11

:ardan

12

iet

13 14

I-ring

15 16

Gearwheel

17

End cover

18

Uasher

shaft of

springs

jistributor

plate set

D-ring

20

Special

21

Screw

22

Name

23

Drive

24

Complete

screw plate screw

25

Spring

26

Complete

27

Ball

28

Spring

- 29

Rolled

relief wire

r3/16

OSPC

valve @1,7x36,6

dual

shock

ion valve

in

pin

JM/KEJ/LKR 30

shock

tmhing

item

9

and dual locktited

OSPC

LS

Hydraulics

Spare parts

Danfoss Steering Units OSPB/OSPC/OSPL/ OSPD/OSPQ/OSPF

,_,

HN.21.UA.52 replaces HN.21.CB.52, HN.21.DA.52, HN.21.EB.52 and HN.21.HB.52

Index

Page Cost-free repairs .........................................................

2

Service shops

2

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

Exploded view OSPB .....................................................

3

Exploded view OSPC/OSPF ................................................

4

Explodes view OSPQ

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

5

Exploded view OSPD

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

6

Exploded view OSPL

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

7

Spare parts ............................................................. Danfoss Hydraulics

02-1998

HN.21 .UA.52

Organization

8

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

Book6 Partition 3

15

1

Vederlagsfri reparation

Vi ger opmaerksomp& at den vederlagsfrie reparation som er omtalt i Danfoss Almindelige Leveringsbetingelser kun udferes hos Danfoss Nordborg eller hos Danfoss autoriserede service shops.

Cost-free repairs

We would point out that cost-free repairs as mentioned in Danfoss General Conditions of Sale, are carried out only at Danfoss Nordborg or at service shops authorized by Danfoss.

Kostenlose Reparatur

Wir machen darauf aufmerksam, dal3die in den "AIIgemeinen Lieferbedingungen" von Danfoss erw&hnte kostenlose Reparatur nur bei Danfoss Nordborg oder bei den von Danfoss autorisierten Kundendienswerkst&tten ausgef(Jhrt wird.

Reparation gratuite

Nous faisons observer que la r_paration gratuite mentionnee dans les Conditions generales de Vente de Danfoss ne devra _tre effectu6e que dans les ateliers Danfoss & Nordborg ou dans les ateliers de d_pannage agrees par Danfoss.

Authorized Service Shops

Australia Austria Belgium Brazil Canada Denmark Finland France Germany Great Britain Iceland India Italy Japan Korea Netherlands New Zealand Norway Republic of South Africa Singapore Spain Sweden Switzerland Turkey U.S.A.

: : : : : : : : : : : : : : : : : : : : : : : : :

Danfoss (Australia) Pty. Ltd., Melbourne HAINZL Industriesysteme, Gesellschaft m.b.H, Linz N.V. Danfoss S.A., Bruxelles Danfoss do Brasil Ind.e Com. Ltda., S&o Paulo Danfoss Mfg. Co. Ltd., Mississauga Danfoss Hydraulik A/S, Stenlose OY DanfossAB, Espoo Danfoss S.a.r.l., Trappes (Paris) Danfoss GmbH, Offenbach/Main Danfoss Limited, Greenford (London) HEDINN VERSLUN H/F, Reykjavik DANTAL HYDRAULICSPVT Ltd., New Delhi Danfoss s.r.l. Division Sordella, Torino DanfossK.K., Gotemba UNITEKCorporation,Seoul ITHO B.V., Schiedam Danfoss (New Zealand) Limited, Auckland Danfoss A/S, Skui Danfoss (Pty) Ltd., Johannesburg Danfoss Industries Pte. Ltd., Singapore Danfoss S.A., San Sebastian de los Reyes, (Madrid) DanfossAB, Mj61by Danfoss Werner Kuster AG, Frenkendorf MERTTEKNIK A.S., Istanbul Danfoss Fluid Power Div. Racine, Wisconsin

Service shops

Australia Australia Australia Australia Czech Rep. Greece New Zealand Portugal Taiwan

: : : : : : : : :

Danfoss (Australia) Pty. Ltd., Adelaide Danfoss (Australia) Pty. Ltd., Brisbane Danfoss (Australia) Pty. Ltd., Perth Danfoss(Australia)Pty.Ltd.,Sydney TECHNOTRADE, Olomouc A. SKOURA& Co. E.E.,Athens Danfoss (New Zealand) Limited, Christchurch Danfoss (Portugal), da., Carnaxide SYMBRIDGE Machinery Co. Ltd., Taipei

2

HN.21 .UA.52

,_

_,"

Exploded

view OSPB

20 22

HN.21 .UA.52

3

Exploded

view OSPC/OSPF

32 32

1

33

38 34

31 30

5 2

7

_ _-o a<

\

2

13 14

_

15

12

\ \

16

_ z

__

23 17

40

24 18 19 20 22

4

HN.21 .UA.52

Exploded view OSPQ

HN.21 .UA.52

5

Exploded view OSPD 32 J

32 33

5O

30

31

I_

57.... 4 _..

10

_o _

z_

36

_

35

13

"

15

"_ 16

_

12

-..

x

51

/

/

"_ 18

17 /

/

\

,

20

24

6

HN.21.UA.52

Exploded view OSPL

HN.21 .UA.52

7

Spare

parts

Item

,

Spare Parts

Code No.

I

1

I

Dust seal ring I

I

I

i

Housing, spoolandsleeve

4

Thread bushing Thread bushing withpin I

Shaft seal

7

Bearing

1

I

I

Set ofsprings

1

I

13

I

1

150-4207 i 150-4209 150-4265 150-4269 i 150N4018

1 1 1 1 1

150 N4019 150N4020 150N4028 150N4035

1 1 1 1

Cardanshaft

14

i

8

change

1 I

On steeringunits manufacturedbeforeweek 20 1991, the gearwheel set must be changed if the cardan shaft is replaced. 150N0653 For gearwheel set without stepped splines 150-0967 OSPD

i

*) Not available,

I

150-0844

Spacer

cardan shaft and gearwheel HN.21 .UA.52

set

I

150-4091

I

i

I

1 1

150N4037 I

I

I

150N4026 Set of spare parts 150-0310 150-0305 I

I

1 1 1

150-4262

I

I

I

I

I

Ring Cross pin

12

I

I

I

10 11

I

150N4014Roto Glyd 150N4007 O-ring/Kin-ring 633B2060 Lipseal

I

i

1

150G4336 OSPD

I

5

1

1

i I

I

I

i

150-0304

I

4

1

150N4027 Set of spare parts 689X1031

Ball 08.5 mm

,

I

I

Notsoldseparately

i

3

I

633B9002

I

2

Comments I

Number per unit

i

1 1 1 i

i

OSP40,OSP50,OSP70nospacer 150-0435 OSP 80 150-0436 OSP 100

1 1

150N0654 OSP 100 for gearwheelset 150-4064 150-0437 OSP 125

1 1

150N0655 ©SP 125 for gearwheelset 150-4065 150-0438 OSP 160

1 1

150N0656 OSP 160 for gearwheelset 150-4070 150-0439 OSP 200

1 1

150N0638 OSP 200 for gearwheelset 150-4071 150-0441 OSP 315

1 1

150-0412 *) 150-0413 *) 150-0414 *) 150-1595 *) 150-0415 *)

1 1 1 1 1

OSP400 OSP 500 OSPB 630 OSPL 630 OSPB 800

i I

Spare

parts

Item

Spare Parts

Code No.

I

I

14

(continued)

I

15

O-ring

I

I

Distributor plate

17

I

Gearwheel set

I

OSP OSP OSPD OSP OSP OSPD OSP

40 50 60 Low excentricity 70 70 Noslip 70 80

I

18

I

O-ring

I

1 1 i

i

w= 6,5 w= 6,5 w = 9,1 w= 9,1 , w = 9,1 w = 9,1 w = 10,4

1 1 1 1 1 1 1

150-4140 OSP 80 Noslip 150G4202 OSPD 80 150-4173 OSP 100 150-4064 OSP 100 Without stepped splines 150-4141 OSP 100 Noslip 150G4203 OSPD100 150-4174 OSP 125

w= 10,4 w= 10,4 w= 13,0 w = 13,0 w = 13,0 w= 13,0 w= 16,2

1 1 1 1 1 1 1

150-4065 OSP 125 Without stepped splines 150-4142 OSP 125 Noslip 150G4204 OSPD125

w = 16,2 w = 16,2 w = 16,2

1 1 1

150G4211 150-4175 150-4070 150-4145 150G4206 150G4212 150-4166 150-4186 150-4071

w = 16,2 w= 20,8 w = 20,8 w = 20,8 w= 20,8 w = 20,8 w= 24,0 w= 26,0 w = 26,0

1 1 1 1 1 1 1 1 1

w= 26,0 w = 26,0 w= 26,0 w= 35,1 w =32,5 w= 40,9 w= 40,9 w= 52,0 w=65,0 w= 67,8 w= 82,0 w= 82,0 w= 104,0 w= 104,0 w = 134 w = 134

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

OSPD 125 Lowexcentricity OSP 160 OSP 160 Without stepped splines OSP 160 Noslip OSPD160 OSPD 160 Low excentricity OSP 185 OSP 200 OSP 200 Without stepped splines

150-4146 OSP 200Noslip 150G4207 OSPD200 150G4214 OSPD 200 Lowexcentricity 150G4215 OSPD 230 Low excentricity 150-4187 OSP 250 150-4188 OSP 315 150G4209 OSPD315 150-4189 OSP 400 150-4190 OSP 500 150-4194 OSPL 520 150-4191 OSPB630 150-4195 OSPL 630 150-4192 OSPB800 150-4196 OSPL 800 150-4193 OSPB 1000 150-4197 OSPL1000 I

I

1

I

150-4169 150-4171 150G4200 150-4170 150-4139 150G4201 150-4172

,

I

150N0610 i 150G4301OSPD J

i

I

I

1 1 1

633B1202

I

16

Number unit per' I

150-1596 *) OSPL800 150-0416 *) OSPB 1000 150-1597 *) OSPL 1000

I

I

Comments i

I

633B1173 633B0208OSPD

I

I

2 6

*) Not available, change cardan shaft and gearwheel set HN.21 .UA.52

9

Spare parts

Number per unit

Item

Spare Parts

Code No.

19

End cover

150-0328 150-1355 Balanced endcover

1 1

20

Washer

684X2481

7

22

Special screw

150-0326 150-0321 150-0322 150-1450 150-0323 150-0324 150-0325 150-0451 150-0452 150-1579

OSP 40/OSP 50 OSP 70/OSP 80 OSP 100 OSP 125 OSP 160 OSP 200/OSP 185 OSP 315 OSP 400 OSP 500 OSPL520

= 67,4 = 63,0 = 106,0 = 68,5 = 73,0 = 78,5 -- 93,5 = 104,5 = 117,5 = 131,5

1 1 1 1 1 1 1 1 1 1

150-0453 150-1580 150-0454

OSPB 630 OSPL630 OSPB 800

= 134,5 = 146,5 = 156,5

1 1 1

150-1581 150-0455 150-1582

OSPL800 OSPB1000 OSPL1000

= 166,5 = 186,5 = 196,5

1 1 1

681X1577 681X1939 681X1270 681X1178 150G4385 681Xl 578 681X1939 681X1480

OSP OSPD OSPD OSPD OSPD OSP OSPD OSPD

= = = = = = = =

30 90 100 105 115 35 90 95

6 7 7 7 7 6 7 7

150G4384 681X1270 681X1178

OSPD 70/195 OSPD 70/230 OSPD 70/270

= = =

97 100 105

7 7 7

681X1487 681X1480 150G4384

OSPD 70/385 OSPD 80/160, OSPD 80/180 OSPD 80/205

= = =

120 95 97

7 7 7

681X1178 681X1940 150G4386

OSPD 80/240 OSPD 80/280 OSPD 80/395

= = =

105 110 125

7 7 7

150G4384 681X1270 681Xl178 681X1940 150G4386 681X1178

OSPD OSPD OSPD OSPD OSPD OSPD

= = = = = =

97 100 105 110 125 105

7 7 7 7 7 7

= = = = = = = = = =

110 115 130 45 50 65 80 90 105 110

7 7 7 6 6 6 6 6 6 6

23

Screws

Comments

40/OSP 50 60/120 60/185 60/220 60/260, OSPD 60/290 70/OSP 80 70/140, OSPD 70/150 70/170

100/200 100/225 100/260 100/300 100/415 125/250

681X1940 OSPD 125/285 150G4385 OSPD 125/325 681X1941 OSPD 125/440 681X1580 OSP 160 681X1581 OSP 185/OSP 200 681X1582 OSP 315 681X1583 OSP 400 681X1939 OSP 500 681X1178 OSPL520 681X1940 OSPB630

10

HN.21 .UA.52

Spare parts Item i

Spare Parts

Code No.

i

23

i

i

(continued

i

681X1487 681X1941 681X1488 681X1339

i

OSPL630 OSPB800 OSPL800 OSPB 1000

I= I= I= I=

120 130 140 160

6 6 6 6

681X1489 OSPL1000

I=

170

6

i

i

24

Name plate

150A6009

1

26

Spacer

150-0443*)

1

27

Intermediate plate

150-1591 OSPL

1

30

Relief valve

150-4270 Open center 150-4281LS

1 1

150N4021 Opencenter 07,2 150-4054 OSPQ

1 1

150-4084

UsedinCNforJohnDeere

1

i

i

31

i

Special reliefvalve

i

i

wire O1,6 wire O2,1

663X6021 663X6022

LS LS

1 1

140-175 bar 2030-2470 Ibf/in2

wire ®1,9

663X6183

OSPQ

1

Spring for relief valve 40-70 bar 580-1015 Ibf/in2 70-105 bar 1015-1525 Ibf/in2 110-155 bar 1595-2250 Ibf/in2 140-180 bar 2030-2610 Ibf/in2 140-180 bar 2030-2610 Ibf/in2

wire O1,8 wire O1,9 wire O2,1 wire 02,2 wire 02,7

663X1800 663X1774 663X1802 663Xl 128 663X6026

Open center Open center Open center Open center For relief valve 150N4021

1 1 1 1 1

33 34

3/16

I

I

150-4080 150G4337OSPD

2 2

i

I

150-1606 150G 1355 OSPQ

1 1

689X1043 689X1005 OSPQ

1 1

150N4091M18 x 1,5 150N4092 3/4 - 16 UNF 150N4093 G1/2,PF/2 150N4094M22 x 1,5

1 1 1 1

663X1134

2

I

I

Check valve

I

38

2

I

LScheck valve,ball3,0mm ball 3/16in

37

689X1005

I

LScheck valve, screw

36

i

i

Pinforsuction valve

35

I

2 2

in

I

I

150-4268

i

Ball

I

I

Springs forsuction valve

i

i

i

i

I

Ii

Completeshockvalve 90-180 bar (1300-2610 Ibf/in2) wire O1,7 170-260 bar (2470-3770 Ibf/in2) wire O1,9 i

i

AllOSPB400-1000andallOSPL800-1000

Spring for relief valve Setting < 70 bar 1015 Ibf/in2 70-210 bar 1015-3047Ibf/in2

i

32

i

Number per unit

Comments

I

i

*) Not available, change cardan shaft and gearwheel set HN.21 .UA.52

11

Spare

parts

Item

Spare Parts

Code No. i

I

39

Seal ring

40

i

i

Mountingpin ! ! !

i

51

Cardan shaft =

52

=

Distributor plate

53

Distributor plate ,

54

,

Valve andvalve housing ,

55

For no slipgearwheelset

1

For no slipgearwheelset

1

i

633B0116

O-ring i

50

I

150N0630

i

i

150G4354 150G4363

OSPD OSPD

60/120 60/185

I = 44,8 I = 56,5

2 2

150G4345 150G4381 150G4370

OSPD OSPD OSPD

60/220 60/260 60/290

I = 61,7 I = 68,2 I = 68,9

2 2 2

150G4354 150G4355 150G4357

OSPD OSPD OSPD

70/140 70/150 70/170

I = 44,8 I= 46,1 I = 48,7

2 2 2

150G4359 150G4363

OSPD OSPD

70/195 70/230

I = 52,0 I = 56,5

2 2

150G4345 OSPD 150G4371 OSPD 150G4356 ii OSPD 150G4358 OSPD

70/270 70/385 80/160 80/180

I = 61,7 I = 76,7 I = 47,4 I = 50,0

2 2 2 2

150G4361 150G4364 150G4367

OSPD OSPD OSPD

80/205 80/240 80/280

I= I= I=

53,3 57,8 63,0

2 2 2

150G4372 150G4359 150G4362

OSPD 80/395 OSPD 100/200 OSPD 100/225

I= I= I=

78,0 52,6 55,9

2 2 2

150G4366 150G4369 150G4373 150G4365 150G4368 150G4370 150G4374

OSPD OSPD OSPD OSPD OSPD OSPD OSPD

I= I= I= I= I= I= I=

60,4 65,6 80,6 59,1 63,7 68,9 83,8

2 2 2 2 2 2 2

100/260 100/300 100/415 125/250 125/285 125/325 125/440

150G4350 OSPD

1

150G4389

1

OSPD,315 cm3 gearwheelset i

150G4303

1

150G4305

1

,

150G4213 ,

Spring

1

,

663X6151 ,

i

Numberper unit

Used in units

1

J

56

Guide pin

60

Amplification spool

61

Spring

633X6145

1

62

Plug

150G1201

1

63

Amplification orifice

12

682L2004 Notsoldseparately

Notsoldseparately

HN.21 .UA.52

1 1

1

Set of seals Item I

Spare Parts I

1 5 15 18 20 I

15 18 20 I

I

I

Dust seal ring Shaft seal

633B9002 150N4014 Roto Glyd

1 1

O-ring O-ring Washer

633B1202 633B1173 684X2481

1 2 7

I

Setofseals

I

I

I

Universal Dust seal ring Shaft seal

150N4039 Setof seals 633B9002 150N4014 Roto Glyd 150N4007 O-ring/Kin-ring 633B2060 Lipseal

1 1 1 1

O-ring O-ring Washer

633B1202 633B1173 684X2481

1 2 7

I

I

I

I

No slip gearwheel set Dust seal ring Shaft seal

150N4044 Set of seals 633B9002 150N4014 Roto Glyd 150N4007 O-ring/Kin-ring

1 1 1

15 18 20

O-ring O-ring Washer

633B1202 633B1173 684X2481

1 2 7

39 40

Sealring O-ring

150N0630 633B0116

!

i

1 5 15 18 20 I

i

15 18 20 I

I

i

i

633B9002 150N4014 Roto Glyd 150N4007 O-ring/Kin-ring

1 1 1

O-ring O-ring Washer

633B1202 633B1173 684X2481

1 3 7

I

I

I

I

OSPD

150N4041 Setofseals

Dust seal ring Shaft seal

633B9002 I 150N4014 Roto Glyd

1 1

O-ring O-ring Washer

633B1202 633B0208 684X2481

1 6 7

I

I

I

150-4206 Set of seals 633B9002

Dust sealring Shaft seal

i 150N4007

O-ring O-ring Washer I

LipSeal Dust seal ring Shaft seal O-ring O-ring Washer

I

150-4267 Setofseals 633B9002 633B2060 Lipseal 633B1202 633B1173 684X2481

I

I

1

O-ring/Kin-ring

633B1202 633B1173 683X2481

I

1 5 15 18 20

1 1

Dust seal ring Shaft seal

O-ring/Kin-ring

15 18 20

i

150N4042 Setofseals

I

1 5

Fornoslipgearwheel set Fornoslipgearwheel set

OSPL

I

1 5

I

I

' Number per! unit

150N4038

I

1 5

_'

I

Comments

Standard

I

1 5

_,_

Code No.

1

i

1 2 7

I

I

1 1 1 2 7

I

HN.21 .UA.52

13

Set of seals Item

1 5 15 18 20

14

Code No.

OSPA

150-4205 Setofseals

Shaft seal

633B9004Kinring

1

O-ring O-ring

633B1202 633B1173

1 2

O-ring Washer

633B1192 683X2481

1 7

Roto Glyd, O-ring/Kin-ring Dust seal ring Shaft seal

150N4040 633B9002 150N4014Roto Glyd 150N4007 O-ring/Kin-ring

1 1 1

O-ring O-ring Washer

633B1202 633B1173 684X2481

1 2 7

HN.21.UA.52

Comments

Number per unit

Spare Parts

Danfoss

Danfoss In addition industrial controls and

Argentina

Danfoss S.A. SanLorenzo 4310 1605 Munro Buenos Aires Tel. 54 1 756 4200 Telex 9900 Booth-AR Fax 5417564100

Danfoss (Australia) Pty. Ltd. Melbourne (Head Office) 1 Ricketts Road Private Bag 20, Mt. Waverley Victoria, 3149 Tel.:613 95431033 Fax:613 9543 4027 Danfoss authorized service shop

Austria

HAINZL INDUSTRIESYSTEME Gesellschaft m.b.H. & Co KG Industriezeile 56 P.O. Box 100 A-4040 Linz Tel. : 43 732 7892 Telex : 22 1522 Fax :43 732 7892 150 Danfoss authorized service shop

Belgium

N.V. Danfoss S.A. ErasmusBusinessPark Av.JosephWybran45 B-1070 Bruxelles Tel. :32 02 525 0711 Telex : 24828 Fax :32 02 525 0757 Danfoss authorized service shop

Brazil

Canada

Danfoss do Brasil Ind.eCom.Ltda. Rua Nelson Francisco 26, Casa Verde CEP 02712-100 S&o Paulo Tel.:55118555400 Fax: 55 11 855 5455 Danfoss authorized service shop DanfossFluid Power 7880 Transmere Drive Mississauga Ontario L5S IL9 Tel. : 1 905 673 0559 Telex : 06961216 Fax : 1 905 673 5039 Danfoss authorized service shop

Chile

TALLERES LUCAS LTDA. Av.BlancoEncalada 1737 Santiago Tel.: 56 2 672 6223/695 4233 Fax: 56 2 698 2515

China

Danfoss (Tianjin) Ltd. Wuging Development Area Road 3 Tianjin 301 700 Peoples Republic of China Tel.: (8622) 2 933 6400-06 Fax:(8622)29336407 SYMBRIDGE INTERNATIONAL Room E 12F GaoJia Building No.1 Chungfeng Road Shenzhen 518005 P.R. China Tel.: +86 755 218 6843 Fax: +867552170147

is an international to the

hydraulic

automatics, for heating

thermostats

Ing. Lahusen S.R.L. Av.Belgrano, 615- 8° I 1092 - Buenos Aires Tel. : 54 1 342 1083/1835 Fax : 541 3317314 Australia

Hydraulics

Organization

concern

precision plant,

with

components, step

system

for refrigerators

in 10 countries

Danfoss

systems,

controls, and

factories the

range

industrial

and subsidiaries

of products

instrumentations,

components

for burners

electrical and

Fiza Ltda. Carrera 40 N° 163-A-55 (Toberin) Santaf_ deBogot& D.C. Colombia S.A. Tel.: 57 1 677 6346/677 6440 5716775142 Fax: 57 677 7025

Croatia

Danfoss d.o.o Heinzelova 6a HR-10000 Zagreb Tel.:+3851 4553 444 Fax:+3851 4487 75

Cyprus

Tektron Ltd. 25, Heroes Street P.O. Box 2123 Strovolos-Nicosia Tel. : 3572497907 Telex : 3968 tektron cy Fax :357 2 31 4844

Greece

Danfoss A/S DK-6430Nordborg International tel.: 45 74 88 2222 National tel.:74882222 Telex: 50599 Fax : 4574490949 45 74 49 1613 (Hydr.) Danfoss Hydraulik A/S Toppevadvej 44-46, GanlQse DK-3660Stenlese Tel. : 4542 184055 Telex : 40041 Sondgd dk Fax :4542184603 Danfoss authorized service shop

France

OY Danfoss AB Kivenlahdentie 7 SF-02360 Espoo Tel. : 358 9 802 81 Fax : Hydraulicsdept. 358 9 802 85 61 Danfoss authorized service shop Danfoss S.a.r.I. Z.A.deTrappes-Elancourt 7, Av. Roger Hennequin P.O. Box 58 F-78193Trappes-Cedex Tel. : 33 1 30 62 5000 Telex : 697 809 F Fax : 33 1 30625009 Danfoss authorized service shop

Germany

Danfoss Antriebs- und Regeltechnik GmbH Gesch&ftsbereichHydraulik CarI-Legien-Str. 8 D-63073 Offenbach/Main P.O. Box 10 04 53, D-63004 Offenbach/Main Tel. 49 069 8902 0 Telex 4-152876 Fax 49 69 8902 319 49 69 8902 316 Danfoss authorized service shop

Great Britain

Danfoss Limited Perivale Industrial Park Horsenden Lane South Greenford, Middx. UB6 7QE Tel. 440819917000 Telex 24223 Fax 44 181 991 7053 Danfoss authorized service shop

HN.21 .UA.52

drives

controls, and

controls,

compressors

A. SKOURA & Co. E.E. SpirouPatsi105 GR-118 55Athens Tel. : 30013453906 30 01 346 3967 Telex : 216713 Deda Gr. Fax : 30-1-34 74106(Skouras)

HongKong NICKO INTERNATIONAL RM. 1203, Chevalier Commercial Centre 8 Wang Hoi Road Kowloon Bay,HongKong Tel. : 85227552783 Fax : 85227988656 Hungary

KITE Nadudvar 4181 Nadudvar, Bem. J.U.2. Tel. 36 54 48 0401 Telex ::72431 Fax : 3654480331

Iceland

HEDINN VERSLUN H/F Seljaveg 2 P.O. Box 512 IS-121 Reykjavik Tel. 354 562 4260 Telex2003Hedinn IS Fax 354 562 4315 Danfoss authorized service shop

India

DANTAL HYDRAULICS PVT Ltd. 805-806ChiranjeevTower Nehru Place NewDelhi110019 Tel.:91 64601 55+ 6425036+ 6453806 Fax:91116476089 Danfoss authorized service shop

Iran

Dancool Iran Co. Ltd. PicheShemiran Kh.TonekabonNo.15 Teheran 11488 Tel. : 98217532026 98 21 7523 835 Fax : 98 21 7530 565 Telex : 222235 dicIR

Israel

Radion EngineeringCompany Ltd. 11 Ha'sivimSt. P.O.B. 7111 Petah-Tikvah49250 Tel. 972 3 922 6688 Telex 3812 93reco IL Fax 972 3 922 6655

Italy

Danfoss s.r.I. Division Sordella StradaCarignano48 1-10024Moncalieri / Torino Tel. : 39 11 682 7111 Fax : 39116827199 Danfoss authorized service shop

Japan

Danfoss K.K. Head Office Shinyokohama Mineta Bldg. 3-19, Shinyokohama 2-chome Kohoku-ku Yokohama, 222 Japan Tel. : 81 45 476 5001 Fax :81454765010 Danfoss authorized service shop

Korea

UNITEK Corporation Korea World Trade Center P.O. Box 181 Room201Seokyung Bldg. 1000-3 Daichi-Dong, Kang Nam-Ku Seoul, Korea Tel. : 822 5670090 Fax : 822 5692894 Danfoss authorized service shop

Czech Republic TECHNO TRADE GmbH Slovak Republic Petr Kejdus Tovarni ul. 41 CS77200Olomouc Tel.: 420 68 52 22 004 Fax: 420 68 52 32 055

Finland

boilers,

in 32 countries. refrigeration

freezers.

Colombia

Denmark

includes

15

Danfoss

Hydraulics

Organization

Malaysia

Danfoss Industries Sdn. Bhd. No. 14, Jalan 5 TamanPerindustrian BatuTiga 40000 ShahAtam, Selangor Tel. : 60 3 550 1685 Fax : 603 5502805

Rumania

Michail Petrache S.C. LYRA PRODIMPEX Ltd. B-dulTimisoara41 BI.P14,Sc.B.Ap.24 773621 BUCURESTI Tel. : 401 323 8373, 401 323 8379 Fax : 4013238399

Mexico

Ignacio Gomez, General Manager MillerPotenciaFluida Israel 301 ESQ Damasco Col. Ricardo B. Anaya 2A Seccion Apdo.PostalF-1241 San Luis Potosi, S.L.P. Mexico Tel. : 5248 21 1937 Fax : 52 48 21 2160

Russia

ZAO Danfoss Marksistskaya ul.34 109147 Moscow Tel.: 7 095 792 5757 7 5017925757(Satellite) Fax: 7 095 792 5760 7 5017925760(Satellite)

Netherlands

ITHO bv Adm. deRuyterstraat 2 3115HBSchiedam P.O. Box21 3100AASchiedam Tel. 31 0104278500 Telex 23 337 Fax 31 10 427 1534 Danfoss authorized service shop

Republic of South Africa

Danfoss (Pty) Ltd. Cambridge Commercial Park 23TrinityClose Paulshof Ext.45 Johannesburg Tel. : 27118038390 Fax : 27 11 8038244 Danfoss authorized service shop

Singapore

Danfoss IndustriesPte. Ltd. 6 Jalan Pesawat Singapore 619364 Tel. :652614088 Fax :652610488 Danfoss authorized service shop

Slovenia

TechnicalOffice Klun Ut. BratovMartinec 16 S1-1000Ljubljana Slovenija Tel. : 386 61 127 3718 Fax : 386 61 127 t624

Spain

Danfoss S.A. Avda. Tenerife No. 22 Pol. Ind. Norte 28700 San Sebastian de los Reyes (Madrid) Tel. : 34 1 663 8051 Fax : 34 1 663 7570 Danfoss authorized service shop

Sweden

DanfossAB Brita Sahlgrens Gata 8C Box 9143 40093 GSteborg Tel. : 031 709 27 00 Fax : 031 709 27 49 Danfoss authorized service shop

New Zealand

Norway

Poland

Portugal

Danfoss (New Zealand) Limited 8 George Bourke Drive P.O.Box12-422, Penrose MT Wellington Auckland Tel. :6492702110 Fax : 64 9 270 2112 Danfoss authorized service shop Danfoss A/S Arenga 2 N-1314 Skui Tel. : 47 87 13 5680 Fax : 47 67 13 6850 Danfoss authorized service shop Danfoss Sp. z o.o. ul. Obozowa20, 01-161 Warszawa Tel. 632 00 75, 632 39 81,632 43 84 Telex 815777 dfoss pl Fax 632 69 32 KOMERTEL: 39 12 1251,39 12 32 91 Danfoss (Portugal),Lda. Av.do Forte,8-1° P EdificioPujol P-2795 Carnaxide Tel. 351 1 417 2455/65 Telex 12872 danfos p Fax 351 1 417 2466

Switzerland

Danfoss Werner Kuster AG Parkstrasse 6 CH-4402Frenkendorf Tel. : 410619011515 Fax :410619014180 Danfoss authorized service shop

Taiwan

Symbridge Machinery Co. Ltd. 28 Lane 205, Sec. 3 ChungChingNorthRoad P.O. Box 47-132 Taipei/Taiwan R.O.C. Tel. 8860259108168 (threelines) Telex 19437 SYMBRI Fax 886025914190

Thailand

Danfoss (Thailand)Co., Ltd. 47/11 Ngam Wong Warn Road Bangkhen, Bangkok 10900 Tel. :662561 1130 Fax :662561 1446

Turkey

MERT TEKNIK FABR. MALZEMELERI TICARET ve SANAYI A.S. Tersane Cad. No. 43 80000 Karak_y - Istanbul Tel. 90 0 212 252 8435 Telex (18)931251 Fax 900 2122456369 Danfoss authorized service shop

U.S.A.

Danfoss Fluid Power Division of Danfoss Inc. Norht American Headquarters 8635 WashingtonAvenue Racine, Wisconsin53406 Tel. : 1 414 884 7400 Fax : 1 414 884 7440 Danfoss authorized service shop Danfoss FluidPower Division, EasleyOperations 1201 Pelzer Highway P.O. Box 2189 Easley, South Carolina 29640 Tel. : 1 864 855 2884 Fax : 1 864 855 5885 (general) 1 864 850 6010 (executiveoffice)

Yugoslavia

Danfossd.o.o. Prizrenska6/111 YU-11000 Beograd Tel. : +381 11 683 077 Fax : +381 11 688 621

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice.This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

DK-6430 Nordborg Denmark 16

c_

HN.21.UA.52

Halvorsen Section 5. Hydraulic Pumps and Motors

LINDE HYDRAULICS CORP. HPR-75-02 PUMP INSTALLATION AND ADJUSTMENT INSTRUCTIONS Variable Displacement Axial Piston Pump SPARE PARTS LIST (REF. 253 804 91 11) Controllable Pump HPR 75-02 SERVICE TRAINING, MAINTENANCE AND PARTS LIST CHX 01 Engine Speed Control Actuator PARKER HANNIFIN CORP. Hydraulic Pump and Motor Division INTRODUCTION AND CONTROL OPTIONS CATALOG (2600-102-1/USA) Series PVP Variable Volume, Piston Pumps (Emergency Pump) PARKER PUMPS PARTS AND SERVICE (BULLETIN PM 1620-12-M1/USA) PVP Series Variable Volume Piston Pump ROSS OPERATION SERVICE MANUAL (2704) Torqmotor MG, MF, MB, ME, MJ Series Service Procedure

HYDRAULIC PUMPS AND MOTORS

5-5 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

HPR-75 Variable Displacement nigh Perfurmance Axial Piston Pump Open Loop, 4.63 cir Peak Pressures to 7250 psi Specifically designed for high pressure, heavy-duty applications with 6090 psi maximum pressure, and a maximum speed of 2600 rpm, this open loop pump features the new 02 rotating group. The HPR-75 also is available with a PTO option. Standard control is LS/Pressure Comp. Optional controls are Load Sense, Pressure Compensated, and Load Sense with a power mode valve. The compact nature and outstanding performance characteristics of the leading edge 02 piston design makes this pump attractive to apply in load sense and other open loop systems where high output is required.

SPECIFICATIONS Displacement

cc (cir)

75.9l4.63 2600 (w/o tank pressurization)

Maximum Input Speed (rpm) Nominal Pressure (psi/bar)

36251250

Maximum

6090/420

Pressure (psi/bar)

7250/500

Peak Pressure (psi/bar)

ANSI 16/32,21T/SAE

Shaft Mount

SAE C, 2 bolt

PTO

SAE 8, 2 bolt Load Sense/Pressure

Standard Controls

&g&l& LINDE

HYDRAULICS

P/N 888 006 6451

C

Comp.

9” x 7.1 u x 9.2”

Envelope

u

World Class Hydraulics for Mobile and Industrial Applications

CORPORATION

-

-

BOX 62 l 5069 WESTERN RESERVE ROAD PHONE (330) 533-6601 l FAX (330) 533-2091 P.O.

l

CANFIELD, OH 44406

/

~=fGGZZlnstallation and Start-Up /-’ Instructions

O&b-

Service Bulletin

HP&startupdoc HPR-02, Section Rev. 1, 5-22-00 Page 1 of 5

B

Installation: l

l

l

l

l

l

Installation must be carried out in accordance with the circuit or piping diagram. Always cover or cap all HPR-02 case drain, control, and high pressure hydraulic lines during the installation of a new or replacement HPR-02 pump. Always insure that all connections to the HPR-02 replacement pump are capped or covered during the initial installation. Connect and tighten each hydraulic line one at a time removing caps or covers just before each connection is made. It is recommended that the HPR-02 pumps be mounted with the control facing upward or facing either side. Avoid mounting the pump with the pump control facing down - Any contaminants in the oil will eventually settle into the control. During the intial start-up, additional care must be taken to vent entrapped air from the pump control via the highest located control port.

Suction/Inlet l

l

Line:

The suction/inlet line must be mounted continuously

rising towards the reservoir.

A flooded suction or pressurized inlet should be of adequate supply as to guard against cavitation. A pressurized inlet should be limited to a maximum pressure of 20 psig. IMPORTANT: The pressure, measured directly in the inlet port of the pump, should never be 0 psi or less under any operating conditions. Violating this important note will result in cavitation damage to the HPR-02 pump.

Venting l

l

l

l

(Case Drain):

Positive venting is vital for the correct operation of the hydraulic system. All case drain lines must be mounted continuously rising towards the reservoir. This allows any entrapped air to escape freely from the pump housing. The highest case drain port of the pump housing must be connected to the reservoir and should be below the oil level in the reservoir, as illustrated on the next page. The case drain line has to be sized and the reservoir has to be installed in such a way as to limit the maximum case pressure to 30 psig. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Service Bulletin

HPR-02 Installation and Start-Up Instructions

HPR-startup.doc HPR-02, Section Rev. 1, 5-22-00 Page 2 of 5

B

Case Drain Line

Piping: l

l

l

Pipe work should be seamless drawn precision steel tube or hoses of suitable pressure rating. During installation, attention should be paid to cleanliness. washed and blown through.

The pipes must be deburred,

Scaled or rusted pipes must be scoured and then neutralized - Hoses must be brushed and flushed through when contaminated. IMPORTANT: The cleanliness of the circuit before commissioning has a crucial influence on the operation and life expectancy of the hydraulic components.

Fillinq the Hydrostatic l

l

Transmission:

The initial filling of the system must be carried out in such a way that all of the air can escape from the high pressure circuit and from the pump/motor housings before the hydraulic units are operated. Manually fill the HPR-02 pump housing at the most accessible case drain port with filtered oil. Manually fill the high pressure line with filtered oil. Fill the oil reservoir to the maximum level with filtered oil and fill all motor housings to the maximum level via the most accessible case drain port with filtered oil. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

r

HPR-02 Installation and Start-Up Instructions

Service Bulletin

HPR-startup.doc HPR-02, Section Rev. 1, 5-22-00 Page 3 of 5

B

Initial Start-Up: 1. Start the prime mover (leave at low idle) and allow the HPR-02 to rotate for 10 seconds. 2. Stop the prime mover and wait 1 minute. 3. Repeat steps #I and #2 four more times. 4. Start the prime mover and set it to low idle, then slowly actuate a function 3 times to allow the HPR-02 to increase to maximum displacement. Leave the function fully actuated for 30 seconds each time. 5. Warm the system up by steadily increasing the prime mover speed and pressure so as to allow any air to be purged from the fluid. 6. Check the HPR-02 stand-by pressure, load sense margin pressure, pressure compensator setting (if applicable), VD3 performance valve setting (if applicable), and maximum flow setting when the hydraulic oil reaches its normal operating temperature. 7. Check the oil level in the reservoir and fill with filtered oil if necessary before delivery of the machine. Routine l

l

l

Maintenance filtration.

of the hydraulic system is limited to changing the hydraulic fluid and system

In order to gaurantee the proper function and efficiency of the HPR-02, the purity of the hydraulic oil over the entire operating period must comply to at least class 18/13 according to IS0 4406. With modern filtration technology, however, much better values can be achieved which contributes significantly to extending the life and durability of the HPR-02 and the complete system.

Changing l

Maintenance:

the Filters:

It is recommended that the filters be changed after the initial start-up or at least 100 hours from the initial operation. Additional filter changes should be made after 500 hours of operation from the previous filter change.

Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

o4!2sbService Bulletin

HPR-02 Installation and Start-Up Instructions

HPR-startupdoc HPR-02, Section Rev. 1,5-22-00 Page 4 of 5

B

Note: These recommendations are provided for guidance to insure long service life and proper operation of the HPR-02 pump. However, depending on the operating conditions of the HPR-02, it may not be necessary to adhere to these recommendations as long as the oil cleanliness level and oil vicosity specifications are strictlv adhered to. Chancjnq l

l

l

the Hydraulic

Fluid:

Oil changes are carried out by first draining the reservoir, cooler, pump, and motor housings. The high-pressure fluid must be changed after 1000-2000 hours of operation, according to the application. High working temperatures and frequent cooling-down phases with low temperatures condense water and will shorten the life of the hydraulic fluid. The oil remaining in the high-pressure circuit itself need not be changed. The instructions regarding initial filling must be adhered to when changing the hydraulic fluid. In some applications, a complete oil change may not be necessary. The oil lost during each filter change must be replaced by fresh filtered oil.

Cleaning: l

Cleaning of the hydraulic system when changing oil is normally not necessary. If the system becomes contaminated due to unusual circumstances (defect, etc.), then it must be thoroughly cleaned before recommissioning. Housings and pipelines must be flushed. If necessary, the pipelines and hydraulic units must be disassembled.

Service: l

l

Maintenance and repairs should be undertaken only by skilled personnel who are familiar and trained with the equipment. Linde offers an excellent after-sales service capable of carrying out the work of repair and overhaul if required. Only spare parts specified in the Linde spare parts catalogs should be used. The serial number stamped on the unit name tag is relevant to the configuration of the unit. Therefore, the serial number should be quoted when ordering spare parts.

Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Service Bulletin Oil Selection

HPR-02 Installation and Start-Up Instructions and Viscosity

HPR-startup.doc HPR-02, Section Rev. 1, 5-22-00 Page 5 of 5

B

Recommendations:

Suitable hydraulic oils are: l Mineral oil HLP to DIN 51524 l Biodegradeable fluids upon request l Other pressure fluids upon request Linde recommends only using hydraulic oils which are confirmed by the producer as suitable for use in high pressure hydraulic installations. For the correct choice of suitable hydraulic oils, it is necessary to know the working temperature in the hydraulic circuit. The hydraulic oil chosen must allow the working viscosity to be within the optimum viscosity range (as shown below). Attention: Due to pressure and speed influences, the temperature of the leakage fluid is always higher than the circuit temperature. The temperature must not exceed 194°F (90°C) in any part of the system. Under special circumstances, if the stated conditions cannot be observed then please consult Linde. l l l

l

Recommended viscosity range for optimum performance: 15 cSt to 30 cSt Maximum allowable working viscosity range: IO cSt to 80 cSt Viscosity limitations: 6 cSt minimum viscosity 1000 cSt maximum viscosity (Intermittent for cold starts) Oil temperature limitations: (-68)“F to 194°F (-20) “C to 90°C

Guidelines l

for Usinq HPR-02 Pumps Without

Suction

Screens:

Provided that proper contamination control is designed into the system and practiced during operation, a suction screen is NOT required for the application of the HPR-02 pumps. Proper contamination control guidelines are considered to be: a. Oil cleanliness control and proper flushing during system manufacturing exercised. b. Assurance that no contaminants up is essential.

must be

are present in the reservoir or lines upon initial start-

c. The HPR-02 must be protected from system contaminants during operation, either by incorporating return-line filtration or off-line filtration with return-line screens. d. Discipline must be exercised during operational maintenance are not introduced into the system or pump. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

to insure contaminants

Ohio 44406

Load Sense and Pressure Compensator Control Adjustment for HPR-02 Pump

Service Bulletin

LS

HPR-LSDA.doc HP&02, Section Rev. 1, 5-22-00 Page 1 of 3

E

Load Sense

I

Pressure

1 To Function

0

0

Tools/Equipment Required: l O-7000 psi pressure gauge or transducer 0 O-500 psi )p-gauge l 13mm wrench l 6mm wrench (optional: small adjustable wrench) WARNING: If performing this procedure on a vehicle, care must be taken. The pump will be put on stroke during this procedure, hence all personnel should be removed from the area of the machine. If using the pump for a propelling function, then the vehicle must be safely elevated to allow the propel motor to free-wheel. Load Sense “Marqin

Pressure”

Adjustment

Procedure:

1. Install the )p-gauge as illustrated in the schematic above. Make sure that the “HI” side of the gauge is connected to “P” and the “LO” side is connected to “LS”. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

I

Service Bulletin

Load Sense and Pressure Compensator Control Adjustment for HP&02 Pump

HPR-LSDA.doc HPR-02, Section Rev. 1, 5-22-00 Page 2 of 3

E

NOTE: There are two methods which can be used to set the “margin pressure” on an HPR-02 pump. The method illustrated in “Step #2” is recommended to accurately set the “margin pressure”. However, the method illustrated in “Step #3” is sufficient for field adjustments or if the parameters in “Step #2” cannot be met. The recommended pressure range for the “margin pressure” setting is 290 to 305 psi. Margin pressure set greater than 305 psi may lead to erratic and unstable performance from the pump. Margin pressure set less than 290 psi may lead to smoother or sluggish performance from the pump. 2. This is the recommended

procedure to use:

a. Set the pump input speed to 2300 RPM. b. Use a loading valve or relief valve to limit the pump output pressure (at port “P”) to 145OV73 psi. c. Set the pump output flow to 18.5Vl.3

GPM.

d. Use the )p-gauge to determine the “margin pressure” setting. e. To Adjust the “Margin Pressure”: l

l

l

Use the 13mm wrench to loosen the locking nut on the “Load Sense Adjustment”. Use the 6mm wrench to turn the “Load Sense Adjustment” stud. Turn it IN to increase the “margin pressure” setting or turn it OUT to decrease it. When the desired “margin pressure” is acquired, hold the adjustment stud stationary with the 6mm wrench and tighten the locking nut with the 13mm wrench.

3. The following procedure is optional for field adjustment: a. Set the pump input speed to 2300 RPM. If this is not possible, set it to high idle. b. Actuate a function so that the pump supplies flow. If possible, limit the pump flow to 18 to 20 GPM. Also, if possible, actuate a function which only requires around 1500 psi to move. c. Use the )p-gauge to determine the “margin pressure” setting.

Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Service Bulletin

Load Sense and Pressure Compensator Control Adjustment for HPR-02 Pump

HPR-LSDA.doc HPR-02, Section Rev. 1, 5-22-00 Page 3 of 3

E

d. To Adjust the “Margin Pressure”: l

l

l

Pressure

Use the 13mm wrench to loosen the locking nut on the “Load Sense Adjustment”. Use the 6mm wrench to turn the “Load Sense Adjustment” stud. Turn it IN to increase the “margin pressure” setting or turn it OUT to decrease it. When the desired “margin pressure” is acquired, hold the adjustment stud stationary with the 6mm wrench and tighten the locking nut with the 13mm wrench. Compensator

Adjustment:

1. Install the O-7000 psi pressure gauge to measure pump outlet pressure (port “P”). 2. Block the pump outlet pressure (port “P”). This can be done by: l Deadheading a cylinder that the HPR-02 supplies flow to l Pinning the wheel or track motor that the HPR-02 supplies flow to 3. Make sure that all supplemental relief valves in the HPR-02 pump’s circuit are adjusted HIGHER than the desired pump pressure compensator setting. 4. Set the prime mover to high idle. 5. Actuate the function from step #2 and read the value on the pressure gauge. 6. To Adjust the Pressure Compensator: l

l

l

Use the 13mm wrench to loosen the locking nut on the “Pressure Compensator Adjustment”. Use the 6mm wrench to turn the “Pressure Compensator Adjustment” stud. Turn it IN to increase the pressure compensation setting or turn it OUT to decrease it. When the desired pressure setting is acquired, hold the adjustment stud stationary with the 6mm wrench and tighten the locking nut with the 13mm wrench.

Note: The pressure compensator spring in this control is NOT adjustable for the full pressure range of the pump. There are several pressure compensator springs available and each spring has a limited pressure range. Consult Linde Engineering for a listing of springs if you cannot adjust the pump control to the desired pressure setting.

Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Maximum Displacement Adjustment Procedure for Sinale HPR-02 Pumps

Service Bulletin

HPR-MAX.doc HPR-02, Section Rev. 0 Page 1 of 2

E

Note: This Service Bulletin is ONLY valid for sinqle HPR-02 pumps Maximum Displacement Adjustment for a CW (Right-Hand) Rotation Pump

F\

ii

Maximum Displacement Adjustment for a CCW (Left-Hand) Rotation Pump Adjustment Stud r(Typical) ’

\

Nut I Seal (Typical)

Tools/Equipment l l

Required:

19mm closed-end wrench 6mm Allen wrench

Adjustment

Procedure

to Set the Pump at Maximum

Displacement:

Note: The prime mover can be OFF for this procedure. 1. Use the figure above to determine where the “Maximum the rotation of your pump.

Displacement

Adjustment”

is for

2. Hold the adjustment stud stationary with the 6mm Allen wrench and loosen the seal nut with the 19mm wrench. 3. Turn the adjustment stud OUT until you feel it lose contact with the stroking piston inside of the pump.

I--

Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

I

Service Bulletin

Maximum Procedure

Displacement Adjustment for Single HPR-02 Pumps

HPR-MAX.doc HPR-02, Section Rev. 0 Page 2 of 2

E

4. Slowly turn the adjustment stud IN until you feel it just touch the stroking piston inside of the pump, then turn the adjustment stud IN l/4 turn. 5. Hold the adjustment stud stationary with the 6mm Allen wrench and tighten the seal nut with the 19mm wrench (The proper torque for the seal nut is 60 N-m [44 ft-lb]). Adjustment

Procedure

to Destroke the Pump:

WARNING: If performing this procedure on a vehicle, care must be taken. The pump will be put j on stroke during this procedure, hence all personnel’should be removed from the area of the machine. If using the pump for a propelling function, then the vehicle must be safely elevated to allow the propel motor to free-wheel. 1. Use the figure above to determine where the “Maximum the rotation of your pump.

Displacement

Adjustment”

is for

2. Start the prime mover and actuate a function that this pump supplies flow to. Make sure that the function you select can accommodate the full flow of the pump. 3. Hold the adjustment stud stationary with the 6mm Allen wrench and loosen the seal nut with the 19mm wrench. 4. Slowly turn the adjustment stud IN until the desired pump flow is acquired. 5. Hold the adjustment stud stationary with the 6mm Allen wrench and tighten the seal nut with the 19mm wrench (The proper torque for the seal nut is 60 N-m [44 ft-lb]).

Note: To decrease the maximum pump flow, turn the adjustment stud IN. To increasethe maximum pump flow, turn the adjustment stud OUT. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield, Ohio 44406

Minimum Displacement Adjustment Procedure for Sinqle HPR-02 Pumps

Service Bulletin

HPR-MIN.doc HPR-02, Section Rev. 0 Page 1 of 2

E

Note: This Service Bulletin is ONLY valid for single HPR-02 pumps Minimum Displacement Adjustment for a CCW (Left-Hand) Rotation Pump

Tools/Equipment l l

Minimum Displacement Adjustment for a CW (Right-Hand) Rotation Pump

Required:

19mm closed-end wrench 6mm Allen wrench

Adjustment

Procedure

to Set the Pump at Minimum

Displacement:

Note: This procedure is ONLY intended to be used if the pump minimum displacement setting has been altered or if the stand-by pressure is unusually high, 1. With the prime mover OFF, disconnect the load sense line from the pump control block. 2. Securely plug the end of the load sense line. 3. Leave the load sense port on the pump control block vented to atmosphere. 4. Start the prime mover and adjust it to high idle. Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Service Bulletin

Minimum Displacement Adjustment Procedure for Single HPR-02 Pumps

HPR-MIN.doc HPR-02, Section Rev. 0 Page 2 of 2

E

5. To Adjust the Pump Minimum Displacement: a. Use the figure above to determine where the “Minimum for the rotation of your pump.

Displacement

Adjustment”

is

b. Hold the adjustment stud stationary with the 6mm Allen wrench. c. Loosen the seal nut with the 19mm wrench. d. Slowly turn the adjustment stud OUT until you feel it lose contact with the stroking piston inside of the pump. WARNING: The minimum displacement adjustment stud is NOT restricted from being removed completely from the pump. Care must be taken to insure you do not remove the adjustment stud completely from the pump. e. Slowly turn the adjustment stud IN until it just touches the stroking piston inside of the pump. f.

Then turn the adjustment stud OUT 114 turn.

’

g. Hold the adjustment stud stationary with the 6mm Allen wrench and tighten the seal nut with the 19mm wrench (The proper torque for the seal nut is 60 N-m [44 ft-lb]). 6. Turn the prime mover OFF. 7. Unplug the end of the load sense line and reconnect it to the load sense port on the pump control block.

Note: To decrease the minimum displacement, turn the adjustment stud OUT To increase the minimum displacement, turn the adjustment stud IN Linde Hydraulics

Corporation,

P.O. Box 82, Canfield,

Ohio 44406

Hydraulics

Series PVP Variable Volume, Piston Pumps Catalog 2600-102-1/USA

hpm102-1.p65, lw, jk

Hydraulics

A179

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

A

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Introduction

A

Quick Reference Data Chart Pump Model

†

Displacement cc/rev (In3/rev)

Pump Delivery @ 21 bar (300 PSI) in LPM (GPM) 1200 RPM

1800 RPM

† Approx. Noise Levels dB(A) @ Full Flow 1800 RPM (1200 RPM)

Input Power At 1800 RPM, Max. Displacement & 34 bar 69 bar 138 bar 207 bar 248 bar (500 PSI) (1000 PSI) (2000 PSI) (3000 PSI) (3600 PSI) 248 bar (3600 PSI)

Operating Speed (RPM) (Maximum)

Pressure bar (PSI) Continuous (Maximum)

PVP16

16

(.98)

19.7

(5.2)

29.5

(7.8)

53 (47)

55 (50)

59 (54)

62 (56)

65 (59)

13.1 kw (17.5 hp)

3000

248 (3600)

PVP23

23

(1.4)

28.0

(7.4)

42.0 (11.1)

61 (57)

64 (59)

67 (63)

69 (65)

70 (65)

19.7 kw (26.5 hp)

3000

248 (3600)

PVP33

33

(2.0)

39.4 (10.4)

59.0 (15.6)

64 (59)

66 (59)

68 (62)

70 (64)

71 (65)

27.2 kw (36.5 hp)

3000

248 (3600)

PVP41

41

(2.5)

49.2 (13.0)

73.8 (19.5)

68 (60)

70 (61)

73 (65)

74 (67)

75 (69)

33.2 kw (44.5 hp)

2800

248 (3600)

PVP48

48

(2.9)

57.6 (15.2)

86.4 (22.8)

69 (60)

71 (62)

73 (65)

75 (68)

76 (69)

40.3 kw (54.0 hp)

2400

248 (3600)

Measured in an anechoic chamber to DIN 45635, measuring error + 2 dB(A). Fluid used: petroleum oil to ISO VG 46; temperature = 50°C (122°F). Since many variables such as mounting, tank style, plant layout, etc., effect noise levels, it cannot be assumed that the above readings will be equal to those in the field. The above values are for guidance in selecting the proper pump.

Pump Delivery @ 21 bar (300 PSI) in LPM (GPM)

* Approx. Noise Levels dB(A) @ Full Flow 1800 RPM (1200 RPM)

Input Power At Pressure Operating 1800 RPM, Max. bar (PSI) Speed (RPM) Displacement & Continuous 34 bar 69 bar 138 bar 207 bar 248 bar (Maximum) (Maximum) (500 PSI) (1000 PSI) (2000 PSI) (3000 PSI) (3600 PSI) 248 bar (3600 PSI)

Pump Model

Displacement cc/rev (In3/rev)

PVP60

60 (3.7)

71.9 (19.0) 106.0 (28.0) 72 (68)

73 (69)

75 (70)

77 (70)

77 (70)

47.7 kw (64.0 hp)

2200

248 (3600)

PVP76

76 (4.6)

91.2 (24.1) 134.4 (35.5) 75 (70)

75 (69)

75 (70)

77 (70)

78 (72)

61.9 kw (83.0 hp)

2200

248 (3600)

PVP100 100 (6.1)

120.0 (31.7) 180.0 (47.5) 73 (67)

75 (69)

78 (72)

79 (75)

81 (75)

83.5 kw (112.0 hp)

1800

248 (3600)

PVP140 140 (8.54)

171.0 (45.5) 252.0 (67.0) 80 (71)

80 (72)

80 (75)

82 (76)

84 (77) 117.8 kw (158.0 hp)

1800

248 (3600)

1200 RPM

1800 RPM

* Since many variables such as mounting, tank style, plant layout, etc., effect noise levels, it cannot be assumed that the above readings will be equal to those in the field. The above values are for guidance in selecting the proper pump. Noise levels are A-weighted, mean sound pressure levels at 1 meter from the pump, measured and recorded in accordance with applicable ISO and NFPA standards. hpm102-1.p65, lw, jk

Hydraulics

A181

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Introduction

COMPENSATOR SPOOL

SERVO PISTON

PUMP HOUSING

CASE DRAIN

BIAS SPRING

SHAFT BEARING

OUTLET PORT

REAR COVER

PISTON

INLET PORT

SHAFT BEARING

PORT PLATE

CYLINDER BARREL

SWASH PLATE

Features

Controls

• • • • • • • •

• • • • • • •

High Strength Cast-Iron Housing Fast Response Times Two Piece Housing For Ease of Service Metric Pilot, Shaft and Ports Available Replaceable Bronze Clad Port Plate Thru-Shaft Capability Low Noise Levels Replaceable Piston Slipper Plate

SHAFT SEAL

Pressure Compensation Load Sensing Horsepower Limiting Horsepower and Load Sensing Remote Pressure Compensation Adjustable Maximum Volume Stop Hi/Lo Torque (Power) Limiting (PVP 41/48, 60/76, 100/140 Only) • Low Pressure Standby

hpm102-1.p65, lw, jk

Hydraulics

A182

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

General Description degrees. The rotating barrel, driven by the prime mover, moves the pistons in a circular path and the piston slippers are supported hydrostatically against the face of the swash plate. When the swash plate is in a vertical position, perpendicular to the centerline of the piston barrel, there is no piston stroke and consequently no fluid displacement. When the swash plate is positioned at an angle, the pistons are forced in and out of the barrel and fluid displacement takes place. The greater the angle of the swash plate, the greater the piston stroke.

All control is achieved by the proper positioning of the swash plate. This is achieved by a servo piston acting on one end of the swash plate working against the combined effect of the off-setting forces of the pistons and centering spring on the other end. The control spool acts as a metering valve which varies the pressure behind the servo piston. As shown in Figure 1, the amount of flow produced by the Parker Piston Pump is dependent upon the length of stroke of the pumping pistons. This length of stroke, in turn, is determined by the position of the swash plate. Maximum flow is achieved at an angle of 15-17

SERVO PISTON

BIAS SPRING

OUTLET

DRIVE SHAFT

INLET

PISTON

SWASH PLATE

CYLINDER BARREL

FIGURE 1 hpm102-1.p65, lw, jk

Hydraulics

A183

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

A

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Pressure Compensated Control (OMIT) and override swash plate forces. The outlet pressure causes the servo piston to move which reduces the angle of the swash plate and thereby reduces the pump’s output flow. When flow is again demanded by the system, the outlet pressure will momentarily fall allowing the compensator spool to move. This movement closes off the outlet pressure to the servo piston and vents the servo piston to case. The result of this venting allows the swash plate forces to move the swash plate angle to maximum displacement, thus responding to the demand for additional flow. Note that the compensator spring chamber is vented to the pump case via a hole internal to the compensator spool.

The swash plate angle controls the output flow of the pump. Swash plate angle is generated by the hydraulic force of the pumping pistons and the mechanical force of the swash plate bias spring. Control of the pump’s outlet flow is obtained by overriding the force of the pumping pistons and bias spring with the hydraulic force of the servo piston by means of internal porting. Pressure is connected from the outlet port to the servo piston via a compensator spool. The compensator spool is held against the spring guide by the outlet pressure. When the outlet pressure reaches the setting of the compensator control, the compensator spool moves, allowing outlet pressure oil to be metered into the servo piston. This metered oil provides adequate force to power the servo piston

OUTLET PORT

+Q -Q

INLET PORT

CASE DRAIN PORT

SERVO PISTON

OUTLET PORT

INLET PORT

PISTON

FIGURE 2 hpm102-1.p65, lw, jk

Hydraulics

A184

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Remote Pressure Control (M) plus the controlled port pressure setting. When the spool moves to the right, outlet pressure oil is metered to the servo piston and the pump swash plate angle is controlled accordingly. With this option the pump outlet pressure can be controlled and varied from a remote location. This control also incorporates a pressure limiting feature preset at the factory. When the pressure in the differential spring chamber reaches the maximum relief setting, the dart unseats allowing the spring chamber to vent to the pump case and limits the maximum pressure attainable.

The pump swash plate actuation is identical to the standard pressure compensator but can be controlled via a remote pressure control. Remote control of the pump output pressure can be achieved by controlling the pressure at port A, Figure 3 on the compensator. Flow is metered through the orifice in the spool from outlet pressure into the spring chamber. The spring chamber pressure is limited by an external relief connected to port A. The controlled pressure at port A is sensed at the differential spring chamber. The compensator spool will move to the right when the pump outlet pressure reaches a force equal to the differential spring setting

REMOTE PORT

OUTLET PORT

+Q -Q

INLET PORT

CASE DRAIN PORT

SERVO PISTON

OUTLET PORT

INLET PORT

PISTON

FIGURE 3 hpm102-1.p65, lw, jk

Hydraulics

A185

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

A

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Flow Control (Load Sensing) (A) spool and will urge the spool to the left until output pressure acting on the left side of the spool balances the forces. As the load increases, output pressure will increase and maintain a constant differential pressure across the orifice and thus a constant flow. Maximum pressure is limited by the internal dart setting. This setting is adjustable up to the maximum preset at the factory.

Figure 4 shows a PVP pump with flow control. The control is identical to the remote pressure compensation control except for an integral orifice, a solid compensator spool and adjustable differential pressure control. Port A is connected downstream of an orifice (variable or fixed) to sense the actual working pressure required. This pressure plus the differential spring force act on the right side of the compensator

VARIABLE OR FIXED ORIIFICE

SENSE LINE OUTLET PORT

SENSE PORT

ORIFICE

+Q

REMOTE PORT

-Q

SIGNAL LINE INLET PORT

CASE DRAIN PORT

PORT “A”

ORIFICE MAX. PRESSURE ADJUSTMENT

COMPENSATOR SPOOL

DIFFERENTIAL SPRING CHAMBER DIFFERENTIAL ADJUSTMENT

VARIABLE OR FIXED ORIFICE

SERVO PISTON

SYSTEM PRESSURE

OUTLET PORT

PISTON

INLET PORT

FIGURE 4

hpm102-1.p65, lw, jk

Hydraulics

A186

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Pressure & Power Control (H)

(Not Available on PVP 60/76 and 100/140) This control option is a Torque Limiting Control, but for constant speed applications it is generally referred to as a Horsepower Control. This control works in conjunction with the Remote Pressure Compensator, control option “M”. A second pressure control device called a horsepower control block, is assembled to the main pump housing. The HP block is plumbed to one of the ports on the remote compensator via steel tubing. The control dart in the HP block and the maximum pressure compensator dart in the remote compensator are connected in parallel. What makes the control dart in the HP block different from any other external relief valve is the pressure setting is mechanically linked to the pump swashplate angle. The cracking pressure of the HP dart is generally lower than the cracking pressure of the remote compensator dart. When the HP dart opens the

pressure in the differential spring cavity is lowered allowing the compensator spool to meter system pressure in the servo piston. As the servo piston extends, it rotates the swashplate and in turn rotates the HP cam. As the cam rotates it increases the force on the HP dart control spring. As the system pressure is allowed to increase, the pump gradually reduces its stroke (flow). When the system pressure reaches the setting of the maximum pressure dart the normal action of the remote compensator takes over. If the HP control is set low enough, the pump may reach zero stroke before the system pressure ever gets a chance to open the maximum compensator dart. This should be considered when making low power settings on systems requiring high working pressures. REMOTE PORT

OUTLET PORT

+Q -Q

INLET PORT

CASE DRAIN PORT

SERVO PISTON

OUTLET PORT

INLET PORT

PISTON SHOWN AT FULL STROKE. CAM WILL ROTATE CW AS PUMP GOES TOWARD ZERO STROKE.

FIGURE 5

hpm102-1.p65, lw, jk

Hydraulics

A187

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

A

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Pressure, Power & Flow Control (C) (Not Available on PVP 60/76 and 100/140)

Refer to the previous section(s) on Flow Control and Power Control. This is another case where multiple controls can be combined in parallel. Since the Power Control is just a special version of Remote Pressure Control, it can be combined with the Flow Control (Load Sense) option. The main point to remember here is that the pressure drop which is required to begin and maintain compensation comes from an external device (such as a proportional valve). This sensed pressure drop will control flow until one of the limits of the other controls has been exceeded. The pump will always respond to the lowest control setting for any given pressure. In addition to Load Sensing,

Power Control, and on-pump Pressure Control, Remote Pressure Control can also be included in this parallel device package. There is a remote port on the compensator body and one on the HP Control body, either of which may be used for remote pressure control. The important concept to remember in load sense circuits is that each pressure control device in and connected to the compensator must be protected from saturation. For this reason, use only the uppermost port on the compensator for connection of the load sense line and insure that an appropriate orifice is installed. All control options using a load sense compensator spool are supplied with this orifice.

SENSE LINE OUTLET PORT

SENSE PORT

+Q

REMOTE PORT

-Q

SIGNAL LINE INLET PORT

CASE DRAIN PORT

ORIFICE MAX. PRESSURE ADJUSTMENT

COMPENSATOR SPOOL

DIFFERENTIAL SPRING CHAMBER

DIFFERENTIAL ADJUSTMENT VARIABLE OR FIXED ORIFICE

SERVO PISTON

SYSTEM PRESSURE

OUTLET PORT

INLET PORT

PISTON

SHOWN AT FULL STROKE. CAM WILL ROTATE CW AS PUMP GOES TOWARD ZERO STROKE.

FIGURE 6

hpm102-1.p65, lw, jk

Hydraulics

A188

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Variable Volume Piston Pumps Series PVP

Catalog 1550-001/USA

Control Options

Hi/Lo Power Control (HLM)

(Available with PVP41 through PVP140 only) The graph shown below represents the flow-pressure characteristics of a Hi-Lo control for PVP pumps. There are up to four separate adjustments that must be made with the pump controls to get a particular setting, all of which influence the shape of the curve. To get the proper settings, it is very important that all pertinent information is supplied with each Hi-Lo pump ordered. As you can see from the graph below, there are two peak power points. Our intention is to have the same magnitude of power required for both peaks. Of course many combination of settings are possible but specification of the settings becomes very difficult. To make factory settings, we need to know the required flow (applicable if pump has a maximum volume stop), the shaft speed, the required Power limit, and the compensation pressure. Based on these requirements, we will adjust the low pressure set point and the reduced flow set point of the Hi-Lo control to best match the requested parameters called out on the order. Important note: As with power controls, not all combinations of flow, power, pressure, etc. are possible. The first rule is that the settings must conceptually be achievable (i.e. power out is ALWAYS less than power in). Be careful in assuming efficiencies when estimating the Out/In relationship, since a pump

operating at low pressure or in a de-stroked condition can have a much lower overall efficiency than expected. The other thing to keep in mind is that the pump will require the peak power at only two points. All other operating pressures will require less than maximum power and therefore the pump will deliver less hydraulic power in the appropriate ratio based on the actual pump efficiency at those conditions.

Typical Hi-Lo Control Flow/Pressure Characteristics

Outlet Flow

CONSTANT POWER CURVE LOW PRESSURE ADJUSTMENT

MAX. PSI ADJUST

LOW FLOW SETTING ADJUSTMENT

System Pressure OUTLET PORT

SENSE PORT

+Q -Q

REMOTE PORT LOW P

INLET PORT

HIGH P

CASE DRAIN PORT

SERVO PISTON OUTLET PORT

INLET PORT

PISTON

FIGURE 7

hpm102-1.p65, lw, jk

Hydraulics

A189

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

A

Bulletin PM 1620-12-M1/USA

Hydraulics

LSHT-120A Parker Pumps Parts & Service

Effective 30,1992 Revised: November May 1998

PVP Series Variable Volume Piston Pump Service Bulletin Model PVP16 **** 12

Bulletin PM 1620-12-M1/USA

Parker Pumps Parts & Service Model PVP16 **** 12

WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.

Offer of Sale

The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed by the provisions stated on the separate page of this document entitled "Offer of Sale". C

Copyright 1998, Parker Hannifin Corporation, All Rights Reserved

2

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Table of Contents

Parker Pumps Parts & Service Model PVP16 **** 12

Pump Cut-A-Way .................................................................................. 4 - 5 Control Options .......................................................................................... 6 Thru Shaft Options ..................................................................................... 7 Exploded View ..................................................................................... 8 - 9 Parts List

................................................................................. 10 - 11

Service Notes

........................................................................................ 12

Basic Troubleshooting .............................................................................. 12 Offer of Sale

........................................................................................ 15

Introduction: The PVP16 **** 12 series piston pumps are designed to provide long life while operating with Hydraulic Oil. Refer to catalog 1550/USA for limits. However, should maintenance be required, the following instructions should be used for disassembly, replacement of parts, cleaning and assembly. Note: Prior to any pump disassembly, plug the open ports and clean all dirt from the outside of the pump. Prior to assembly all parts should be cleaned and then lightly coated with oil. Warning: Protective eye wear should be worn during all maintenance procedures.

3

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Pump Cut-A-Way

Parker Pumps Parts & Service Model PVP16 **** 12

Notes: 1. 2. 3. 4. 5.

Make sure "R" or "L" stamped on port plate (corresponding to rotation) is by antirotation pin. Installed depth of item 2 (trunnion pin) below surface of item 35 (housing) to be .050/.100 with swashplate clearance removed by pressing "in" on pin. Installed height of item 14 (servo post) above item 45 (rear cover) to be 1.538/1.534. Installed height of item 29 (needle bearing) above item 45 (rear cover) to be .150/.130. Illustration shows righthand (CW) rotation pump. Lefthand (CCW) pumps will have inlet and outlet ports reversed with compensator on outlet side.

4

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Pump Cut-A-Way

Parker Pumps Parts & Service Model PVP16 **** 12

5

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Control Options

Parker Pumps Parts & Service Model PVP16 **** 12

Notes: 1.

Must be used with proper compensator assembly. Horsepower (torque) control assembly does not include pressure compensator assembly. For "H" option use "M" compensator, for "C" option use "A" compensator.

6

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Thru Shaft Options

Parker Pumps Parts & Service Model PVP16 **** 12

Notes: 1. 2.

Shaft and cover assemblies not included in kits. They must be ordered separately. Later designs incorporate a gasket, P/N 801209 rather than an O-ring.

7

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Pump Exploded View

Parker Pumps Parts & Service Model PVP16 **** 12

Notes: 1. 2.

Illustration shows righthand (CW) rotation pump. Lefthand (CCW) pumps will have the compensator on opposite side, and port plate kidneys reversed. Seal kit (SKPVP16 - 12) consists of all O-rings, gaskets and shaft seal.

8

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Pump Exploded View

Parker Pumps Parts & Service Model PVP16 **** 12

9

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Parts List

Parker Pumps Parts & Service Model PVP16 **** 12

CAUTION These service parts are intended for use in hydraulic pumps. Incorrect installation or assembly of these parts could cause the pump or pumps being repaired to fail in subsequent use or to operate incorrectly. The following precautions should be followed: 1. All parts should be cleaned and then lightly coated with mineral oil, or another lubricating fluid compatible with the system fluid being used, prior to assembly. 2. The pump should be disassembled, repaired and reassembled in a clean environment. 3. Use proper tools to disassemble and reassemble the pump. 4. If you are uncertain at how to install these parts, you should obtain assistance either from a Parker Hannifin distributor, or from the Hydraulic Pump/Motor Division.

10

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Parts List

Parker Pumps Parts & Service Model PVP16 **** 12

Notes: 1. 2. 3. 4.

O-Ring compound designation =Nitrile, V = Viton. For proper operation of "H" control, it must be used with a remote compensator assembly. For proper operation of "C" control, it must be used with a load sense compensator assembly. Seal Kit P/N SKPVP 16 12 Rotation Group Kit P/N: RRKPVP16 12 R - CW L - CCW

11

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Service Notes & Basic Troubleshooting

Parker Pumps Parts & Service Model PVP16 **** 12

Service Notes: l l

l l

l

l

Use a clean lubricant (compatible with the working fluid) on all pump components during assembly. Most premature pump failures occur when contaminants from a previous failure have not been removed from the system, or cause for previous failure is still present (i.e. water in oil, filter bypassing, etc.) Thoroughly clean the reservoir, suction lines, suction strainer, drain lines, etc. before re-installing the pump. Always fill the pump case with clean fluid before starting a new or serviced pump for flooded suction, purge air from suction lines by cracking the inlet fitting or vent plug on pump. This should prevent an airlock condition and allow for faster priming. Starting the pump slowly by jogging (or turning over engine without allowing it to start) will help the pump prime and make it easier to determine when priming has occurred. Start pump with an open circuit whenever possible. Reduce the compensator to it's minimum setting during start-up. Cycle the pump on and off stroke while increasing the compensator to its required setting. This will assist in break-in of new components and help purge air from the case.

Basic Troubleshooting: Pump Will Not Prime . Pump should prime within 30 seconds. If it does not, STOP. . Check for proper drive rotation. . Make sure pump shaft is turning (i.e. key at coupling hubs is engaged). . Make sure reservoir is full. . Check for major sources of a suction leak (vent plug open, shaft seal missing (PAVC), flange not tight, pinched O-Ring at flange or pump housing.

Can Only Build A Few Hundred PSI . Compensator is backed all the way out. . The remote or load sense line is vented. . Control orifice or spool is plugged. . Incorrect compensator spool (PVP). . Pressure control dart is lodged open. . Torque control plug is missing (PAVC). Pump Will Not Compensate . Differential spring over-compressed (i.e. spring guide dislocated). . Control drain line blocked (PAVC). . Pressure control stem vent hole is plugged. . Control spool travel is hindered. . Control orifice is missing (PAVC). . Saturation orifice is missing in load sense circuit.

Cannot Build Any Pressure . Make sure pump is primed. . Check alignment, especially on PAVC pumps without "9" option. . Make sure systems is not an open circuit. A pump produces flow, not pressure. It can only limit pressure when the system requirement is higher than the pump compensator setting.

12

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Bulletin PM 1620-12-M1/USA Offer of Sale

Parker Pumps Parts & Service Model PVP16 **** 12

The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and its acceptance by any customer (“Buyer”) shall be governed by all of the following Terms and Conditions. Buyer’s order for any such item, when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor (“Seller”) verbally or in writing, shall constitute acceptance of this offer.

1. Terms and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Seller’s products are subject to and shall be governed exclusively by the terms and conditions stated herein. Buyer’s acceptance of any offer to sell is limited to these terms and conditions. Any terms or conditions in addition to, or inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional, different or inconsistent terms and conditions shall become part of the contract between Buyer and Seller unless expressly accepted in writing by Seller. Seller’s acceptance of any offer to purchase by Buyer is expressly conditional upon Buyer’s assent to all the terms and conditions stated herein, including any terms in addition to, or inconsistent with those contained in Buyer’s offer. Acceptance of Seller’s products shall in all events constitute such assent.

8. Buyer’s property: Any designs, tools, patterns, materials, drawings. Confidential information or equipment furnished by buyer, or any other items which become Buyer’s property, may be considered obsolete and may be destroyed by Seller after two (2) consecutive years have elapsed without Buyer placing an order for the items which are manufactured using such property. Seller shall not be responsible for any loss or damage to such property while it is in Seller‘s possession or control.

9. Taxes: Unless otherwise indicated on the face hereof, all prices and charges are exclusive of excise, sales, use, property, occupational or like taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must be paid by Seller or if Seller is liable for the collection of such tax, the 2. Payment: Payment shall be made by Buyer net 30 days from the amount hereof shall be in addition to amounts for the items sold. Buyer date of delivery of the items purchased hereunder. Amounts not timely paid agrees to pay all such taxes or to reimburse Seller therefore upon receipt of shall bear interest at the maximum rate permitted by law for each month or its invoice. If Buyer claims exemption from any sales, use or other tax portion thereof that the Buyer is late in making payment. Any claims by imposed by any taxing authority, Buyer shall save Seller harmless from and Buyer for omissions or shortages in a shipment shall be waived unless Seller against any such tax together with any interest or penalties thereon which receives notice thereof within 30 days after Buyer’s receipt of the shipment. may be assessed if the items are held to be taxable. 3. Delivery: Unless otherwise provided on the face hereof, delivery 10. Indemnity For Infringement of Intellectual Property Rights: shall be made F.O.B. Seller’s plant. Regardless of the method of delivery, Seller shall have no liability for infringement of any patents, trademarks, however, risk of loss shall pass to Buyer upon Seller’s delivery to a carrier. copyrights, trade dress, trade secrets or similar rights except as provided in Any delivery dates shown are approximate only and Seller shall have no this Part 10. Seller will defend and indemnify Buyer against allegations of liability for any delays in delivery. infringement of U.S. patents, U.S. Trademarks, copyrights, trade dress 4. Warranty: Seller warrants that the items sold hereunder shall be and trade secrets (hereinafter “Intellectual Property Rights). Seller will defend at its expense and will pay the cost of any settlement or damages free from defects in material or workmanship for a period of 18 months from awarded in an action brought against Buyer based on an allegation that an date of shipment from Parker Hannifin Corporation. THIS WARRANTY item sold pursuant to this contract infringes the Intellectual Property Rights COMPROMISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO of a third party. Seller’s obligation to defend and indemnify Buyer is ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARcontingent on Buyer notifying Seller within ten (10) days after Buyer RANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSObecomes aware of such allegations of infringement, and Seller having sole EVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, control over the defense of any allegations or actions including all MERCHANTABILITY AND FITNESS FOR PURPOSE, WHETHER negotiations for settlement or compromise. If an item sold hereunder is EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW. TRADE subject to a claim that it infringes the Intellectual Property Rights of a third USAGE, OR COURSE OF DEALING ARE HEREBY DISCLAIMED. party, Seller may, at its sole expense and option, procure for Buyer the NOTWITHSTANDING THE FOREGOING, THERE ARE NO right to continue using said item, replace or modify said item so as to WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY make it noninfringing, or offer to accept return of said item and return the OR PARTIALLY, TO BUYER’S DESIGNS OR SPECIFICATIONS. purchase price less a reasonable allowance for depreciation. Notwith5. Limitation of Remedy: SELLER’S LIABILITY ARISING FROM standing the foregoing, Seller shall have no liability for claims of OR IN ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS infringement based on information provided by Buyer, or directed to items CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR delivered hereunder for which the designs are specified in whole or part by REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE Buyer, or infringements resulting from the modification, combination or use PRICE PAID BY BUYER, AT SELLER’S SOLE OPTION. IN NO EVENT in a system of any item sold hereunder. The foregoing provisions of this SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL Part 10 shall constitute Seller’s sole and exclusive liability and buyer’s sole OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER. and exclusive remedy for infringement of Intellectual Property Rights. INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING FROM OR If a claim is based on information provided by Buyer or if the IN ANY WAY CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD design for an item delivered hereunder is specified in whole or in part by HEREUNDER, WHETHER ALLEGED TO ARISE FROM BREACH OF Buyer, buyer shall defend and indemnify Seller for all costs, expenses of CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN TORT, or judgments resulting from any claim that such item infringes any patent, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE TO WARN trademark, copyright, trade dress, trade secret or any similar right. OR STRICT LIABILITY. 11. Force Majeure: Seller does not assume the risk of and shall 6. Changes, Reschedules and Cancellations: Buyer may request not be liable for delay or failure to perform any of Seller’s obligations by to modify the designs or specification for items sold hereunder as well as the reason of circumstances beyond the reasonable control of Seller (hereinafquantities and delivery dates thereof, or may request to cancel all or part of ter “Events of Force Majeure”). Events of Force Majeure shall include this order, however, no such requested modification or cancellation shall without limitation, accidents, acts of god, strikes or labor disputes, acts, become part of the contract between buyer and Seller unless accepted by laws, rules or regulations of any government or government agency, fires, Seller in written amendment to this Agreement. Acceptance of any such floods, delays or failures in delivery of carries or suppliers, shortages of requested modification or cancellation shall be at Seller’s discretion, and materials and any other cause beyond Seller’s control. shall be upon such terms and conditions as Seller may require. 12. Entire Agreement/Governing Law: The terms and conditions 7. Special Tooling: A tooling charge may be imposed for any special set forth herein, together with any amendments, modifications and any tooling, including without limitation, dies, fixtures, molds and patterns, different terms or conditions expressly accepted by Seller in writing, shall acquired to manufacture items sold pursuant to this contract. Such special constitute the entire Agreement concerning the items sold, and there are no tooling shall be and remain Seller’s property notwithstanding payment of any oral or other representation or agreements which pertain thereto. This charges byBuyer, in no event will Buyer acquire any interest in apparatus Agreement shall be governed in all respects by the law of the State of Ohio. belonging to Seller which is utilized in the manufacture of the items sold No actions arising out of the sale of the items sold hereunder or this hereunder, even if such apparatus has been specially converted or adapted Agreement may be brought by either party more than two (2) years after the for such manufacture and notwithstanding any charges paid by Buyer. cause of action accrues. Unless otherwise agreed, Seller shall have the right to alter, discard or otherwise dispose of any special tooling or other property in its sole FPG 9-91-P discretion at any time.

15

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 USA

Parker Hannifin Corporation Hydraulic Pump/Motor Division 2745 Snapps Ferry Road Greeneville, TN 37745 USA Tel. (423) 639-8151 FAX (423) 787-2418 Web site: http://www.parker.com 5/98 DBHESS 5000

Table of Contents

Design Features ............................................. Definitions ................................................................

Page Jnside Front Cover .3 ...5

... ..: ....................................................... Troubleshooting Guide ...................................................... Introduction

.6

Troubleshooting Check List .................................................. Tools and Material Required for Servicing ......................................

.7

Bolt Torque ................................................................ Exploded Assembly View ...............................................

.9

.8 .I0 & 11

MG Service Parts List Chart ................................................. MF Service Parts List Chart .................................................

.I2 .13

MB Service Parts List Chart ................................................. ME Service Parts List Chart ...................................................

.14

MJ Service Parts List Chart ................................................. Disassembly & Inspection ..................................................

.I6

Assembly ................................................................

.25

.I5 .I7 ...................

.35

Rotor Set Component Assembly Procedure (Two Piece Stator) ................... Final Checks ..............................................................

.36

Hydraulic Fluids ........................................................... Filtration, Operating Temperature ............................................

.38

Tips for Maintaining the System .............................................

.39

Rotor Set Component Assembly Procedure (One Piece Stator)

.38 .38

Definitions NOTE:

A NOTE provides key information to make a procedure easier or quicker to complete.

CAUTION:

A CAUTION refers to procedure that must be followed to avoid damaging the TorqmotorTM or other system components.

WARNING:

A WARNING REFERSTO PROCEDURETHAT MUST BE FOLLOWED FOR THE SAFETY OFTHE EQUIPMENT OPERATORAND THE PERSON INSPECTING OR REPAIRING THE TORQMOTORTM.

w

Disclaimer This Service Manual has been prepared by Ross Operation for reference and use by mechanics who have been trained to repair and service hydraulic motors and systems on commercial and non-commercial equipment applications. Ross Operation has exercised reasonable care and diligence to present accurate, clear and complete information and instructions regarding the techniques and tools required for maintaining, repairing and servicing the complete line of Ross MG, MF, MB, ME, & MJ TorqmotorTM Units. However, despite the care and efforttaken in preparing this general Service Manual, Ross makes no warranties that (a) the Service Manual or any explanations, illustrations, information, techniques or tools described herein are either accurate, complete or correct as applied to a specific TorqmotorTM unit, or (b) any repairs or service of a particular TorqmotorTM unit will result in a properly functioning TorqmotorTM unit. If inspection or testing reveals evidence of abnormal wear or damage to the TorqmotorTM unit or if you encounter circumstances not covered in the Manual, STOP - CONSULT THE EQUIPMENT MANUFACTURER’S SERVICE MANUAL AND WARRANTY. DO NOT TRY TO REPAIR OR SERVICEATORQMOTORTM UNIT WHICH HAS BEEN DAMAGED OR INCLUDES ANY PART THAT SHOWS EXCESSIVEWEAR UNLESS THE DAMAGED AND WORN PARTS ARE REPLACED WITH ORIGINAL ROSS REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTOREDTO ROSS SPECIFICATIONS FOR THE TORQMOTORTM UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular TorqmotorTM unit to (a) inspect the unit for abnormal wear and damage, (b) choose a repair procedure which will not endanger his/her safety, the safety of others, the equipment, or the safe operation of the TorqmotorTM, and (c) fully inspect and test the TorqmotorTM unit and the hydraulic system to insure that the repair or service of the TorqmotorTM unit has been properly performed and that the TorqmotorTM and hydraulic system will function properly.

3

w’

Torqmotor’” Design Features CDUPL~~DSHAFT HIGH PRESSURESEA1

MATCHED ROTORSET MATCHEDCDM~UTATDR SETe.4

TorqmotorTM MG Series features includes l The roller vane rotor set design offers a low-friction, wear compensation which maximizes the useful performance life of the motor. . Zero leak commutation valve provides greater, more consistent volumetric efficiency. . Design flexibility - MG offers the widest ~H~U~~~EA~~~~ selection of shaft options, displacements and mounting flanges in the industry. . Patented 60-40 spline member arrangement transmits more torque with less weight. . Full flow lubrication maximizes cooling and may provide up to 50% longer life than motors not having this feature. Higher pressure rating provide greater torque than competitive brands. Full interchangeability with other motors which are designed according to industry standards. . Compatible with most hydraulic systems with regard to pressure, torque and speed. A unique high-pressure shaft seal that eliminates the need for case drains. Up to 13 horse power output.

r CDUPl~~R SHAFT HIGH PRESSURES \

\

I-

NEEDLERADlAL DEARI~G IVIATCHEDROTORSET MATCHEDCDMMUTATDR SET 1

F HOUSING

TorqmotorTM MF Series features include: l Roller vanes to reduce friction and internal leakage and to maintain efficiency. . Zero leak commutation valve provides greater, more consistent volumetric efficiency. . Wheel mount version available. . More starting torque than competitive motors in applications where the shaft is side loaded. (Competitive brands require more pressure to start the motor.) . A needle-roller mounted coupling shaft and steel-caged thrust bearing which can withstand lOOO-poundthrust loads. Side load capacity is 1600 Ibs. (727.3 kg) maximum at center of output shaft. A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing. . Up to 17 horsepower output. . Greater durability due to superior lubrication and minimum drive spline wear. l Patented 60-40 spline member arrangement transmits more torque with less weight.

Ld

wi

i

Torqmotor’” Design Features

H ~~~~~E~

TorqmotorTM MB Series features includes l Heavy-duty thrust and roller bearings for up to twice side-load capacity to the previous motor. l Roller vanes to reduce friction and internal leakage, and to maintain efficiency. l A patented orbiting commutation system for less wear and longer life. l A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight. l A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing. l A unique manifold designed to improve operating efficiency. l Up to 1000 Ibs. (453.6 kg) end-thrust capacity in either direction. l A design that is less sensitive to contamination than competitive motors. l Up to 36 horsepower output. l Greater durability because of superior lubrication and minimum drive spline wear. l Superior low speed performance. l Zero leak commutation valve provides greater, more consistent volumetric efficiency. TorqmotorTM ME & MJ Series features include: l Roller vanes to reduce friction and internal leakage and to maintain efficiency. l A patented orbiting commutation system for less wear and longer life. l A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight. l A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing. l A manifold designed to improve operating efficiency. l Heavy-duty thrust and roller bearings for up to twice the side-load capacity to the previous motor. l Up to 1000 Ibs. (453.6 kg) end-thrust capacity in either direction. l A design that is less sensitive to contamination than competitive motors. l Up to 49 horsepower output. l Greater durability because of superior lubrication and minimum drive spline wear. l Zero leak commutation valve provides greater, more consistent volumetric 2 efficiency.

Introduction Service Manual for Series MG, MF, MB, ME, MJ This service manual has one purpose: to guide you in maintaining, troubleshooting, and servicing the MG, MF, MB, ME, & MJ TorqmotorTM (low-speed, high-torque hydraulic motor). Material in this manual is organized so you can work on the TorqmotorTM and get results without wasting time or being confused. To get these results, you should read this entire manual before you begin any work on the TorqmotorTM. This manual also contains troubleshooting information and checklist. If you must service the TorqmotorTM, the checklist will help you to determine where the problem may be. The three-column format of the Disassembly and Inspection, and Assembly sections will make it easier for you to conduct major work on the TorqmotorTM. Column 1 gives a brief key for each procedure. Column 2 explains in detail the procedure you should follow. Column 3 illustrates this procedure with photographs. Read all material carefully and pay special attention to the notes, cautions, and warnings. A page with the TorqmotorTM exploded assembly view is provided several places in this manual. The component part names and item numbers assigned on this exploded assembly view correspond with names and item numbers (in parentheses) used in the disassembly and assembly procedures set forth in this manual. Service part list charts are also provided in this manual with the part names and exploded view item numbers cross referenced to Ross service part numbers. Service parts are available through the Original Equipment Manufacturer approved MG, MF, MB, ME, & MJ Distributors.

or Ross

As you gain experience in servicing the TorqmotorTM, you may find that some information in this manual could be clearer or more complete. If so, let us know about it. Do not try to second guess the manual. If you are stuck, contact us. Servicing the TorqmotoP should be a safe and productive procedure, in order for the unit to deliver the reliable, long-life operation engineered into it.

Troubleshooting Guide NOTE: Before troubleshooting any system problem, check service literature published by the equipment and/or component manufacturers. Follow their instructions, if given, for checking any component other than the TorqmotorTM unit.

Hydraulic Components

Preparation Make your troubleshooting lows:

easier by preparing as fol-

l

work in a clean, well-lighted place;

l

have proper tools and materials nearby;

l

have an adequate supply of clean petroleum-based solvent.

WARNING: SINCE SOLVENTS ARE FLAMMABLE, BE EXTREMELYCAREFUL WHEN USING ANY SOLVENT, EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE SURE TO ,flL”r,DMPLY WITH OSHA AND OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

Preliminary Checks Hydraulic systems are often trouble-free. Hence, the problem an operator complains of could be cause by something other than the hydraulic components. Thus, once you have determined that a problem exists, start with the easy-to-check items, such as: l

l

l

parts damaged from impact that were not properly repaired, or that should have been replaced; and improper replacement parts used in previous servicing mechanical linkage problems such as binding, broken, or loose parts or slipping belts

If you think the problem is caused by a hydraulic component, start by checking the easy-to-reach items. Check all hoses and lines for cracks, hardening, or other signs of wear. Reroute any useable hoses that are kinked, severely bent, or that rest against hot engine parts. Look for leaks, especially at couplings and fittings. Replace any hoses or lines that don’t meet system flow and pressure ratings. Next, go to the reservoir and filter or filters. Check fluid level and look for air bubbles. Check the filter(s). A filter with a maximum 50 micron filtration is recommended for the Torqmotor system. Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear. Excessive heat in a hydraulic system can create problems that can easily be overlooked. Every system has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the following can occur: l

oil seal leaks

l

loss of efficiency such as speed and torque

l

pump loss of efficiency

l

pump failure

l

hoses become hard and brittle

l

hose failure

A normal temperature range means an efficient hydraulic system. Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperature and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The TorqmotorTM is not recommended for hydraulic systems with maximum temperatures above 200°F (93.3%

6

Troubleshooting Checklist Trouble

Cause

Remedy

Oil leakage

1. Hose fittings loose, worn or damaged. 2. Oil seal rings (4) deteriorated excess heat.

Check & replace damaged fittings or “0” Rings. Torque to manufacturers specifications. by

3. Special bolt (1, lA, IB or 1C) loose or its sealing area deteriorated by corrosion. 4.

Internal shaft seal (16) worn or damaged.

5. Worn coupling shaft (12) and internal seal (16). Significant

loss of speed under load

1. Lack of sufficient oil supply

w

Replace oil seal rings by disassembling TorqmotoP unit. (a) Loosen then tighten single bolt to torque specification. (b) Replace bolt. Replace seal. Disassembly of TorqmotorTM unit necessary. Replace coupling shaft and seal by disassembling TorqmotorTM unit. (a) Check for faulty relief valve and adjust or replace as required. (b) Check for and repair worn pump. (c) Check for and use correct oil for temperature of operation.

2. High internal motor leakage

low mechanical efficiency or undue high pressure required to operate TorqmotorTM unit

3. Severely worn or damaged internal splines.

Replace rotor set, drive link and coupling shaft by disassembling TorqmotorTM unit.

4. Excessive heat.

Locate excessive heat source (usually a restriction) in the system and correct the condition.

1. Line blockage

Locate blockage source and repair or replace.

2.

Disassemble TorqmotorTM unit, identify and remedy cause and repair, replacing parts as necessary.

Internal interference

3. Lack of pumping pressure

Check for and repair worn pump.

4. Excessive binding or loading in system external to TorqmotorTM unit,

Located source and eliminate cause.

CAUTION: If the hydraulic system fluid becomes overheated shrink, harden or crack, thus losing their sealing ability.

7

(a) Replace worn rotor set by disassembling TorqmotorTM unit.

[in excess of 200°F (93.3%)], seals in the system can

k&

Tools and Materials Required for Servicing MG. MF, MB, ME, MJ Series Service Manual Clean, petroleum-based

solvent

Emery paper Vise with soft jaws Air pressure source Arbor press Screw driver Masking tape Breaker bar Torque wrench-h. Ibs. (N m) Sockets: l/2 or 9/16 inch thin wall, 1 inch Allen Sockets: 3/16,3/8 inch Adjustable crescent wrench or hose fitting wrenches SAE lOW40 SE or SF oil Special bearing mandrel for MG & MF Torqmotors (SEE FIGURE 1) Special bearing mandrel for MJ Torqmotors (consult factory) Special bearing mandrel for MB & ME Torqmotors (SEE FIGURE 2) Feeler gage .005 inch (.I3 mm) MG & MF Torqmotors require blind hole bearing puller for 1.06 inch (26.9) mm) and 1.62 inch (41.1 mm) diameter bearing/ bushing. MJ Torqmotors require blind hole bearing puller for a 1.575 inch dia. (40.0 mm) and 2.130 inch dia. (54.1 mm) bearings. MB & ME Torqmotors require blind hole bearing puller for 1.400 inch dia. (35.6 mm) and 2.130 inch dia. (54.1 mm) bearings. Clean corrosion resistant grease. Part # 406018 is included in each seal kit. Recommended grease is Ross Specification #tl45236 or Mobil Mobilith SHC@460 NOTE: The available service seal kits include the recommended grease as a grease pack #I406018

m

CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

CONVERSIONS INCHES

mm

INCHES

mm

.020 ,021 .029 ,030 .lll .119 .152 .I60 .296 .304 ,460 .470 .500 .585 ,595 .660 .675 1.058

.51 .53 .74 .76 2.81 3.02 3.86 4.06 7.52 7.72 11.68 11.94 12.70 14.86 15.11 16.76 17.15 26.87

1.060 1.295 1.297 1.396 1.398 1.620 1.622 1.983 1.985 2.120 2.122 2.233 2.235 2.483 2.485 2.500 2.88

26.92 32.89 32.94 35.46 35.51 41.15 41.20 50.37 50.42 53.85 53.90 56.72 56.77 63.07 63.12 63.5 73.2

Torque Chart Part Name

Item Number

Torque

bolt 5/16 24 UNF 2A bolt 3/8 24 UNF 2A bolt5/8 18UNF2A nut 3/4 16 UNF 2B nut I-20 UNEF 2B nut l-1/8 18 UNEF 2B

l,lA,lBorlC 1, lA, IB or IC 12D 12B (MG, MF) 12B (MB, ME) 12B (ME)

22-26 ft. Ibs. (30-35 N m) 45-55 ft. Ibs. (60-76 N m) 140-180 ft. Ibs. (190-244 N m) 175-255 ft. Ibs. (237-305 N m) 300-400 ft. Ibs. (407-542 N m) 300-400 ft. Ibs. (407-542 N m)

(Fabricate if considered necessary) FIGUREI-MG & MF

9

(Fabricate if considered necessary) FIGURE2-MB & ME

w

e

Toirqmotor” Exploded Assembly View -Typical , ,$iiii18A /A%22$ /+%0$~$4E-, 12c

12E 120 \

Alternate Construction ME Rotor Set

se

NOTE: Assemble Seal Flat Side Out as Shown in Enlarged View of Sectioned Segments of Items Number 5 and 3

/

80

Item No. Description Special Bolts 15 or 7) 1. ‘A. Special Bolts (7) ‘B. Special Bolts (7) 1c. Special Bolts (7) End Cover Seal Ring-Commutator Z: 4. Seal Ring (5) 5. Commutator Commutator Ring 8. Manifold 7. 8. Rotor Set 8A. Rotor Stator or Stator Half E: Vane (71 80. Stator Half 8E. Vane (71 9. Wear Plate 10. Drive Link

/

11. 12. 12A. 128. 12c. 120. 12E. 12F. 13. 14. 15 1;: 18sA. 19.

Thrust Bearing Coupling Shaft Key Nut Washer Bolt Lockwasher Retaining Ring Bearing/Bushing, Thrust Washer Thrust Bearing Seal Backup Washer Housing O-Ring (2) Bearing/Bushing,

20. 21. 22. 23. 24. 25.

O-Ring 12) Spring Valve (Shuttle or Relief) Backup Washer

12A

Alternate Construction Shuttle Valve End Cover ‘8A-P0

Manifold Port End Cover

Inner

Outer

Alternate Construction Relief Valve End Cover

10

I

Torqmotor” Exploded Assembly View -Typical (Identical

to page IO)

This Component -Included in MB & ME Torqmotors Only.

12E

MATCHED

12C

\

I

22%’

NOTE: Assemble Seal Flat Side Out es Shown in Enlarged View of Sectioned Segments of items Number 5 and 3

/

80

Alternate Construction Shuttle Valve End Cover

18A-r-m

Item No. Description 1. 1A. Ic”: 2. 2 5. 6. i:

9. 10.

11

8A. 8B. El 6E:

Special Bolts (5 or 7) Special Bolts (7) Special Bolts (7) Special Bolts (7) End Cover Seal Ring-Commutator Seal Ring 15) Commutator Commutator Ring Manifold Rotor Set Rotor Stator or Stator Half Vane (7) Stator Half Vane (7) Wear Plate Drive Link

1:. 12k. 128. 12c. 120. 12E. 12F. 1:. 15’ 16. 1;. 18A. 19.

1B Thrust Bearing Coupling Shaft Key Nut Washer Bolt Lockwasher Retaining Ring Bearing/Bushing, Thrust Washer Thrust Bearing Seaf Backup Washer Housing O-Ring (2) Bearing/Bushing,

25.

Dirt & Water Seal Plug (21 O-Ring (2) Spring Valve (Shuttle or Relief) Backup Washer

Manifold Port End Cover

Inner

Outer

.lC

Alternate Construction Relief Valve End Cover

MG Service Parts list Chart .e

CHART USE EXAMPLE: MG02060 IAAAB TORQMOTOR” INCLUDESPART NUMBERS LISTEDTO THE RIGHT OF MG (SERIES),02 (LISP.), OG(HOUSING), Ol(SHAFT), AND AAAB (OPTION) SHOWN IN LEFTHAND COLUMN OF CHART. CAUTION:THE CHARTEDCOMPONENT SERVICEINFORMATIONIS FORTHE TORQMOTORS LISTEDONLY. REFERTO THE ORIGINAL EQUIPMENTMANUFACTUREROF THE EQUIPMENT USING THE TORQMOTORFORASSEMBLY NUMBERS NOT LISTED BELOW. EXPLODEDVIEW ITEM#

v) Y ii

DESCRIPTION MG-

Service Part#

5&6

COMMUTATORMANIFOLD & RINGASSY (SEENOTE) MF018000-Al

EXPLODEDVIEW ITEM#

2 & 5 g E s #$

1

ts I s I

MF015000

‘8

DESCRIPTION

BOLT(5)

ROTOR SET

0203s 04050608lo121416-

Service Part# Service Part# Service Part# Service Part# Service Part/I Service Part # Service Part # Service Partt Service Partt Service Part#

;;I

p;

24-

Service Part#

021311 021311 021306 021382 021357 021307 021358 021308 021359 021310 021383 021384 021414

MF027003 MF037003 MF047003 MF057003 MF067003 MF087003 MF107003 MF127003 MF147003 MF167003 MF187003 MF207003 MF247003

;;;;

EXPLODEDVIEW ITEM# s B w

1

0609loll1213-

DESCRIPTION Service Part# Service Part# Service Partt Service Part# Service Partl Service Part#

“18 HOUSING SERVICEPART# MF012001-A2 MF012003-A2 MF012004-J2 MFOl2005-J2 MF012006-A2 MF012007-A2

9

“13

14

15

17

79

20

WEAR PLATE

BRONZE BUSHING

THRUST WASHER

THRUST BEARING

BACiiUP WASHER

“DU” BEARING

DIRT&WATER SEAL

477341

069511

028483

065066

028516

065505

478036

10 DRIVE LINK MF023000 MF033000 MF043000 MF053000 MF063000 MF083000 MF103000 MF123000 MF143000 MF163000 MF183000 MF203000 MF243000

EXPLODEDVIEW ITEM#

4 8W zti m P = s 8

Ol09. IOII12. 131415.

DESCRIPTION ServicePart# ServicePart# ServicePart# ServicePart# ServicePart# ServicePart# ServicePart# ServicePart#

12 12A COUPLING WOODRUFF SHAFT KEY MF019007 MFOI9000 MFOI9006 G124553 MF019003 MF019004 G124553 MF019005 G124553 MF019001 MFOI9002

L18A O-RING(2) 032200-10 032200-10

12B NUT

025136

‘I

% & E i= E

EXPLODEDVIEW ITEM#

2

DESCRIPTION

END COVER

AAAB Service Part # AAAC Service Part # AAAH Service Part #

MG016000 MG016000 MG016000

3

4

COMMUTATOR SEAL SEAL RING(5) 032435 032435 032435

032821 032821 032822

16 INNER SEAL 032377 032377 032809

a Servicehousing ass’yITEM#I8 with part numbersuffix-AZincludesITEM#I3 and #19. Servicehousing ass’y ITEM #I8 with part number suffix-J2 includes ITEM #13, #I9 AND two ITEM 18A.

Standardseal kit SK000090includesfive I/O32821seal rings, #032435 commutatorseal,#03’2377inner seal,#028516 backup washer,#478036 dirt &water seal, #406018 grease pack, bulletin #887. Special seal kit SK000091for units that use fire retardant fluids include five #032822 seal rings,#032435 commutatorseal, #032809 inner seal,#028516 backup washer,#478036 dirt &water seal,#406018 greasepack,bulletin #887. Forreverseflow manifold, use MF015001.

I

MF Service Parts list Chart CHARTUSE EXAMPLE: MF0206OlAAAA TORQMOTORTMINCLUDESPARTNUMBERS LISTEDTO THE RIGHT OF MF(SERIES),OZ(DISP.),OG(HOUSING),Ol(SHAFT) AND AAAA (OPTION)SHOWN IN LEFTHAND COLUMN OF CHART. CAUTION:THE CHARTEDCOMPONENT SERVICEINFORMATION IS FORTHE TORQMOTORSLISTED ONLY.REFERTO THE ORIGINPL EQUIPMENT MANUFACTUREROF THE EQUIPMENTUSING THE TORQMOTORFORASSEMBLY NUMBERS NOT LISTED BELOW. EXPLODED VIEW ITEM# Y E %

DESCRIPTION MF-

0203s !!$ !i

050405 08-

2

12IO-

8 s

1& 182024-

% &

0609-

5&6 7 COMMUTATORMANIFOLD & RINGASSY (see note)

A13 NEEDLE BEARING

14 THRUST WASHER

15 THRUST BEARING

17 BACKUP WASHER

“19 NEEDLE BEARING

20 DIRT&WATER SEAL

069512

028483

065066

028516

065506

478036

MF018000-Al

MF015000

477341

EXPLODEDVIEW ITEM#

1

10

DESCRIPTION

BOLT(5)

0 ROTOR SET

DRIVE LINK

Service Partf Service PartI Service Part # Service Part% Service Part # Service Part# Service Part# Service Part# Service Parti Service Part# Service Part# Service Part# Service Part#

021311 021311 021306 021382 021357 021307 021358 021308 021359 021310 021383 021384 021414

MF027003 MF037003 MF047003 MF057003 MF067003 MF087003 MFl07003 MFI27003 MF147003 MF167003 MF187003 MF207003 MF247003

MF023000 MF033000 MF043000 MF053000 MF063000 MF083000 MF103000 MF123000 MF143000 MF163000 MF183000 MF203000 MF243000

Service

Part#

9 WEAR PLATE

EXPLODED VIEW ITEM#

“18

“18A

DESCRIPTION

HOUSING SERVICEPART/#

O-RING(2)

Service Part# Service Part# Service Part# ServicePart# Service Part# Service Part#

MF012001-Al MF012003-Al MF012004-Jl MF012005-Jl MFOl2006-Al MF012007-Al

a Service housing ass’y ITEM #I8 with part number suffix-Al ‘Select the required bolt number in designated ’ Nut #LX51 13 is required if the designated

032200-I0 032200-10

“DISPLACEMENT

Ol09. IO12. ll-

s m 4 4 8

5 E E F 8

13. 14. 15-

DESCRIPTION Service Part# ServicePart# ServicePart# ServicePart# ServicePart# ServicePart# ServicePart# SewicePart#

EXPLODEDVIEW ITEM#

AAAB AAAC AAAD AAAG

DESCRIPTION Service Part# Service Part# Service Part# Service Part#

12A

128

COUPLING WOODRUFF SHAFT KEY MFOI9007 MF019000 MF019006 G124553 MFOI9003 MF019004 G124553 MFOI9005 G124553 MF019001 MFOI9002

NUT

025136

2 3 4 END COMMUTATOR SEAL COVER SEAL RING(5) MF016000 032435 032821 MF016000 032435 032821 MF016000 032435 032821 MF016000 032435 032822

16 INNER SEAL 032377 032377 032809 03809

GROUP” under bolt ITEM #I, IA, 16 or IC shown in designated

“OPTION GROUP”

“OPTION GROUP” is AAAF, AAAN, or AAAU

Special seal kit SK000091 for units that use fire retardant &water seal, #406018 grease pack, bulletin 5887.

13

5 zt

12

includes ITEM #13, #14, #I5 and #I9

Standard seal kit SKOOOOSO includes five #032821 seal rings, #032435 commutator bulletin #887.

For reverse flow manifold, use MF015001

EXPLODEDVIEW ITEM#

seal, #032377 inner seal, #028516 back up washer, #478036 dirt &water

fluids include five #032822 seal rings, #032435 commutator

hid

seal, #406018 grease pack,

seal, #032809 inner seal, #028516 back up washer, #478036 dirt

MB Service Parts List Chart CHART USE EXAMPLE: MB050101AAAA TORQMOTORTMINCLUDESPART NUMBERS LISTED TO THE RIGHT OF MB(SERIES),05(DISP), Ol(HOUSING), Ol(SHAFT) AND AAAA (OPTION) SHOWN IN LEFTHAND COLUMN OF CHART. CAUTION:THE CHARTEDCOMPONENT SERVICEINFORMATION IS FORTHE TORQMOTORSLISTED ONLY.REFERTO THE ORIGINAL EQUIPMENT MANUFACTUREROF THE EQUIPMENT USING THE TORQMOTORFORASSEMBLY NUMBERS NOT LISTED BELOW. EXPLODEDVIEW ITEM# ‘5 & 6 7 9 11 “13 “14 “15 17 “19 20 25

B

E w

s s W

s s

: =i & ii

5 K P I :

MB-

050608097

Service Part# Service Part# Service Part# Service Part#

021326 021326 021271 021390

021340 021340 021386 021273

021386 021386 021273 021273

021273 021379

IO12151823-

Service Part# Patt# Service Part# Service Part# Service PartI EXPLODEDVIEW ITEM#

021376 021352 021272 021340 021387

021387 021379 021391 021392 021378

021387 021379

021391

021392 021378

DESCRIPTION Ol0204050607-

4

8

i v) P 3 5 8

5 K E F 8

COMMUTATOR MANIFOLD WEAR THRUST INNER THRUST THRUST BACKUP OUTER DIRT& WATER BACKUP DESCRIPTION ASSEMBLY (SEENOTE) PLATE BEARING BEARINGWASHER(Z) BEARING WASHER BEARING SEAL WASHER Service Part # ME18000-Al ME015000 477340 068024 071019 400136 069017 028515 068027 478035 029118 EXPLODEDVIEW YSELECTITE$I BOLTPEFiiPTlON GR;;P) ITEM# IB OR IC 8 IO DESCRIPTION BOLT(7) BOLT(7) BOLT(7) BOLT(7) ROTORSET DRIVELINK

Service Part # Service Part # Service Part# Service Part# Service Part# Service Part# EXPLODEDVIEW ITEM# DESCRIPTION

Ol02030405060708-

AAAA AAAC AAAF AAAG AAAH AAAM AAAN AAAP AAAT AAAU BBBA BBBB BBBC BBBC

MB057003 MB067003 MB087003 M 8097003

MB063000 MB063000 MB083000 MB093000

021385

MB127003 MB107003 MB157003 MB187003 MB237003

MB103000 MB123000 MB153000 MB183000 MB233000

12E LOCK WASHER

12F RETAINING RING 40133

“18 SERVICE HOUSINGASS’Y ME012001-Al ME012002-Al ME012004-Al ME012005-Al ME012006-Al Me012007-Al 12 COUPLING SHAFT MB019001 MB019002 MB019003 MB019004 MB019005 MB019006 MB019007 MB019000

Service Part # Service Partf Service Partf Service Part # Service Part# Service Part# Service Part# Service Part # EXPLODED VIEW ITEM# bl, lA, IB, 1C DESCRIPTION

BOLT(71

Service Pat-l# Service Part# Service Part# Service Part# Service Part# Service Part# Service Patt# Service Part# Service Parti Service Part# Service Part# Service Part# Service Part# Service Part#

Item#l Item#l Item#I Item#l Item#I Item #lB Item#l B Item#I B Item#lA Item#IA Item#lC Item#lC Item#lC Item#I C

12A

12B

12c

KEY

NUT

WASHER

120 5/8-18 BOLT

028413

G223734

6103325

028413

G223734

G103325

G124553 039028

G124554 2

cO251 26 3

4

END COMMUTATOR SEAL COVER SEAL RING(51 MB016000 MB016000 MB016000 MB016000 MB016000 ME016002 ME016002 ‘ME016001-Jl ‘ME016003-Al ‘MEOl6003-Al ‘ME016004-Al ‘ME016004-A2 ‘ME016004-A3 ‘ME016004-A4

032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435

032819 032819 032819 032820 032820 032819 032819 032819 032819 032819 032819 032819 032819 032819

16

‘218422

INNER PLUG& O-RING SEAL ASSEMBLY 032817 032817 032817 032818 032818 032817 032817 032817 032817 032817 032817 032817 032817 032817

415463-A2 415463-A2 411063-Al 411063-Al 411063-Al 411063-Al

W&j

‘23

‘24

O-RING

SPRING121

VALVE

032200-90 032200-90 032424 032424 032424 032424

401642 401642

415569 415569 410009-74 (2),1000PSI 410009 -71 (2),2OOOPSI 410009 -72 (2),3000PSI 410009 -73 (2).4OOOPSI

For reverse flow manifold,use ME015001 “, Servicehousingass’y ITEM#I6 wth part numbersuffix-Al includes ITEM#13.#I4 two req’d,#I5 and #I9 Selectthe requiredbolt numberin designated“DISPLACEMENT GROUP”under bolt ITEM#I, 1A. 19 or1C shown in designated“OPTIONGROW ’ Nut#025113IS requiredIf the designated“OPTIONGROW is AAAF.AAAN, 01AAAU. j-20 UNEF ITEM#22 is part of plug & o-ring assy’s but can be serviced separately. e Serviceandcover ME016001-Jl includestwo #032200-IOo-rings, ITEM 18A on the explodedass’y view that can also beserviced separately, ‘Endcover assembly item #2 also IncludesItem#21, #22,#24 and if required stem#23. All but item #21 can be serviced separately gME018001-A1commutator&y. is requiredif the designated“OPTIONGROW ISA&AM. AAAN. or AAAP Standardseal kit SK000092Includesfive 832819 seal rings,#032435commutatorseal.#I32817 innerseal. #028515and#029118back washers. #478035dirt&water. 1406018grease pack, bulletin#687. Specialseal kit SK0000093for wts that use fire retardantfluids Includesfive #032435commutatorseal, PO32818innerseal,#028515and#029118back upwashers, W78035dirt & water seal.WO6018grease pack, bulletinX697

ME Service Parts list Chart CHART USE EXAMPLE: MB090101AAAA TORCIMOTORTM INCLUDESPART NUMBERS LISTEDTO THE RIGHT OF ME (SERIES),OS(DISP),Ol(HOUSING), Ol(SHAFT) AND AAAA (OPTION)SHOWN IN LEFTHAND COLUMN OF CHART. CAUTION:THE CHARTEDCOMPONENT SERVICEINFORMATION IS FORTHE TORQMOTORSLISTED ONLY.REFERTO THE ORIGINAL EQUIPMENT MANUFAC- b& TUREROF THE EQUIPMENTUSING THE TORQMOTOR FORASSEMBLY NUMBERS NOT LISTED BELOW. EXPLODED VIEW ITEM# h5& 6 7 9 11 13 “14 “15 17 19 20 25 v) COMMUTATOR MANIFOLD WEAR THRUST INNER THRUST THRUST BACKUP OUTER DIRT;;ATER BACKUP Y DESCRIPTION ASSEMBLY (see note) PLATE BEARING BEARINGWASHER(Z) BEARING WASHER BEARING WASHER B v1 ME- Service Part # MEIEOOO-A1 ME015000 477342 068024 071019 400136 069017 028515 068027 478035 029118 EXPLODED VIEW “(SELECTITEM# BOLTPEROPTIONGRCIIP) ITEM# 1 OR IA 18 OR 1c 8 Ill 2 8 m s 2 t 9

091215IE2129-

56

337 4858-

a s 6 g w

p. z % Ii %

P Y Ei

z

5 & i3 F 8

L

15

DESCRIPTION BOLT(7) ServicePart # 021390 Service Part# 021352 Service Part# 021272 Service Partl 021340 Service PartB 021273 Service Part# 021392

BOLT(7) 021273 021379 021391 021393 021385 021394

BOLT(7) 021273 021379

BOLT(7)

ROTORSET

DRIVELINK

021379

021392 021385 021394

021385

ME097003 ME127003 ME157003 ME187003 ME217003 ME297003

ME093000 ME123000 ME153000 ME183000 ME213000 ME293000

Service Part # 021385 Partkc 021395 Service Part# 021396 EXPLODEDVIEW ITEM# “18

021393 021388 021389

021393 021388 021389

ME487003 ME337003 ME587003

ME483000 ME333000 ME583000

DESCRIPTION Ol020405-

Ol0203s 04050607OE17IE19207

AAAA AAAC AAAF AAAG AAAM AAAN AAAP AAAT AAAU BBBA BBBB BBBC BBBD

Service Part# Service Part# Service Part% Service Part# Service Part# Service Part# EXPLOOEDVIEW ITEM#

021393 021395

1

<

SERVICE HOUSINGASS’Y ME012001-Al ME012002-Al ME012004-Al ME012005-A1 MEOl2008-Al ME0127007-Al 12

COUPLING DESCRIPTION SHAFT Service Part# ME019001 Service Patti! ME019002 Service Part, ME019003 Service Part# ME019004 Service Part# ME019005 Service Part# ME019006 Service Partf ME019007 Service Part# ME019000 Service Part+? ME019008 Service Part# ME019009 Service Part# ME019010 Service Part# ME019011 EXPLODEDVIEW ITEM# 7. IA. IB. IC 2 DESCRIPTION

BOLT(7)

Service Part# Service Patti Service Part # Service Part # Service Partt Service Part# Service Part # Service Part# Service Part# Service Part# Service Part# Service Partt Service Part#

Item#I Item#I Item#I Item#l Item#I B Item#I B Item#lB Item#!A Item#IA Item#lC Item#I C Item%1C Item#lC

I

12A

128

12c

120

12E

12F

KEY

NUT

WASHER

518-18 ilOlT

LOCK WASHER

RETAINING RING

028413

6223734

G103325

401333

028413

6223734

6103325

028518

G223734

6103325

6124553 039028

G124554

“025126

6124554 039028

‘025138 3

4

END COMMUTATOR SEAL COVER SEAL RING(5) ME016000 ME016000 ME016000 ME016000 ME016002 ME016002 ‘ME016001-Jl ‘ME016003-Al fME016003-A1 fME016004-A1 ‘MEO16004-A2 ‘ME016004-A3 ‘ME01804-A4

032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435

032819 032819 032819 032820 032819 032819 032819 032819 032819 032819 032819 032819 032819

16 21&22 INNER PLUG& O-RING SEAL ASSEMBLY 032817 032817 032817 032818 032817 032817 032817 032817 032817 032817 032817 032817 032817

415463-A2 415483-A2 411063-Al 411063-Al 411063-Al 411063-Al

401658 92

23

D-RING

SPRING(2)

032200-90 032200-90 032424 032424 032424 032424

401642 401642

VALVE

415569 415569 410009-74 (2),1000PSI 410009-71 (2),2000PSI 410009-72 (2),3000P: 41009 -73 (2),4000Ph&,

E Servicehousingass’y ITEMX18 with part numbersuffix-Al includesITEM#13,#14 two req’d.X15 and#19 Selectthe requiredbolt numberin designatednOISPLACEMENT GROUP”underbolt ITEM#I. 1A. 19 or 1C shown in designated“OPTIONGROUP” ‘l-20 UNEFnut #025113is requiredif the designated“OPTIONGROUP”is AAAF.AAAN. or AAAU. dlTEM#22 is part of plug &o-ring assy’s but can be serwad separately. For reverseflow manifold.use ME015001 eService endcover ME016001-Jlincludestwo #032200-IOo-rings. ITEM18A on the explodedass’)’view that can also be serviced separately. fEndcover assemblyitem 62 also includesitem #21,X22, %24and if requireditem #23.All but item #21 can be serviced separately. ‘1 l/8-18 UNEFnut#025139is requiredif the designated“OPTIONGROUP”is AAAF.MAN. or AAAU “ME018001-Alcommutatorass) is requitedif the designated“OPTIONGROUP”is AAAM, AAAN. or AMP Standardseal kit SK0000092includesfive #032819seal rings.#032435commutatorseal. #032817inner seal,#028515and#029118back washers, #478035dirt &water seal. #406018greasepack, bulletin #687. Specialseal kit SK000093for units that use fire retardantfluids includesfive #032820seal rings.#032435commutatorseal,#II32818innerseal,#028515and#029118back up washers. #478035dirt & water seal.#406018greasepack, bulletin #WI

MJ Service Parts list Chart CHART USE EXAMPLE: MB090101AAAATORQMOTORTM INCLUDES PARTS NUMBERS LISTEDTO THE RIGHT OF MJ(SERIES), OS(DISP.),Ol(HOUSING), Ol(SHAFT) AND AAAA (OPTION) SHOWN IN LEFTHAND COLUMN OF CHART. -3

CAUTION:THE CHARTEDCOMPONENT SERVICEINFORMATIONIS FORTHE TORQMOTORSLISTED ONLY.REFERTO THE ORIGINAL EQUIPMENT MANUFACTUREROF THE EQUIPMENT USING THE TORQMOTORFORASSEMBLY NUMBERS NOT LISTED BELOW. EXPLOOEDVIEW ITEM# %&Ii 7 9 11 “13 “14 “15 17 “19 20 25 COMMUTATORMANIFOLD WEAR THRUST INNER THRUST THRUST BACKUP OUTER DIRT&WATER BACKUP ii DESCRIPTION ASSEMBLY (SEENOTE) PLATE BEARING BEARING WASHER(2) BEARING WASHER BEARING SEAL WASHER z z Service Part # ME18000-Al ME01 5000 477342 068024 028537 069021 487063 028538 MJ071031 069023(2) 069022 EXPLODEDVIEW YSELECTIT;;# BOLTPE;;PTlON GR;;P) ITEM# IB OR IC 8 IO ROTOR SET DRIVE LINK DESCRIPTION BOLT (7) BOLT (7) BOLT (7) BOLT (7) k

E; z z Y

120915 18-

Service Part # Service Part# Service Part#

021390 021352 021272 021340

021379 021273 021391 021393

021379 021273

021379

021392

021385

z 5 % E

21;;:

Service Parti ;;;i;; ;;$I Service Part# Service Part# Service Part# EXPLODEDVIEW ITEM#

021273 021392 021385 021366 021395 021396

021385 Ei.! 021329 021388 021389

021385 021394 021393

021393 021395 021388

$1 58-

5 & z 3 z

DESCRIPTION Ol-

0205-

-2

PE zt 31s 2 320 w 36-

Service Part# Service Part# Service Part# EXPLODEDVIEW ITEM#

iz x F k

ME217003 ME297003 ME337003 ME377003 ME487003 ME587003

ME213000 ME293000 ME333000 ME373000 ME483000 ME583000

“18

MJ012002-Al MJ012001-Al MJ012003-Al 12

12A

12B

12c

120

12E

12F

DESCRIPTION

COUPLING SHAFT

KEY

NUT

WASHER

7/B-14 BOLT

LOCK WASHER

RETAINING RING

Service Part# Service PartI Service Part#

MJ019000 MJ019001 MJ019002

039039 039040

025133

028492

6426477

6103327

DESCRIPTION

4

ME093000 ME1 23000 ME153000 ME183000

SERVICE HOUSINGASS’Y

EXPLODEDVIEW ITEM# bl.lA,lB,lC

AAAA AAAC AAAF AAAG AAAH AAAM AAAN AAAP AAAT AAAU BBBA BBBB BBBC BBBC

Ii 021389

ME097003 ME127003 ME157003 ME187003

Service Part# Service PartI Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part# Service Part#

BOLT(7) Item#I Item#I Item#l Item#I Item#l Item #lB Item#I B Item#l B Item#IA Item#lA Item#1C Item#l C Item#l C Item#l C

2

3

4

END COMMUTATOR SEAL SEAL COVER RING(5) 032435 MB016000 032819 MB016000 032435 032819 MB016000 032435 032819 MB016000 032435 032820 032435 MB016000 032820 ME016002 032435 032819 ME016002 032435 032819 “ME016001-Jl 032435 032819 ‘ME016003-Al 032435 032819 ‘ME016003-Al 032435 032819 ‘ME016004-Al 032435 032819 ‘ME016004-A2 032435 032819 ‘MEO16004-A3 032435 032819 ‘ME016004-A4 032435 032819

16

?!I&22

INNER PLUG& O-RING ASSEMBLY SEAL 032817 032817 032817 032818 032818 032817 032817 032817 032817 032817 032817 032817 032817 032817

415463-A2 415463-A2 411063-Al 411063-Al 411063-Al 411063-Al

Y!2

‘23

24

O-RING

SPRING(2)

VALVE

032200-90 032200-90 032424 032424 032424 032424

401642 401642

415569 415569 410009-74 121.1000PSI 410009 -71 (2),2OOOPSI 410009 -72 (2),3OOOPSI 410009 -73 (2).4OOOPSI

For reverse flow manifold.use MF015001. a Servicehousingass’y ITEM#19 with part numbersuffix-Al includesITEM#I% #14two req’d,#I5 and#lg. b Selectthe requiredbolt numberm designated“DISPLACEMENT GROUP”underbolt ITEM#I. IA, 16 or IC shown in designated“OPTIONGROUP.” ‘Nut #025113is requiredif the designated“OPTIONGROUP”ISAAAF.MAN, or AAAU. j-20 UNEF ITEM#22 is part of plug &o-ring assy’s but can be serviced separately. e Serviceand cover MEO%OOl-Jl includestwo #032200-10o-rings, ITEM18A on the explodedass’y view that can also be serviced separately. ‘Endcover assemblqitem #2 also includesitem #21,R2. #24 and if requireditem P23. All but item #21 can be serviced separately. GME018001-A1 commutatorass’y. is requiredif the designated“OPTIONGROUP”is AAAM. A&IN. or AAAP Standardseal kit SK000092includesfive #032819seal rings, #032435commutatorseal, #032817inner seal,#028515and #029118back washers. W78035 dirt &water, #406019grease pack. bulletin#687. Specialseal kit SK0000093for unitsthat use fire retardant fluids includesfive #032435commutatorseal,#032919inner seal.#028515and#I291 18 back up washers. #478035dirt & water seal, #406018greasepack

1697.

16

Disassembly and Inspection

(Preparation Before Disassembly)

l

l

l

l

l

Before you disassemble the TorqmotorTM unit or any of its components read this entire manual. It provides important information on parts and procedures you will need to know to service the TorqmotorTM. Determine whether the TorqmotorTM you are about to disassemble is the Small Frame Series MG or MF or the Large Frame Series MB, ME, or MJ so you can follow those procedures that pertain to that Series Torqmotor TM.The first two letters of the “spec” number on the TorqmotorTM identification tag is the Series designation. Also determine the type of end construction from the alternate views shown on the exploded view. The Small Frame Series MG & MFTorqmotorsTM will have a 3.66 inch (92.9 mm) main body outside diameter and five 5/16-24 UNF 2A cover bolts. The Large Frame Series MB, ME, & MJ TorqmotorsTM will have a 5 inch (127.9 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts. Refer to “Tools and Materials Required for Services” section for tools and other items required to service the TorqmotorTM and have them available. Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the Torqmotor TM.Remove rust or corrosion from coupling shaft.

l

Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.

l

Remove the TorqmotorTM from system, drain it of fluid and take it to a clean work surface.

l

Clean and dry the Torqmotor TMbefore you start to disassemble the unit.

l

As you disassemble the Torqmotor TM clean all parts, except seals, in clean petroleum-based and blow them dry.

solvent,

WARNING: PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSUREREQUIREMENTS. CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts. l

l

17

Keep parts separate to avoid nicks and burrs. Discard all seals and seal rings as they are removed from the Torqmotor TM.Replace all seals, seal rings and any damaged or worn parts with genuine Ross or OEM approved service parts.

Disassembly and Inspection

(Reference Exploded Assembly View) Place Torqmotor in a vise

1.

WARNING

Scribe alignment mark & loose valve plugs

Remove special bolts & inspect bolts

Place the TorqmotorTM in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable. WARNING: IF THE TORQMOTOR~ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY.

2.

3.

Scribe an alignment mark down and across the TorqmotorTM components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover. 3/16 or 3/8 inch allen wrench or 1 inch hex socket required. SEE FIGURE 3 & 4.

Figure 3

Figure 4

Remove the five or seven special ring head bolts (1,l A, 1 B, or 1C) using an appropriate l/2 or 9/16 inch size socket. SEE FIGURE 5. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts. SEE FIGURE 6.

18

Remove end cover & inspect bolts

4.

NOTE: Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being serviced.

NOTE

Remove plugs and valves

Remove end cover assembly (2) and seal ring (4). Discard seal ring. SEE FIGURE 7.

5.

If the end cover (2) is equipped with shuttle valve or relief valve (24) components, remove the two previously loosened plugs (21) and orings (22). SEE FIGURE 8.

CAUTION

CAUTION: Be ready to catch the shuttle valve or relief valve components that will fall out of the end cover valve cavity when the plugs are removed.

NOTE

NOTE: O-ring (22) is not included in seal kits but serviced separately if required.

NOTE

NOTE: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part of the end cover.

Wash & inspect end cover

6.

NOTE

Remove & inspect commutator ring

Figure 7

Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. SEE FIGURE 9.

Figure 9

NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set.

7.

Remove commutator ring (6). SEE FIGURE 10. Inspect commutator ring for cracks, or burrs. Figure 10

19

Remove & inspect commutator

8.

Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set. SEE FIGURE 11 & 12.

Remove manifold

9.

Remove surface manifold FIGURE surface normal. that are

NOTE

Remove 81 inspect rotor set & wearplate

NOTE

manifold (7) and inspect for cracks scoring, brinelling or spalling. Replace if any of these conditions exist. SEE 13. A polished pattern on the ground from commutator or rotor rotation is Remove and discard the seal rings (4) on both sides of the manifold.

NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set. 10.

Remove rotor set (8) and wearplate (91, together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. SEE FIGURE 14. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor (8A) and wearplate. SEE FIGURE 15. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wearplate for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and wearplate. NOTE: The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pencil before removal from TorqmotorTM will ensure correct reassembly of rotor into stator and rotor set into Torqmoto?. Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and TorqmotorTM.

Figure 14

NOTE

NOTE: Series ME TorqmotorsTM may have a rotor set with two stator halfs (8B & 8D) with a seal ring (4) between them and two sets of seven vanes (8C & 8E). Discard seal ring only if stator halfs become disassembled during the service procedures.

NOTE

NOTE: A polished pattern on the wear plate from rotor rotation is normal.

Check rotor, Vance clearance

11

NOTE

Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than -005 inches (0.13 mm) of clearance, replace rotor set. SEE FIGURE 16. NOTE: If rotor set (8) has two stator halfs (8B & 8D) and two sets of seven vanes (8C & 8E) as shown in the alternate construction ME rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

Figure

16

Remove & inspect drive link

12.

Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. SEE FIGURE 17. Remove and discard seal ring Figure 17 (4) from housing (18).

Remove thrust bearing

13.

Remove thrust bearing (11) from top of coupling shaft (12) if Torqmotor is a Series MB or ME. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 18.

21

Figure

18

Check coupling shaft for rust or corrosion

14.

Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. SEE FIGURE 19. Remove any key (12A), nut (12B), washer (12C), bolt (12D), lock washer (12E), or retaining ring (12F).

Figure 19

Remove & inspect coupling shaft

15.

Remove coupling shaft (12), by pushing on the output end of shaft. SEE FIGURE 20. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. SEE FIGURE 21. Replace coupling shaft if any of these conditions exist.

NOTE

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE

NOTE: A slight “polish” is permissible in the shaft bearing areas. Anything more would require coupling shaft replacement.

Remove seal ring from housing

16.

Remove and discard seal ring (4) from housing (18). Figure 21

Remove & inspect thrust washer 81 thrust bearing NOTE

17.

Remove thrust bearing (15) and thrust washer (14) if the unit is a Series MG or MF. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 22. NOTE: Large Frame Series MB & ME Torqmotors have a thrust bearing (15) sandwiched between two thrust washers (14) that cannot be removed from housing (18) unless bearing (13) is removed for replacement.

Remove seal &washer or washers

18.

Remove seal (16) and back up washer (17) from Small Frame, MG & MF housing (18). Discard both. SEE FIGURE 23. Remove seal (16), backup washer (17), and backup washer (25) from Large Frame, Series MB & ME TorqmotorTM housing by working them around unseated thrust washers (14) and thrust bearing (15) and out of the housing. Discard seal and washers. SEE FIGURE 24.

NOTE

Figure 23

NOTE: The original design units of large Frame, Series MB 81 ME TorqmotorsTM did not include backup washer (25), but must include backup washer (25) when reassembled for service.

Remove seal

19.

Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller required. SEE FIGURE 25.

Inspect housing assembly

20.

Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. SEE FIGURE 26. If the housing is defective in these areas, discard the housing assembly. Figure 2

23

Inspect housing bearing/bushing

21.

If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. SEE FIGURE 27. The MG Series bushing (19) or (13) to coupling shaft diameter clearance must not exceed ,010 inch (.025 mm). A bearing, bushing, or thrust washer that does not pass inspection must be replaced. SEE FIGURE 28. If the housing has passed this inspection the disassembly of the TorqmotorTM is completed.

Figure 27

NOTE: The depth or location of bearing/ bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/bushings. This will facilitate the correct reassembly of new bearings/bushings. SEE FIGU Remove bearings or bushings &thrust washers

22.

If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). SEE FIGURES 30 & 31.

THE DISASSEMBLY OF TDRQMDTORTM IS COMPLETED.

24

TorqmotorM Assembly *

Replace all seals and seal rings with new ones each time you reassemble the TorqmotorTM unit. Lubricate all seals and seal rings with SAE lOW40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available. SEE FIGURE 32. The parts should be available through most OEM parts distributors or Ross approved TorqmotorTM distributors. (Contact your local dealer for availability).

l

NOTE: Unless otherwise assembly.

l

*

indicated,

do not oil or grease parts before

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

WARNING

WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR USE INJURY OR DEATH. FIRE COUL

WARNING

WARNING: WEAR EYE PROTECTION AND BE LY WITH OSHA OR OTHER SURE TO PRESSURE REQUIREMENTS. MAXIMU

Press in outer bearing/bushing

1.

If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel such as described in figure 1 or figure 2 which will control the bearing/ bushing depth. Small Frame Series MG and MF TorqmotorTM housings require the use of bearing mandrel shown in figure 1 to press bearing/ bushing (19) into the housing to a required depth of .151/.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. SEE FIGURE 33. Large frame Series MB and ME TorqmotorTM housings require the use of the bearing mandrel shown in figure 2 to press bearing (19) into the housing to a required depth of .290/.310 inches (7.37/7,87 mm) from the outside end of the bearing counterbore. SEE FIGURE 34. Large Frame Series MJ Torqmotor housings require the use of a bearing mandrel. Consult factory for specifications. Figure 34

25

NOTE

NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.

CAUTION

CAUTION: If the bearing mandrel specified in the “Tools and Materials Required for Servicing” section is not available and alternate methods are used to press in bearing/bushing (13) and (19) the bearing/bushing depths specified must be achieved to insure adequate bearing support and correct relationship to adjacent components when assembled. SEE FIGURE 35.

Figure 35

CAUTION: Because the bearing/bushings (13) and (19) have a press fit into the housing they must be discarded when removed. They must not be reused.

CAUTION

Figure 36

Press in inner Bearing/bushing

2.

The Small Frame Series MG and MF TorqmotorTM inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to .03 inch (76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). Reference figure 1, “Tools and Materials Required for Servicing” section. SEE FIGURE 36. The Large Frame Series MB and ME TorqmotorTM housing (18) requires that you assemble a new backup washer (25), new seal (16), with the lip facing to the inside of Torqmotor (see figure 69A), new thrust washer (14), new thrust bearing (15) and a new second thrust washer (14) in that order before pressing in the inner housing bearing (13). SEE FIGURE 37 & 38. When these components are in place, press new bearing (13) into the housing (18) to a depth of .105/.125 inches (2.67/3.18) below the housing wear plate contact face. Use the opposite end of the bearing mandrel used to press in outer bearing (19). Reference figure 2, in the “Tools and Materials Required for Servicing” section. SEE FIGURE 39.

Figure 37

Figure 38

Press in dirt & water seal

3.

Press a newdirt and water seal (20) into the housing (18) outer bearing counterbore.

Figure 39

The Small Frame Series MG and MF TorqmotorTM dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. SEE FIGURE 40.

Figure 40

The Large Frame Series MB and ME TorqmotorTM dirt and water seal (20) must be pressed in with the lip facing out and until the seal is flush to ,020 inches (51 mm) below the end of housing. SEE FIGURE 41.

Figure 41

Place housing assembly into vice

Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. SEE FIGURE 42.

Figure 42

27

Assemble backup washer 81 seal

5.

Large Frame, Series MB and ME TorqmotorTM housing (18) that did not require replacement of the bearing package will require that the two “captured” thrust washers (14) and thrust bearing (15) be unseated and vertical to the counterbore and the new backup washer (17), new backup washer (25), and new seal (16) be worked around the thrust bearing package and placed into their respective counterbores. The seal lip must face out of the seal counterbore and toward the inside of TorqmotorTM (see figure 69A). Be sure the thrust bearing package is reseated correctly after assembly of the seal and backup washer. SEE FIGURE 43 & 44. CAUTION: Original design large Frame, MB & ME TorqmotorsTM that do not have backup washer (25) when disassembled must be assembled with a new backup washer (17), new backup washer (25). and new seal (16).

CAUTION

!

‘\

Assemble thrust washer & bearing

6.

NOTE

Auulv maskina tiie ;o shaft ”

On Small Frame, Series MG & MF TorqmotorsTM assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of TorqmotorTM (see Figure 69B), into their respective counterbores in housing (18) if they were not assembled in procedure 2.

Figure 44

Assemble thrust washer (14) then thrust bearing (15) that was removed from the Series MG or MF Torqmotorm. SEE FIGURE 45. NOTE: Small Frame Series MG and MF TorqmotorsTM require one thrust washer (14) with thrust bearing (15). The coupling shaft will be seated directly against the thrust bearing.

7.

Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal. SEE FIGURE 46.

-

Figure 46 28

Install coupling shaft

8.

Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in MG and MF Series housings and against the second thrust washer (14) in MB and ME Series housings. SEE FIGURE 47.

CAUTION

CAUTION: The outer bearing (19) is not lubricated by the system’s hydraulic fluid. Be sure it is thoroughly packed with the recommended grease, Ross Gear grease specification #045236, E/M Lubricant #K-70M.

NOTE

NOTE: Mobil Mobilith SHC @I 460 NOTE: A 102 Tube (P/N 406010) is included in each seal kit.

NOTE

NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Small Frame, Series MG and MF TorqmotorsTM when properly seated while the coupling shaft (12) on Large Frame, Series MB and ME TorqmotorsTM will be Figure 48 approximately .I0 inch (2.54 mm) below the housing wear plate surface to allow the assembly of thrust bearing (11). The coupling shaft must rotate smoothly on the thrust bearing package. SEE FIGURE 48.

Install thrust bearing

9.

Install thrust bearing (11) onto the end of coupling shaft (12) only if you are servicing an MB or ME Series TorqmotoP. SEE FIGURE 49

Insert seal ring

10.

Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. SEE FIGURE 50.

NOTE

Figure 47

Figure 49

NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/1624 UMF 2A bolts as required that are over .5 inch (12.7 mm) longer than the bolts (1, IA, IB, or 1C) used in the TorqmotorTM. Figure 50

Install drive link

11.

Install drive link (18) the long splined end down into the coupling shaft (12)and engage the drive link splines into mesh with the coupling shaft splines. SEE FIGURE 51. NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

NOTE

Figure 51

Assemble wear plate

12.

Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). SEE FIGURE 52.

Assemble seal ring

13.

Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (88). SEE FIGURE 53.

Install the assembled rotor set

14.

Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines. SEE FIGURE 54.

NOTE

NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE

NOTE: If necessary, go to the appropriate, “Rotor Set Component Assembly Procedure.”

NOTE

NOTE: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down. The rotor set seal ring groove faces toward the wear plate (9).

Figure 52

Figure 53

Figure 54 30

Assemble seal ring in manifold

15.

NOTE

Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). SEE FIGURE 55. NOTE: The manifold (7) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

Assemble manifold

16.

Figure 55

Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. SEE FIGURE 56.

Figure 56

Insert a seal in manifold

Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. SEE FIGURE 57. Figure 57

Assemble commutator 31

ring

18.

Assemble the commutator ring (6) over alignment studs onto the manifold. SEE FIGURE 58.

Figure 58

Assemble seal & commutator

19.

Assemble a new seal ring (3) fiat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. SEE FIGURE 59,60.

Figure 59

Figure 60

Assemble shuttle valve parts into end cover

20.

If shuttle valve components items #21, #22, #23, #24 were removed from the end cover (2) turn a plug (21) with a new o-ring (22), loosely into one end of the valve cavity in the end cover. Insert a spring (23) the valve (24) and the second spring (23) into the other end of the valve cavity. Turn the second plug (21) with a new o-ring (22) loosely into the end cover valve cavity. 3/16 inch Allen wrench required. SEE FIGURE 61. Figure 61

Assemble relief valve parts in end cover

21.

If relief valve components items #21, #22, #24 were removed from the end cover (2) assemble a new o-ring (22) on the two plugs (21). Assemble a two piece relief valve (24) in each of the plugs, with the large end of the conical spring into the plug first and the small nut of the other valve piece in the small end of the conical spring. Turn each of the plug and relief valve assemblies into the end cover loosely to be torqued later. 3/8 inch Allen or 1 inch Hex socket required. SEE FIGURE 62. Figure 62

32

Assemble seal ring & end cover

22.

NOTE

Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. SEE FIGURE 63,64. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown in FIGURE 65.

NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

Figure 63

Figure 64

Figure 65

Assemble cover bolts

33

23.

Assemble the 5 or 7 special bolts (1, lA, 1B or 1C) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. Ibs. (30-35 N m) for the five MG & MF Series 5/16 24 threaded bolts or 45-55 ft. Ibs. (61-75 N m) for the seven MB & ME Series 3/8-24 threaded bolts. SEE FIGURE 66,67, 68.

Figure 66

NOTE

NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the boits required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

Fiuure 67

Figure 68 Torque the valve plugs

24.

Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. Ibs. (1216 N m) if cover is so equipped. SEE FIGURE 69. Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. Ibs. (6175 N m) if cover isso equipped. rlyure

Thrust 1 Washers’cl

DJ

I HTl

I

r Thrust earin

UL~

Figure 69A

Large Frame

THE ASSEMBLY OF THE TORQMOTORTM IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY (12A), NUT (12B), WASHER (12C), BOLT (120), LOCKWASHER (12E), RETAINER RING (12F) or PORT O-RINGS (18A) AT INSTALLATION. IF APPLICABLE. PROCEED TO FINAL CHECKS SECTION.

i,l

Figure 69

.--

Shaft

/.-.~’

:

Small Frame

Rotor Set Component Assembly

One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures. Assemble stator

1.

Insert two bolts

Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following TorqmotorTM assembly procedures 1 through 13. Be sure the seal ring is in place. SEE FIGURE 70. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

Assemble rotor

Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. SEE FIGURE 71.

NOTE

NOTE: If the manifold side of the rotor was etched during Torqmotor disassembly, this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

Assemble vanes

Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. SEE FIGURE 72.

CAUTION

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

Assemble full complement of vanes

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. SEE FIGURE 73.

Remove two assembled bolts

6.

Figure 70

Figure 71

Figure 72

Remove the two assembled bolts (1) if used to retain stator and wear plate. Go to TorqmotorTM assembly procedure #15, to continue TorqmotorTM assembly. Figure 73

35

Rotor Set Component Assembly Procedure Two Piece Stator Construction A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures. Assemble stator halfs

1.

Place stator half (8B) onto wear plate (9) with seal ring (4) side down, after following TorqmotorTM assembly procedures 1 through 13. Be sure the seal ring is in place.

Insert two alignment studs

2.

Align stator bolt holes with wear plate and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary.

Assemble rotor

3.

Assemble rotor (8A), counterbore down if applicable, into stator half (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

NOTE

Assemble vanes

NOTE: Use any set components components in ensure ultimate 4.

CAUTION

marking you applied to rotor to reassemble the their original relationship to wear life and performance.

Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. CAUTIUN: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

Assemble full complement of vanes

5.

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator half (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Assemble seal ring in stator half

6.

Place second stator half (8D) on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring (4) and assemble it into stator half ring groove.

Assemble second stator half

7.

Assemble the second stator half (8D) over the two alignment studs and rotor (8A) with seal ring side down onto the first stator half (8B) aligning any timing marks applied for this purpose.

CAUTION

CAUTION: If the stator half (8B) is a different height (thickness) than stator half (8D) the stator vanes (8C) or (8E) of the same length (height) as the stator half must be reassembled in their respective stator half for the rotor set to function properly.

Assemble vanes

Assemble six vanes (8E), or as many vanes that will readily assemble into the stator vane pockets.

Assemble full complement of vanes

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8E) into stator (8D), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. Go to TorqmotorTM assembly procedure #15, to continue TorqmotorTM assembly.

37

Final Checks

Final Checks . Pressurize the

TorqmotorTM with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks.

.

Check TorqmotorTM for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. Ibs. (68 N m)

.

On MC & MF Series Torqmotors, pressure port with “A” cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “B” cast under it is for counter clockwise coupling shaft rotation.

.

On MB, ME, & MJ Series Torqmotors, pressure port with “B” cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “A” case under it is for counter clockwise coupling shaft rotation.

.

Use test stand if available, to check operation of the TorqmotorTM.

Hydraulic Fluid Keep the hydraulic system filled with one of the following: .

lOW40 SE or SF manufacturers

.

Hydraulic fluid as recommended by equipment manufacturer, drop below 50 SSU or contain less than .125% zinc anti-wear

suggested oil. but the viscosity should not additives.

CAUTION: Do not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals. Maintain the proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. It is suggested also that you flush the system with clean oil.

Filtration Recommended

filtration 20-50 micron.

Oil Temperature Maximum operating temperature

200°F (93.3” C).

38

Tips for Maintaining the TorqmotorTM Hydraulic System

.

Adjust fluid level in reservoir as necessary.

.

Encourage all operators to report any malfunction the hydraulic system or component.

.

Do not attempt to weld any broken TorqmotorTM component. original equipment only.

.

Do not cold straighten,

.

Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps before checking oil level.

.

Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

.

Comply with manufacturer’s

or accident that may have damaged Replace the component

with

hot straighten, or bend any TorqmotorTM part.

specifications

for cleaning or replacing the filter.

CAUTION: 00 not weld, braze, solder or any way alter any TorqmotorTM component. CAUTION: Maximum pressure capacity.

operating

pressure must not exceed recommended

TorqmotorTM

CAUTION: Always carefully inspect any system component that may have been struck or damaged during operation or in an accident. Replace any component that is damaged or that is questionable. CAUTION: Do not force any coupling onto the TorqmotorTM coupling shaft as this could damage the unit internally. Ross extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact your local Ross approved Distributor or Ross Technical Support, Our phone number and fax number and address are on the back cover of this manual.

39

MG, MF, MB, ME, MJ Series Service Procedure

Ross Operation Snapps Ferry Road P.O. Box 1790 Greeneville, TN 37744 USA Phone: (615) 639-8151 FAX: (615) 787-2418 MG, MF, MB, ME, MJ B&B 2500 9/95

Halvorsen Section 6. Hydraulic Cylinders

PARKER HANNIFIN CORP. Mobile Cylinder Division CYLINDER INFORMATION DRAWINGS Front and Rear, Side Shift Cylinders CLOVER HYDRAULICS & ENGINEERING, INC. SPECIFICATIONS AND PARTS LIST DRAWINGS Front Roll, Rear Roll, Constant Velocity Telescopic Lift, and Helper Cylinders CYLINDER SEAL REPLACEMENT PROCEDURES Front, Rear, Main Lift, and Helper Cylinders TEXAS HYDRAULICS, INC. MAINTENANCE MANUAL Z and K Cylinder Heads, and Z and M Cylinder Pistons

HYDRAULIC CYLINDERS

5-6 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

MAINTENANCE MANUAL

General Information Contents General - General Information Teardown - Non-specific Teardown Procedures Inspection - Inspection Procedures for Rod, Head, Piston, and Tube Rebuild - Non-specific Rebuild Procedures Test - Procedures for Testing Rebuilt Cylinder

Warning

!

Hydraulic cylinders are designed to hold hydraulic fluid under high pressure. In addition, cylinders may contain holding valves and other means that could cause pressure to remain locked in the cylinder. As such, incorrect handling or process steps can create an unsafe situation. Be sure all appropriate measures are taken to relieve any residual pressure in the cylinder and further ensure that the cylinder is restrained in such a way that it cannot fall or move during the disassembly and assembly processes.

General This manual describes those teardown and rebuild practices that are common to all standard Texas Hydraulics cylinder designs. Specific practices are available based on the component to be rebuilt. Please see your Texas Hydraulics sales engineer for this information. Standard Texas Hydraulics cylinders are designed to operate with fluids per MIL-L-2104 or equivalent. Fluid cleanliness should be maintained at an ISO 18/15 for maximum life.

Teardown Remove the cylinder and drain hydraulic fluid. Clean away all dirt or other foreign substance from openings - particularly at the head. NOTE: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90° to the pin rotation axis. Remove the head retaining device. See specific procedure for your head design. Extend the rod until the piston bottoms out on the head. Gently tap the piston against the head to drive the rod assembly out. Place the rod assembly on a surface that will not damage the chrome. Remove the piston locknut and separate the piston from the rod. Slide the head off the rod from the piston end. Discard all old seals.

Inspection INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the rod should be repaired or replaced.

MAINTENANCE MANUAL

INSPECT HEAD: Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out-of-roundness. If out-of-roundness exceeds 0.007", this is unacceptable. Check the condition of the dynamic seals looking particularly for metallic particles embedded in the seal surface. It is normal to cut the static seal on the retaining ring groove upon disassembly. Remove the rod seal, static o-ring and backup and rod wiper. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the head should be replaced. INSPECT PISTON: Visually inspect the outside surface for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the diameter should be checked for out-of-roundness. If out-ofroundness exceeds 0.007", this is unacceptable. Check the condition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface. Remove the seals and bearings. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the piston should be replaced. INSPECT TUBE ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail but are less than 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. The roughness of the bore should be between 10 and 20 µinches RMS. Significant variations (greater than 8 µinches difference) are unacceptable. In the event that an unacceptable condition occurs, the tube assembly should be repaired or replaced.

Rebuild Thoroughly rinse the inside of the tube and allow to drain. A high-pressure rinse followed by a wipe with a lint-free rag is preferable. Clean all internal components of any foreign material. Visually inspect for material defects and contamination. Lubricate the head and all seals with hydraulic fluid prior to installation. Rebuild the head and seals per the specific practice for this design. Lubricate the piston and all components with hydraulic fluid. Rebuild the piston and seals per the specific practice for this design. Place the rod on a clean table. Install the static o-ring seal per the recommended practice. Install the head followed by the piston onto the rod noting the proper orientation of each component. Torque the piston nut to the proper torque. When the rod assembly is ready to be installed in the tube, liberally apply an anti-seize lubricant per the below specification to the head outer surface, especially the static seal. Permatex Industrial Division of Loctite Anti-Seize Lubricant Brush-on: P/N 80208 Spray-on: P/N 80470 Dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube. Watch the seals as they pass over the rod port (if visible) to be sure they are not nicked or cut. Tighten the head per the specific procedure for this design.

Test Set test stand pressure to the recommended test pressure and attach hose fittings to cylinder. The cylinder shall be stroked its full length in both directions to fill it with oil and remove trapped air. Pressurize to recommended test pressure at each end, beginning with the rod end, for a minimum of 10 seconds per end. While under pressure, cylinder shall be checked for leaks at welds, pipe fittings, and at all external static and dynamic seals. When testing is complete, retract the cylinder using air in the rod port to remove oil. Seal ports with port plugs to prevent contamination from entering cylinder.

MAINTENANCE MANUAL

Z Head General The Z series head uses ductile iron material and has a polyurethane u-cup as the primary sealing element. Cylinders rated for pressures above 3500 psi, may have a back up ring behind the u-cup. The wiper is a standard type D polyurethane. The head is retained within the tube by means of its own buttress threads. There is a sealing o-ring that prevents contaminant from reaching the threads and provides an anti-rotation function. General procedures for teardown, inspection, and rebuild are contained in the General Procedures Maintenance Manual. See your Texas Hydraulics Sales Engineer if you have any questions.

BACK UP RING (ON SOME DESGINS)

Teardown Remove the head as follows: Insert a spanner wrench into the holes provided. Turn the head counter-clockwise (it is a right-hand thread) to remove it. If the head is difficult to remove or moves erratically, tap the tube adjacent to the head with a brass or plastic mallet while turning it.

Rebuild Lubricate the head and all seals with hydraulic fluid prior to installation. Using round-nose pliers or special installation tools, twist the dual lip u-cup seal into a "C" shape and allow it to snap into groove. Use a similar technique for installing the wiper. Install the static o-ring and backup into the static seal groove verifying that the backup is closest to the threads. Install the sealing o-ring into the groove between the threads and the flange lip. If possible, the head/seal assembly should sit for at least one hour to allow the seals to elastically restore. Slide the head into the tube and engage the threads. Turn the head counterclockwise until the first thread just passes the engagement point (The head will move noticeably) then turn the head clockwise until it is hand-tight or fully seated. Insert a spanner wrench into the holes provided and tighten 1/8 to 1/4 turn past fully seated.

MAINTENANCE MANUAL

K Head General The K series head uses aluminum material and has a polyurethane u-cup as the primary sealing element. The wiper is a standard type D polyurethane. The head is retained within the tube by means of a square retaining ring, half of which is engaged by the head and the other half by the tube. General procedures for teardown, inspection, and rebuild are contained in the General Procedures Maintenance Manual. See your Texas Hydraulics Sales Engineer if you have any questions.

Wiper Static Back-Up Static O-Ring

Head

U-Cup

Retaining Ring

Teardown Remove the head retaining device as follows: Insert a spanner wrench into the holes provided. Rotate the head clockwise until the edge of the retaining ring appears in the milled opening of the tube. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. Rotate the head counter-clockwise until the retaining ring is completely removed.

Rebuild Lubricate the head and all seals with hydraulic fluid prior to installation. Using round-nose pliers or special installation tools, twist the dual lip u-cup seal into a "C" shape and allow it to snap into groove. Use a similar technique for installing the wiper. Install the static o-ring and backup into the static seal groove verifying that the backup is closest to the retaining ring groove. If possible, the head/seal assembly should sit for at least one hour to allow the seals to elastically restore. NOTE: When installing the head, pay careful attention to the retaining ring hole to insure that the static seal on the head does not extrude into the slot. Insert the spanner wrench into the holes provided and rotate the head until the retaining ring hole is visible through the slot milled in the tube. Insert the retaining ring hook into the hole and rotate the head 1-1/4 turns until the retaining ring is completely pulled into the tube and the ends are covered.

MAINTENANCE MANUAL

Z Piston General The Z series piston uses ductile iron material and glass-filled nylon wearrings (bearing rings). It is available in two basic design styles. The first uses a groove sized for a specially designed teflon seal called the AQ seal. The teflon sealing ring has a small groove on its outside diameter that houses a quad ring seal. The entire ring is energized by a square section rubber loader. The second series uses an interference fit split nylon sealing ring with an oval section rubber loader and is called a Chemcast seal. A small static o-ring seal is fitted to a groove in the piston and is held in place by the shoulder of the rod. General procedures for teardown, inspection, and rebuild are contained in the General Procedures Maintenance Manual. See your Texas Hydraulics Sales Engineer if you have any questions.

PRS STATIC O-RING

ROD

LOCKNUT

WEARRING

AQ SEAL

PISTON

WEARRING

Teardown After removing the piston, remove and discard the PRS static o-ring from the rod shoulder. Remove the AQ seal by means of blunt instruments of bronze or aluminum. Be sure there are no sharp edges on these tools. Be particularly careful of scratching the groove surface finish.

Rebuild Separate the three components of the seal assembly. For easiest installation, warm the teflon outer ring in 150 to 200°F hydraulic fluid or water. Lubricate the piston and all components with hydraulic fluid. Stretch the inner rubber expander into the seal groove. Do not use sharp edged tools and verify that it has not twisted. Likewise, stretch the teflon outer ring into the groove. Be extremely careful to avoid damaging the seal grooves during installation. Scratching the groove may cause by-pass leakage. The teflon ring will have a memory and may take as long as 24 hours to return to the correct size. This can be accelerated by pushing the piston/seal assembly through a honed or polished tube with an ID equal to the nominal cylinder bore to plus .010 inches. Clean the groove in the teflon ring and install the rubber quad ring. Verify that it has not twisted. Install the wearrings into the wearring groove. If possible, allow the piston/seal assembly to sit at least one hour to allow the seals to elastically restore. See the next page for information on the alternative style.

MAINTENANCE MANUAL

Z Piston (Threaded) General The Z series piston uses ductile iron material, glass-filled nylon wearrings (bearing rings), and a specially designed teflon seal called the AQ seal as the primary sealing element. The teflon sealing ring has a small groove on its outside diameter that houses a quad ring seal. The entire ring is energized by a square section rubber loader. A small static o-ring seal is fitted to a groove in the piston and is held in place by the shoulder of the rod. General procedures for teardown, inspection, and rebuild are contained in the General Procedures Maintenance Manual. See your Texas Hydraulics Sales Engineer if you have any questions.

Teardown Remove the piston as follows: locate and remove the set-screw (it may be underneath one of the wearrings). Insert a spanner wrench into the holes provided and turn the piston counter-clockwise (it is a right-handed thread) to remove it. After removing the piston, remove and discard the PRS static o-ring from the rod shoulder. Remove the AQ seal by means of blunt instruments of bronze or aluminum. Be sure there are no sharp edges on these tools. Be particularly careful of scratching the groove surface finish.

Rebuild Separate the three components of the seal assembly. For easiest installation, warm the teflon outer ring in 120 to 150 °F hydraulic fluid or water. Lubricate the piston and all components with hydraulic fluid. Stretch the inner rubber expander into the seal groove. Do not use sharp edged tools and verify that it has not twisted. Likewise, stretch the teflon outer ring into the groove. Be extremely careful to avoid damaging the seal grooves during installation. Scratching the groove may cause by-pass leakage. The teflon ring will have a memory and may take as long as 24 hours to return to the correct size. This can be accelerated by pushing the piston/seal assembly through a honed or polished tube with an ID equal to the nominal cylinder bore to plus .010 inches. Clean the groove in the teflon ring and install the rubber quad ring. Verify that it has not twisted. If possible, allow the piston/seal assembly to sit at least one hour to allow the seals to elastically restore. Place the rod on a clean table. Slide the piston onto the rod noting the proper orientation. Turn the piston clockwise until it is hand tight or fully seated (it is a right-handed thread). Insert a spanner wrench into the holes provided, torque the piston and install set-screws as indicated on the print. Install the wearrings into the wearring grooves.

MAINTENANCE MANUAL

M Piston

ROD PRS STATIC O-RING

LOCKNUT PISTON BACK-UP CROWN SEAL BACK-UP

Teardown After removing the piston, remove and discard the PRS static o-ring from the groove in the rod. Remove the Crown seal and back-ups by means of blunt instruments of bronze or aluminum. Be sure there are no sharp edges on these tools. Be particularly careful of scratching the groove surface finish.

Rebuild Lubricate the piston and all components with hydraulic fluid. Stretch the backups and Crown seal into the seal groove. Be extremely careful to avoid damaging the seal groove during installation. Scratching the groove may cause by-pass leakage. Verify that the rubber o-ring under the Crown seal, the Crown seal itself, and backups are not pinched or twisted. Back-ups are not required on some cylinders. Please reference the cylinder print for your specific requirements.

Halvorsen Section 7. Brakes

AUSCO PRODUCTS SERVICE NOTES Brakes No. 79848 MICO, INC. PRODUCT CATALOG Hydraulic Brake Valves INSTALLATION AND SERVICE INSTRUCTIONS 530 Series Hydraulic Apply Disc Brakes 530 Series Spring Brakes SERVICE INSTRUCTIONS Single Pedal Actuated Power Brake Valves 466 Series - Tandem Power Brake Valve

BRAKES

5-7 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

&*

=e@' BRAKE NUMBER 79848

l nOOUcTs

*

SERVICE NOTES

INC.

EC011916

REV

CAUTION: FOR CORRECT OPERATION, NO 8ACK IN BRAKE HYDRAULIC SYSTEM.

BRAKE DISASSEMBLY 1.

DISASSEMBLY 1.1 REMOVE ‘1.2 STATOR 1.2.1. 1.2.2 1.3

O-RING 1.3.1. 1.3.2. 1.3.3 1.3.4

1.4

2.

INFORMATION:

BLEEDER BLEEOER

LUBRICATE O-RINGS WITH DOW CORNING

2.3,

INSTALL O-RINGS IN THE HOUSING BORE.

2.4.3. 2.4.4.

2.5

I2. I3.

WITH WITH

I I I

GROOVE A 7/16’ A l/4’

AND 200.

THE

SECOND

HOUSING

16. 7. 18.

I4.

GROOVE

1

I

GROOVES

I SERVICE KIT [STATOR

ASSEMBLY: EXPAND SMALL EN0 OF EOOT AND INSTALL THIS EN0 FIRST OVER CLOSED END OF PISTON. INTO ABOUT l/4’ DEEP. THEN ENGAGE BOOT LIP IN BOOT GROOVE OF HOUSiNG. - ---. . _ . .PUSH PISTON ABOUT 3/4 CAVITY DEPTH AND ENCAGE SMALL END OF BOOT IN GROOVE OF PISTON. PUSH PISTON IN SLOWLY UNTIL IT BOTTOMS. IF A PISTON ASSEMBLY SLEEVE IS USED, INSTALL BOOT IN FIRST GROOVE IN HOUSING BORE. INSERT PISTON ASSEMBLY SLEEVE THROUGH BOOT UNTIL IT GENTLY STOPS AGAINST BOOT PORTION ENGAGED IN BOOT GROOVE OF HOUSING. PUSH PISTON THROUGH PISTON ASSEMBLY SLEEVE AND JUST PAST O-RING. REMOVE PISTON ASSEMBLY SLEEVE.ENGAGE BOOT IN BOOT GROOVE AT OPEN END OF PISTON.

!%);(BLE TWO END BOLTS WITH WASHER UNOER BOLT HEAD, SLEEVE AND FLAT WASHER. 2.5.;.5A;S:MBLE FLANGED LOCKNUTS AS FOLLOWS: TO . . . . FOUR CENTER NUT TO BE TORQUE0 80-90 LB FT. 2.5.3.2. THE TWO END NUTS ARE TOROUED AFTER INSTALLATION TO BRACKET.

EILEiD 8RAKE COIGLETELY VIA BLEEDER SCREWS. KEEP FLUI 0 OFF FRICTION SURFACES OF BRAKE ROTATING DISC AND STATORS.

I

OF

HOUSING ASSEM0LY: 2.5.1. ASSEM6LE HOUSING ASSEMBLY WITH PISTONS RETRACTED, SPACER, SECONDARY PLATE AND FOUR CENTER BOLT WITH WASHER UNDER BOLT -.2.5.2.

I5.

WRENCH. WRENCH.

INFORMATION

THERE MUST BE A MIN. OF l/4’ CLEARANCE BETWEEN AND AROUND THE BRAKE. MOUNTING BRACKET MUST BE PERPENDICULAR TO AXLE AND PARALLEL TO BRAKE ROTATING DISC. BRAKE ROTATING DISC: 3.1. INSTALLED OD RUNOUT 0.03’ TIR MAX 3.2. INSTALLED LATERAL RUNOUT &O;&T I R MAX 3.3. FRICTION SURFACE FINISH 3.4. PARALLELISM (FRICTION AREA) 0.001 TOTAL 3.0. ASSEMBLE BRAKE TO VEHICLE USING Two HAND TIGHTENED BOLTS. TOROUE BOLTS 80-90 FT LBS ATTACH INLET PORT: l/8-27 DRYSEAL NPTF. Ihi’ORTANT: USE FLEXIBLE HOSE CONNECTION TO BRAKE. MAXIHU HYDRAULIC OPERATING PRESSURE 2000 psi. ;I. USED TO APPLY BRAKE MUST BE PETROLEUM BASED l

I

IN HOUSING MUST BE FREE OF AN0 PARTICLE CONTAMINANTS.

2.2.

2.4.2.

INSTALLATION Il.

DISASSEMBLY: DETACH BOOT FROM PISTON REMOVE PISTON REMOVE BOOT FROM HOUSING REMOVE O-RING

ASSEMBLY PROCEDURE: 2.1. INTERNAL GROOVES SAND. DIRT. CHIPS

PISTON 2.4.1.

PERMISSIBLE

PROCEOURE: TWO END NUTS. DISASSEMBLY. REMOVE TWO EN0 BOLTS. REMOVE STATOR ASSEMBLY.

BLEEDER REMOVAL. 4.1.1. REMOVE 26127 4.1.2. REMOVE 33425

2.4

PRESSURE

ISEAL

I

IPISTON

KIT KIT &

BLEOER IMPORTANT:

PK-1081

-

PK-1480

SEAL

KITS

INFORMATION:

-

KIT

-

PK-1481

-

PK-850

INCLUOES STATOR ASSEMBLY INCLUOES O-RINGS. BOOTS, AN0 CAUTION LABEL INCLUOES PlsTONSl O-RINGS. AND BOOTS, AN0 CAUTION LABEL INCLUDES AN0 PLUG

THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REWIRES. CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY.

I

1 I I I

BLEEDERS.

0

ITEM 1

PART

79847 27418

5 I

-~

1 9 I 10 I 8

12

14 15 16

I

33389 31520 31297 ~39524 31516 26930 -~ 30551 33425 71071 26127 33147 31522

DESCRIPTION

I HOUS I NG O-RING I BOOT --~ SPACER SECONDARY PLATE HEX BOLT -~ WASHER -STATOR ASSEMBLY PISTON PROTECT I VE PLUG LOCKNUT BLEEDER SCREW CAUTION LABEL BLEEDER SCREW WASHER SLEEVE

QTY

1 2 2

0

Hydraulic Brake Valves

Versatile, High-performance Hydraulic Brake Valves

Hydraulic Brake Valves Catalog Index Foreword . . . . . . . . . . . . . . . . . . . . . . . 2 Purpose of Catalog . . . . . . . . . . . . . . . . . . 3 Modulating Valves (spool design) . . . . . . . . . 4 Pedal Actuated - Single . . . . . . . . . . . . . 6 Lever Actuated - Single . . . . . . . . . . . . . 7 Tandem Modulating Valves (spool design) . . . . . 8 Pedal Actuated . . . . . . . . . . . . . . . . . 10 Lever Actuated . . . . . . . . . . . . . . . . . 11 Pedal/Pilot Actuated . . . . . . . . . . . . . . 12 Modulating Valves (poppet design) . . . . . . . . 14 Pedal Actuated - Single . . . . . . . . . . . . 16 Pedal Actuated - Dual . . . . . . . . . . . . . 17 Reverse Modulating Valves (spool design) . . . . 18 Reverse Modulating Valves (poppet design) . . . 20 Accumulator Charging Valves (combined housing) Single . . . . . . . . . . . . . . . . . . . . . . 22 Dual . . . . . . . . . . . . . . . . . . . . . . . 24 Single and Dual with Relief Valve. . . . . . . 26 Load Sensing . . . . . . . . . . . . . . . . . 28 Accumulator Charging Valves (split housing) Single . . . . . . . . . . . . . . . . . . . . . . 30 Dual . . . . . . . . . . . . . . . . . . . . . . . 32 Integrated Valve . . . . . . . . . . . . . . . . . . . 34 Full Power Valve . . . . . . . . . . . . . . . . . . 36 Park Brake Valve . . . . . . . . . . . . . . . . . . 38 Open Center Valve . . . . . . . . . . . . . . . . . 40 Additional Application Information . . . . . . . . 42

Foreword The same dependability, safety and performance that goes into every MICO Safety Braking System Product also goes into our versatile, high-performance Brake Valves and Brake Valve Components. This is an important consideration when you select a source of supply for your fluid power needs. The MICO Brake Valves presented in this catalog are designed for use with vehicles that are equipped with other hydraulic power devices in either open center, closed center or load sensing hydraulic systems. This design feature eliminates the need for a separate power brake unit or separate hydraulic fluid system. Unless specified, all valves in this catalog are for use with mineral base hydraulic oil. Consult MICO for information on use with other fluids.

MICO Brake Data Sheet . . . . . . . . . . . . . . . 43 MICO Negative Braking Data Sheet . . . . . . . . 45 Conversion Factors . . . . . . . . . . . . . . . . . 47 Useful Formulas. . . . . . . . . . . . . . . . . . . 48 Low Pressure Warning Switches . . . . . . . . . 49 Model Number/Page Cross Reference List . . . . 50 Limited Warranty . . . . . . . . . . . . . . . . . . 52 2

MICO has made every attempt to present accurate information in catalogs, brochures and other printed material. MICO can accept no responsibility for errors from unintentional oversights that may exist. Due to a continuous program of product improvement, both materials and specifications are subject to change without notice or obligation.

Brake Valve Applications found in . . . Purpose of this Catalog This catalog was designed to assist you in selecting the MICO Brake Valve best suited to your requirements. Separate sections are presented on each style Brake Valve and Charging Valve. All of these sections contain features, principles of operation, typical circuit, exterior dimensional drawing, and specifications chart. The specification charts contain variants for specific models. All dimensional drawings give dimensions in millimeters/inches. The conversion factor is 25.4 millimeters equal 1 inch. For more detailed application information we have listed some additional publications on page 42. This is followed by two Brake Data Sheets and a section with conversion factors and formulas to assist you in any calculations. A section on the MICO Low Pressure Warning Switch is presented on page 49. These switches can be used in conjunction with the MICO Brake Valves and Charging Valves, shown in this catalog, to complete your hydraulic brake system needs. In the back of the catalog you will find a Model Number/Page Cross Reference to help locate specific Models. For assistance in determining which Brake Valve is right for your needs, complete one of the Data Sheets on pages 43 or 45 and mail or fax it to us. These same data sheets can be filled out online at www.mico.com. Our Application Department will analyze your application and recommend the Brake Valve suitable for your needs. If you prefer, we will have one of our sales engineers call on you to discuss your applications. Most of these valves and controls can be adapted for use in closed center and load sensing hydraulic circuits. Consult MICO for assistance. We hope you will find this catalog to be a useful reference manual as well as a product catalog.

· Forestry Vehicles · Logging Equipment

· Contractors · Trailers · Construction Equipment · Agricultural Vehicles and Equipment

· Airport Ground Support

· Waste Haulers · Recycling Vehicles · Landfill Vehicles · Mining Vehicles and Equipment

· Material Handling · Rental Yards

· Cranes

3 Return to Catalog Index

(Spool Design)

Tandem Modulating hydraulic power brake valve PRINCIPLES OF OPERATION The MICO Tandem Modulating Valves are an extension of our Modulating Valves. These valves isolate front and rear brakes by providing two individual pressure outputs within a single valve. In the event of failure in either half of the brake system the other portion of the valve will continue to function. Like the MICO Modulating Valves, these Tandem Modulating Valves can provide normal and emergency power off braking in a variety of open center, closed center, and load sensing hydraulic systems, when used with a properly sized accumulator and MICO Accumulator Charging Valve. These valves are available with either pedal or lever options. For more information on these options see pages 10 & 11.

TYPICAL CIRCUIT SCHEMATIC

8 Return to Catalog Index

FEATURES l Compact size for use in restricted space l Wet cavity (oil immersed spring cavity) l Power off braking through limited stored energy in the accumulator(s) l Spool type construction provides smooth modulation at all pressures l Direct acting spool provides a pedal feel accurately representing brake pressure l Communicated tank cavities allow for one or two return lines direct to tank l Various reaction areas in combination with a fixed pedal ratio provides pedal force requirements for different brake systems l Split pressure option available with two different pressure outputs

TYPICAL BRAKE VALVE

millimeters inches

NOTE: Dimensions may vary slightly between units and are to be used for reference purposes only.

PERFORMANCE DATA Maximum brake pressure settings . . . . . . . . . . to 207 bar (3000 psi) Maximum input pressure . . . . . . . . . . . . . . . . 207 bar (3000 psi) Brake valve displacement is a variable specification with all Modulating Hydraulic Power Brake Valves. The determining factors include brake volume, accumulator capacity as it relates to brake pressure, the number of "power-off" stops, and brake response time required.

9 Return to Catalog Index

Pedal Actuated - Tandem hydraulic power brake valve

(spool design)

TYPICAL BRAKE VALVE Standard Mount

Horizontal Mount

millimeters inches

NOTE: Dimensions may vary slightly between units and are to be used for reference purposes only.

10 Return to Catalog Index

Lever Actuated - Tandem hydraulic power brake valve

(spool design)

TYPICAL BRAKE VALVE millimeters inches

NOTE: Dimensions may vary slightly between units and are to be used for reference purposes only.

SPECIFICATIONS (Lever Models)

Maximum brake pressure settings . . . . . . . . . . to 207 bar (3000 psi) Maximum inlet pressure . . . . . . . . . . . . . . . . . 207 bar (3000 psi)

Maximum Brake Pressure Setting bar (psi)

Model

121 ± 7

06-466-916

PERFORMANCE DATA

(1750 ± 100)

Consult MICO Applications Department for other available models.

The non-restrictive lever assembly consists of a base, cam, and lever which can be rotated 120° from full-on to full-off. The lever can be locked in the full-on position which allows the valve to be used with either standard hydraulic apply brakes or spring apply/hydraulic release brakes.

PERFORMANCE DATA

SPECIFICATIONS (Pedal Models) Model

06-466-202 06-466-206 06-466-210 06-466-216 06-466-230 * 06-466-282 * 06-466-286 * 06-466-288 * 06-466-290

Pedal Angle

50° 50° 50° 50° 40° 50° 50° 35° 35°

Approximate Pedal Force at Maximum Pressure kgf

(lb)

26 30 31 21 21 26 25 27 24

(57) (67) (69) (46) (46) (57) (56) (59) (52)

Pedal Travel

15° 20° 15° 20° 20° 15° 15° 15° 15°

Maximum Brake Pressure Setting bar

(psi)

152 ± 7 103 ± 5 69 ± 5 41 ± 5 41 ± 5 152 ± 7 52 ± 5 103 ± 5 138 ± 7

(2200 ± 100) (1500 ± 75) (1000 ± 75) (600 ± 75) (600 ± 75) (2200 ± 100) (750 ± 75) (1500 ± 75) (2000 ± 100)

Maximum brake pressure settings . . . . . . to 207 bar (3000 psi) Pedal force . . . 155 - 311 N @ max. brake pressure (35 - 70 lb nom. @ max. brake pressure) Maximum inlet pressure . . . . . . 207 bar (3000 psi) Materials Pedal. . . . . . . . . . . . . . . . . . Aluminum Base and valve housing . . . . . . . . . . . iron

* Horizontal Mount Consult MICO Applications Department for other available models.

11 Return to Catalog Index

(Spool Design)

Pedal/Pilot Actuated - Tandem hydraulic power brake valve PRINCIPLES OF OPERATION The MICO Pedal/Pilot Actuated Tandem Valves are a combination of a MICO Tandem Modulating Valve and a pilot section. The pilot feature allows for operation with a remote hydraulic signal. Like the Tandem valves these valves isolate front and rear brakes by providing two individual pressure outputs within a single valve. In the event of failure in either half of the brake system the other portion of the valve will continue to function. These valves can also provide normal and emergency power-off braking in a variety of open center, closed center, and load sensing hydraulic systems, when used with a properly sized accumulator and MICO Accumulator Charging Valve.

TYPICAL CIRCUIT

12 Return to Catalog Index

FEATURES l Compact size for use in restricted space l Wet cavity (oil immersed spring cavity) l Power-off braking through limited stored energy in the accumulator(s) l Spool type construction provides smooth modulation at low pressures l Direct acting spool provides a pedal feel accurately representing brake pressure l Communicated tank cavities allow for one or two return lines direct to tank l Various reaction areas in combination with a fixed pedal ratio provides pedal force requirements for different brake systems l Split pressure option available with two different pressure outputs

Single Pedal Actuated POWER BRAKE VALVES

l

ttcms included

in Repair

2~Nat used in aft modcfs

PEDAL DISASSEMBLY 1. Separafe pcdat (1) from pedal base (?-“, by removing OIW c-ring (2) frbrfi pin (4) and sliding pm from base. 2. Remove bushings (8 & 10) from podal base (13).

NOTE: Not all models use bushings (8 & 10).

3. Inspect pin f3) and cam (5) 10 maiico sure cam is in good working Grdor arid moving fretily. It is unnecessary to remove pin (3). cam (5), cap screw (6) or nu! (7) unless damaged. 4. Separat6 valve assembly from base (13) by rcmoving cap sorews (tl) arid washers (f2).

Kit 06-406-188

PEDAL ASSEMBLY

1

N6TE

Before asscmbitng pin (4) lubricate poiyrncr base moly grease.

-

with a good rtu;~lity ----I

I. Attaach valve eS,scmbly to base (f3) using cap scruws (11) and washers (12). Torque cap screws 24,4-29.8 N-m (18-22 tb-fl). 2. instalf new bushing?; (6 & 1Oj in base jiaj. NO-F*-- et I ai: medels USC bushings (8 & 10;. 3. Align pedal !?! bef~een ear,c of gcda! base (13) and insert pin (4). install e-ring (2). tf cap screw (6) or M(7)

am loosened

or fumoved

assembtnd, adjust cap sc:ow (8) to allow fho val\is spool to fully release. .Ar!er adjustmer?t is made !ightefl nut (7)

&I ‘d

Service instructions

466 Series - Tandem POWER BWAKE VALVE REPACR TABLE -I*_.

06-400-l

52

1 (Specificaths) . Model

-T

Number

03-466-204 CJ3-466-206 03-400209 UG~466.200 06-466-202 OG-466-206 06465208 OF-466-210 06.465.art I:_-,.OG-466-7 16

130kQ.9

45f 3.5 103~5.2 83*5.2 152 t; 6.9 103.L5.2 138 t 6.9 69 P 5.2 9QOa5.2 1 41P5.2

(~000 1180) (tm$50) ~l5oof75) (t2ask7!g

06-4e6-2tZI~ 06~466*220 +$g$g

a6-&6-234

(xx0 t 76) (ZOVOf I QQ)

W-+EG-236 O6-4G6.238 N-466-240

(loco*75) (raOoLt75) -@%7Sj_~

oo-*66-246 06-466-248

(22Oof

too)

06466.244

-i I I I I 1

FIGURE

1

Installation velocity

dtrectly

BI ‘d

2

A WARNSNG and test note: Piston (21) must be retained mcchanicaiiy.This willpreveotil from blowing out&high the power source is Incorrc-tl****,, ,,. ~unnectod to tank pcirts. Be sure the tank poris clre connecicd to tank, Faibre to do this cc&! resutt in s.erCc?usinjury or &%:!h. if

OOPZOPOZliE I IO ‘ONX&i

i I

MODELS:

93-466-202 03-466-208

06-a66210 06-466-216 084x-21

os-gee-2go

4

08-466-234 08-466-236 06.466.240 06-466.244 06-466-248

l

fkpair

inr?udec!

06-466-292

in

kit 06-460-l

* Mot aH models these park.

06-466-266

06.466.232

!k?ms

52

use

DlSASSEMBLY (Rcfor

to PkJum 3)

(8 B 13) and spools (9 & 12) are tnanttfaclured 3s matched sets. ‘l’haso sots (housina & spool) should not be intermixed ~7th other parts. Housings

1. RemCVe boot (22) from piston (2f) and housing (13). Not all niodels USCboot (22). 2. R9illOv6 piston (21), springs (16. 19 L 2Q), shim(s) (17) and rctaincr assembly (16) from houskq (13). Not aI1 models us0 spring (18). NOTE: Be aware of the number of shrm(s) bdng removed from housing. 3. Careluiiy remove cup (15) and seal (14) from housing (13) bore. NOTE: Be careful not to Scratch hcusing bar@.

or mar

4. Remove end plug (1) 31x-i spring (3) from housing (8). Fier’il6v~ &ring (2} from end plug (1). 5. R~rncvo plug (6j from housing (6). Remove o-ring (7) frcm piug (6). Not ail modofs use ~llrg (6) and a-ring (7). 6, %?parato housings (8 & t3) by removing cap scr%ws (4) and waehers (5). Remove O-rings (10 & 11) from houSing$ (B & 13), 7. CtirofulIy r@mdve Spools (9 & f2) from housing3 (8 A 13). NOTE: Be careful not to damage spooir or houslng

FIGURE

If either part Is damaged, sptoUhaisJiig assambly required.

bores.

d CAlrTlON IDo not intermix spook & housings.

Spool (9) and houslng (8) are a matched sot as are spoot (12) and housing ($3).

I

ASSEMBJ%Y (E&v to Figure 3) LWBFKATE ALL RUBBER COMPCNENis liFid~ REPAIR KIT WITH CLEAN TYPE FLUID USEI) IN THE SYSTEM. 1, Clean all parts thoroughly belore assembling. 2. Install new o-rings (IO & 1 I ) in proper o-ring pockets on hOu.&qs (a & 13). 3. Lubricate spoot (12) with dean systam fiuid and mrcfuily pIids into botlorn end of housing 113) bore. Nc16 direction of spool (12). NOTE: Spool inust slide freely Into &ore.

!?I ‘d

now SQaI (14) inlohouving (13) bcre. Rote dirodicn and order of

a new may be

cup and sear.

WW

a-kg

(3) CR pkJg(6)

be required.

7. fnstalt new o-ring (2) on end plug t’b 6. hstd! spring (3) and end plug (;I into housing (0). Tcrque end plu3 54.2-67.8 N-m (40-50 lb-@. 9. Carefully install new cup (r-5) and

10 ‘ONXWZI OOPZOPOZS&

Be careful

he sphng (18j. ' 11. Corefutfy institlt piston (27) gswrnbly into housing (I 3) bore. 12. !t~er~~~ “V\Urn.?ew bc6: (22) on hoaxing (13) and piston (21). Not alt mor,lelr, use boat (22). 13. When reinsWing pcd,? adrtaled Vaivc use new hex cap screw.5 (23j. S!j,/!&t8 grsdc B. Torque cap screws24.4~%I,8N-rn (1 B-22 lb.ft).

hCM#igs kne up CWeZtly and that o-tlngs (10 & 31) remain in their pockets during assrmbiy.

and install in houslng (8). Tighten securely. Net all mad& tise plug (6) and o-ring (7). 6. Lubricaie spool (Sj with clean system !!uid and carefully Slide intc housing (8) bore. Noto direction of spool (9). NOTE: Spool must shk treeiy Into bore, If &her part Is damaged, a new spnallhous!ng assemh!y may

MOTE:

not to scratch or mar housing

4. kasscmble housings (8 & 13) using cap screws (4) and washerS (Sj. Use Locfito 242 on cap screws and !orque 27.1-33.9 N ,rn (22-25 Ib-ft). NOTE: Make sum

5. !Mm

3

r

NOTE Aftef SBrvico, fho valve must duvolop tho pre%ure lnfficattod in thg speclliI o&ions, TABLE i, Shim(sj (17) may 1 ha . ..-usddfid .” of wmxw.l lo ob:ain :ha correct pressure setting.

BLEEDING Brakehes should be bled very carefully as soon as’ thn v&e Is insktllcd In llro machine. Air In the system wiIl not affow the bmkcs to release prupcrly and may severely damage 4!ram. 1. &art crqline r\nd allow aceumulalor to reach full charge. Shut down engine, IllOn slowly apply and fcio;iso brakes. waking one minute bolwccn applicatlohs until brakes will not apply. Re@x~t ihis SIC@ lhree times. 2. OpeMe engine to malnlain accumulator

~KS.WO wilhin working limits thioughOtit thC blaoding procedure. 3. Open blaedcr straw at wheel closest to brdko valve and apply brakes cetiiousty untii @ii Jr is bled out of iin@. Then close bleeder screw. Ropes? this SIep et es@3 Wheel, moving lo the nokf frrthesl wheel ifOfrl the brake \nlVC 0iK.h time, a8 lo~low3: a. Lefl front b. Right tront C. Right rear

d. Loft rcor 4. Rcleasc brake pfcssure for at legst noe (1) minute. 5. Apply brakes. holding f~ecisl down 20 seconds; lhcn rclcxc pressure for ono (1) minute, Rcpc3t this step two m$rc limes.

SERVJCE CHECKS FOR 466 SERIES POWER BRAKE VALVES BRAKES SLOW TO APPLY 1. No or improper gas charge in xcumuIem 1. Chock 90s charge 2. Bnkcs 1101properly sdjuslcd 2. Adjust brakes 3. lnopcmtivc tmkcn 3. Chack brakes 4. i~ydraulio lines or finings Is&king Q. Check fQr loaks and repair 5. lnopcmlivo nulometic sdjuslcr 5. Chock adjuster operation 6. Oornagcd hydraulic brake lines 6. Check Unes for dents that restrtcl flow of ON INSUFFICIENT BRAKES 1. No oil or low oil level in tank 1. Ch4ck oil level in tank 2. Dr&kcS r\yt properly adjuslod 2. Check brsko rdjustment 3. Oil or grcaso on brake lining 3. Ct00n or install new linings 4. @rake line damaged 4. Check iincs and replace 5. lnopentivc automatic sdjustcw 5. Check operation of ndjualers 6. No or Improper gas chnrgc in ilccumuWar 6. Check gas oherge 9. fnopcrotivo brakes 7. Cheek brakes

SERVICE DJAGNOSIS (Hcler

to Figures

I thru 4)

BRAKES WILL NOT RELEASE COMPLETELY 1 a Piston (21) bfncfitrg 2. Pedsl ,Inglo oul of adjuslmcnt 3. Spring (3) bfokcn BRAKES WILL NOT RELEASE 1. Blndlng spools (9 8 72) 2. Piston (21) binding

91 'd

8. Brake v&c Inoperative 8. Fteptacc valve 3.

lil0pC73.llv0

Sysiefrt

9. Check pressure Valve 10. iiiorn pump 10, Check preeaure

i&W v&c in prcsaum

line ta

!n prcsswe

line to

VRIW8

EXCESSIVE RRAKtNG 1. Inopemlivc brakes 7. Check brakes 2. fnoparative brake v~fv~ 2. Wpl8cr broke vaiw RRAKES WILL NOT RELEASE COMPLETELY 1, Brokos no! property sdj:tis;cd 1. hljuct brakes 2. Inopsretive brakes 2. Check brakes 3. Pedal nngle out of aUjusZmcn! 3. Adjust pa&i at@ 4. Inoperative wheel cyffndors 0. Repface wheel cy!inders 5. fnopcmtlve automatic adjuster 5. Cheek opwetion of adjustera 6. F?? ifl brakes (when WtOiflaiic ors used Goodrich Hi-torque Brakes only) 6. mod brek.ae

&juSt-

NO BRAKE6

EXCEGSIVE ACCUMULATOR LEAKAGE WHEN 8RAKES ARE APPLIED i. Damaged spooir (Y CL1%) 2. Damaged houslnps (6 & 13)

OOPZOt7019E I IO ‘ONXV4

7. f. 6. 9,

Prcssuro on return line !oo high Reduce presorrcc lnoper;ltive brake vaivo RepIace brake Valve

NO 1. 1. 2. 2.

BRAKES NO oil in hydraulic syslem Chock oil level in tank Di&un or diamsgod broke iino Check lines for break.: Q? dnrnnmvl -- *.-~-condilian 3. Urilkos not prop&y adjusl@d 3. p.dj& b&es 4. inoporxivc sys4em r&e! ~+lVo 4. Ctwck preseure In pr4sovru itne to rrlfve 5. worn pump 5. Chtck preaeure Tn pr~asura tine to v&e 0. InnprHiVe au!ofnetic ;rrfjrrslcr 6. Check brake line pressure 7. lnpporative or worn brakes 7. Check brabs 6. Inopemlivc broke valve 8. f?epiaee breke Vaivc

PEDAL KiClfBAC% APPLiED 1. Air in brakes 1. Bleed bmkos

WHEN

BRAKES

ARE

EXCESSIVE ACCUMULATOR LEAKAGE WHEN BRAKES ARE NUT BEJNG USED I. Damaged spools (3 a 12) 2. Damaged housings (6 R 13) iNSUFFlCIEt4T BRAKES 1. Brokeii Drcssurc rouuiating 2. Pedal trsVcl IS inlribiled

spring

(f 9)

'ONI'OXI Wd94:&ONOM IOOZ-Zi-WLI

Halvorsen Section 8. Air Conditioner and Heater

ESPAR HEATER SYSTEMS OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST Airtronic M D4 Air Heater VISIONAIRE, INC. MAINTENANCE GUIDE Halvorsen Loader Air Conditioner

AIR CONDITIONER AND HEATER

5-8 Page 1 December 2015

THIS PAGE INTENTIONALLY LEFT BLANK

Manufacturers and Distributors of Heating and Air Conditioning for Heavy Duty Equipment

502 Jesse Street Grand Prairie, Texas 75051 (972) 647-1056 Fax (972) 606-1076

www.visionaire-inc.com

HALVORSEN LOADER AIR CONDITIONER MAINTENANCE GUIDE

WARNING This document is not a substitute for comprehensive air conditioner service training. All technicians that service air conditioning components should be properly certified to handle refrigerants and trained in the safe and proper handling and use of the refrigerants and tools required. Servicing hydraulic systems can be dangerous to both personnel and equipment and should only be done by properly trained technicians.

Inspection and Maintenance– without gages • Discussion of Inspection & Maintenance • Visual Inspection - System Off • Electrical System Inspection • Performance Inspection - Engine Running • Preventive Maintenance Worksheet Discussion of Inspection & Maintenance Survey Results There are three reasons for regular inspection and maintenance procedures: 1. They save money in the long run by reducing down time and often prevent more costly repairs. 2. They help to insure driver comfort and safety. 3. They add to your store of knowledge about these systems and maintain your level of efficiency. About half of all heavy duty vehicles have air conditioners. Surveys of AC system owners find that over 30% of the systems are serviced every six months or less, and another 62% are serviced at least once a year. The survey also covered how often the different components required maintenance. Figure 7.1 below shows survey finding percentages. Failure of any of the AC components listed in the survey could cause a system to malfunction or stop cooling.

Visual Inspection - System Off Your observations and the corrective measures you take may be different depending on circumstances. The following inspection procedures are explained in more detail below: 1. 2. 3. 4.

Observe the System Inspect Parts Check Hoses and Fittings Check for Refrigerant Leaks

Use the following procedures as a general rule in performing a visual inspection with the AC system off:

1. Observe the System Your first inspection step is to answer the following question if you can: • Has the vehicle just come in off the road and has the HVAC system been in use? • Did the operator or work order explain or describe any problems about the system? • Did someone else work on the system yesterday? Last week? Your first inspection step is to answer these questions if you can. CAUTION Even when someone has told you what is wrong with an HVAC system, you should perform a visual inspection. Always make a visual inspection before you hook up the manifold gage set. Never add refrigerant to a system until you have made a complete visual and performance inspection.

2. Inspect Parts Look at the system for what might come loose, leak, wear out or become dirty and not function the way it should. The main points for visual inspection of the system are emphasized in Figure 7-2. A. Condenser – Is it free of leaves, bugs, bird feathers, dust or mud? The condenser must be relatively clean to work well as a heat exchanger. The condenser fin comb, air hose and nozzle, or soap and water may be used. Check condenser mounting bolts and tighten them if necessary. Condenser failure often results from loose hoses. Hose movement will cause fatigue failure of condenser tubing adjacent to the fittings. Make sure the hoses are securely clamped. While inspecting the condenser check the receiver-drier sight glass and connections. Be sure the condenser fan is working properly and all parts and electrical connections are securely fastened. The deck mounted condenser fan may come on when the system is turned on. Like the thermostat the normal on-off cycling action of the fan can not be observed until the engine is running with the AC system on. B. -Compressor- Is the compressor clean and are it's mounting bolts secure? Check for oil leaks at the motor and compressor hose connections. While examining the compressor check the oil return canister and hose connections for leaks and unsecured hoses. With the engine off open the inspection port on the compressor bell housing and check for leaks or debris. Coupling spider should be intact and snug. C. -Evaporator- Are condensate drain hoses and rubber check valves intact and secure? Is thereturn air filter clean and intact? Are the control switches secure?

3. Check Hoses and Fittings Check all hoses and fittings. Look for places where hoses flex when the cab is extended. Any places the hoses or fittings are fastened, clamped, connected, bent or secured are potential wear points. This also applies to places where hoses are not clamped or supported but should be. All of these spots are potential leak or damage points. Tighten, re-fasten, add, or replace as indicated by your inspection.

4. Check for Refrigerant Leaks System refrigerant leaks can be anywhere but there are obvious places. You can spot some by looking for signs of refrigerant oil forced out with refrigerant leakage. One location leaks frequently occur is the compressor shaft seal. The shaft and seal are hidden in the compressor bell housing, but centrifugal force will throw the oil off the shaft and against the inner housing wall. A solution of soap and water applied around potential leak points works well for detecting leaks. A leak in the evaporator may be indicated if you feel around the condensate drain pan and find oil present.

Electrical System Inspection The two stages of an electrical inspection are explained in more detail below: 1. Inspect Electrical Connections 2. Check Electrical Current Flow and Device Functions

Use the following procedures to perform an electrical system inspection:

1. Inspect Electrical Connections First, while you are making your visual inspection outside of the cab, take a moment and check all electrical connections visually and by feel. Look for any corrosion on leads or connectors and clean them. Make sure all leads and wires are properly supported and securely connected.

2. Check Electrical Current Flow and Device Functions Perform the following steps to check current flow and electrical device functions: A. Turn the Ignition On – To check current flow the ignition must be on. B. Turn the AC System On – This will power the thermostat. A volt-ohm meter should indicate power in and out of the thermostat, low pressure switch and high pressure switch. Voltage should be present on the ungrounded leg of the condenser fan control switch and applying a test light (but not an LED or multimeter) should cause the fan to engage. You can not check thermostat cycling on and off until you do the performance inspection. D. Check Compressor Engagement – Since you can’t see and may not hear the compressor engage, get out and touch it. If it’s engaged, you will feel a slight vibration and the discharge line will be quite warm. E. Test Blower Speed Operation – Test blower speed operation by adjusting the blower control switch. Feeling the air flow from the ducts or note blower sound (speed) changes.

Performance Inspection – Engine Running The purpose of visual and electrical inspection is to detect obvious problems and assure AC system function for an accurate performance inspection. If you do the performance inspection first, you could be mislead. Problem areas discovered during the performance inspection can give you false clues or symptoms, and result in repair errors and come-backs. The following performance inspection procedures are explained in more detail below: 1. Inspect System Component Cycling and Cab Temperature Levels 2. Check Compressor Cycling Under Load 3. Check Sight Glass

The performance inspection does not cover pressure and temperature sensitive safety devices (pressure switches, fan control, etc.). Testing these devices requires the use of the manifold gage set for observation of internal system pressures during tests. These are explained in Chapter 8. Use the following procedures as a general rule in a performance inspection:

1. Inspect System Component Cycling and Cab Temperature Levels A. Turn On the Engine and Air Conditioner – Inspect for system component cycling and cab temperature levels. B. Check Thermometer Readings – In the cab you can use your thermometer to measure air temperature at the vents. In moderate climates when the AC unit is on and working correctly, you can see the thermometer dial needle move down to about 32 degrees, then rise six to ten degrees and move back down again. The movement up and down indicates that the cycling compressor and thermostat are functioning correctly. The needle movement is called “temperature swing.” In very warm climates it is likely that the compressor will not cycle at all when the blower is on the 'high' setting. Test the thermostat by setting the blower to it's lowest setting. If cab temperature is still to high to cycle thermostat use a piece of paper to partially obstruct return air inlet. When you measure air temperature, an electronic thermometer/pyrometer is a great tool to have. You can easily measure cab air temperature at several locations quickly. Swing temperatures vary depending on where you measure temperature, and on outside temperature, humidity and altitude. The chart in Figure 7-6, shows some examples of typical temperature variables.

2. Check Clutch Cycling Under Load With compressor cycling re-inspect compressor assembly. Is the noise level normal? Does it stop and start smoothly? A loud rattling, clattering, or ticking is not normal and should be investigated.

3. Check Sight Glass The sight glass is the only point where you can actually see inside the air conditioner during operation. Check the sight glass through the window on the top of the receiver-drier. If the system is functioning properly and cooling the cab adequately, the sight glass should be clear (you will not see anything in it). If it is not clear when the system is first turned on, wait a few minutes for the system to stabilize, then look again. Figure 7-7 illustrates and explains what you may observe in the sight glass. Condenser fans may run continuously or cycle on and off. A few bubbles may be visible as the fan cycles.

MAINTENANCE GUIDELINE THIS IS A GENERAL GUIDE AND DOES NOT SUPERCEED THE VEHICLE MAINTENANCE INSTRUCTIONS

COMPONENT

3 MO.

COMPRESSOR-NOISE LEVEL

X

RUN 5 MINUTES

X

INSPECT SHAFT SEAL

6 MO.

X

CHECK PRESSURES (RUNNING)

X

CONDENSER- CLEAN

X

CHECK HOSES, MOUNTING BOLTS

X

FAN CYCLE

X

DRIER-SIGHT GLASS

X

INLET/OUTLET BOTH WARM

X

EVAPORATOR-SWITCHES FUNCTION

X

FILTER CLEAN

X

OUTLET TEMPERATURE

X

THERMOSTAT CYCLE CONDENSATE DRAIN

THOROUGHLY INSPECT WIRING AND HOSES

12 MO.

X X

X

Troubleshooting & Service Procedures • Troubleshooting Overview • Understanding System Function • A Troubleshooting Example • Manifold Gage Set Installation • Troubleshooting by Manifold Gage Set Readings • Review of Frequent Problem Areas • Conclusion Can you fix an air conditioner or heater system without finding and correcting the cause of the problem? You bet you can! It happens every day and it’s not good for business. Here is an example. A truck pulls in off the road and the operator asks to have his rig serviced in a hurry. He tells you the air conditioner isn’t cooling like it should and dashes into the restaurant for lunch. You tip the hood, and check the sight glass on top of the receiver-drier. You see bubbles, not a lot but a fairly constant stream of them. It is obvious the system is low on refrigerant so you hook up the manifold gage set, purge the gage set hoses of air, and add refrigerant until the sight glass clears. Then you check evaporator temperature and it’s OK. The air conditioner is repaired right? Wrong! What you did is add refrigerant and the problem went away. You did not find and fix the cause of the problem. Component failure in an air conditioning system may be the result of a problem elsewhere in the system. An unsecured hose can loosen its connection and leak gradually. The constantly undercharged compressor fails early. The real cause: A missing clamp. Many fans are replaced when the real problem is a faulty ground. Take time to look beyond the obvious for hidden problems.

Troubleshooting Overview Troubleshooting includes collecting enough information to locate the cause of the problem, then correcting the problem and its cause by replacement, adjustment, and/or repairing. You begin by gathering information from the most to the least important sources. Starting with the most important: 1. Your personal knowledge and experience with AC systems. 2. The vehicle operator's knowledge and experience—question him or her. 3. The work order. 4. Good test equipment and the HVAC system Experienced troubleshooters talk to the operator if they can, then personally verify the symptoms of the problem whenever possible. They attempt quick fixes on the basis of their knowledge of common system problems and causes when appropriate. They know where components are located, and make repairs when they have a good idea of what the problem is. They fix the cause or causes as well as the problem. They are confident of their knowledge and ability.

Note: The best troubleshooters all know who to call when they get stuck. They know someone who knows more than they do and are not too proud to ask for help or suggestions when needed. The key—understanding system function Your complete understanding of AC and heater systems and how they work, plus what can go wrong, is the key to troubleshooting and repair. When you turn on the air conditioner at the control panel the thermostat is supposed to sense a warm temperature at the evaporator. A circuit in the thermostat should close, allowing current to flow through the thermostat, through the high and low pressure safety switches, to the compressor hydraulic control circuit. The engine provides the hydraulic power to turn the compressor. When operating, the compressor compresses and pushes refrigerant gas to the condenser, through the receiver-drier, and to the expansion valve orifice. When it does, it puts a lot of pressure on the gas. The compressor raises the temperature and pressure of the refrigerant inside the high side of the system. At the same time, the compressor is also sucking in low pressure refrigerant gas from the expansion valve orifice, evaporator and through the low side of the system. The movement of the refrigerant inside the system transfers heat energy from the cab to the outside air for occupant comfort. The automatic functions of the thermostat ,pressure and fan cycle switches, and the expansion valve help maintain pressures and temperatures inside the system at safe and efficient operating levels. Pressure and temperature are constantly changing due to compressor and expansion valve action, the amount of heat energy being moved and the environment or weather conditions. Note: Clean refrigerant and refrigeration oil should be inside the system in the amount specified by the manufacturer. Moisture, sludge (moisture combined with refrigerant oil or desiccant), or desiccant particles will prevent the correct performance of the system and may cause component damage.

Troubleshooting by Manifold Gage Set Readings Pressures within the air conditioning system vary with ambient temperature. A normal pressure range is defined as follows: Low side 15–40 PSIG High side 150–310 PSIG In desert/tropical conditions where the ambient temperature is above 110°F ( 43°C) low side pressures may be as high as 50 PSIG and high side pressures up to 350 PSIG may be permitted. Extended operation at upper limit pressures reduces compressor life.

Repair Procedure: To inspect and service the compressor, you must fully recover refrigerant. Remove the compressor cylinder head and check the appearance of the reed valve plate assembly. If defective, replace the valve plate and install with new gaskets, or replace the compressor assembly. Always replace coupling spider when replacing compressor. If you find particles of desiccant in the compressor, remove and replace it and the receiver-drier. Before doing so, back flush other system components (except the expansion valve) using a flushing kit. After flushing, reassemble the components. Always check the oil level in the compressor. Tighten all connections and evacuate the system. Recharge the air conditioner with refrigerant and check system operation and performance.

Review of Frequent Problem Areas In HVAC systems a limited number of things can go wrong. Moving parts of the compressor, clutch, and expansion valve or refrigerant metering device can malfunction or break down from metal fatigue, contamination, abnormal pressure or lack of lubrication. Electrical connections may corrode, become disconnected or break. Fuses blow from shorts or overload. Belts slip or break. Vibration from the engine or road surface can work bolts and air or vacuum lines loose, or rub and break or wear parts out. Motors may burn out. The inside of the system can become contaminated from moisture, air or desiccant material breakdown. Refrigerant may leak out of the system quickly or very slowly. Moisture in the system can combine with refrigerant to form acid and attack (corrode) metal parts from the inside. Moisture and refrigeration oil can combine to form sludge that may block refrigerant flow. The following problems are discussed in more detail in this section: 1. Condenser 2. Refrigerant Lines, Hoses, and Fittings 3. Refrigerant Metering Valves 4. Other Problems

1. Condenser Condensers get dirty and the dirt reduces heat movement by insulating the condenser. The fittings come loose or break from stress if the condenser or connecting hoses are not secured properly to keep the effects of vibration at a minimum. Heat transfer efficiency and pressure in the condenser are affected by the amount of outside air flowing through condenser fins. A lack of air flow can mean the refrigerant doesn’t give up enough heat energy to the outside air (it doesn’t change state). The refrigerant arrives at the evaporator as a gas and can’t pick up any heat energy from cab air. In the cab, air from the vents is only slightly cool or warm. A lack of air through the condenser fins can raise high side pressure and blow out the weakest point in a system, or damage the compressor.

2. Refrigerant Lines, Hoses and Fittings Problems with these parts may be caused by normal deterioration, vibration damage, lack of maintenance or human error (improper installation or replacement). All rubber parts are attacked by ozone (oxygen) in the air. Rubber parts break down slowly and become more vulnerable to the effects of vibration with the passage of time. Heavy duty vehicle vibration causes stress on all lines, fittings and connections. Regular maintenance includes checking and tightening any suspect line, or hose retainers, or grommet position where the grommet is protecting a line or hose from abrasion. Any insulating material wrapped around hoses must be in place and securely fastened.

3. Refrigerant Metering Valves When you consider valve problems there are obvious differences in valve construction and what can go wrong. If a valve is clogged with sludge or other obstruction, the result is a valve problem but the cause is contamination in the system. Valves get stuck open or closed, although most often closed when the gas charge is lost from the diaphragm housing in a traditional TXV. The diagnosis of a valve as defective calls for replacement but you should look for the root cause. Always replace the drier when replacing the expansion valve.

4. Other Problems—Leaks, Moisture, and Adding Refrigerant Before any refrigerant was put inside the AC system, someone used a vacuum pump to evacuate any air and moisture. Vacuum is really a force pulling against all hoses, fittings and components from the inside. When the system is charged with refrigerant, the pressure goes from minus (a vacuum) to plus pressure inside the hoses and all components. The refrigerant and refrigeration oil are trying to escape from the system at all times. Technicians frequently add refrigerant to a system, replacing refrigerant seepage through system connections or fittings. If the system has been maintained regularly (every three to six months), adding a small amount of refrigerant may result in normal system function. However, the best procedure is to check all connections and look for, find and repair any leaks before adding refrigerant. When your leak detector indicates the presence of a leak, you can’t tell how long the system has been leaking. Finding one leak doesn’t mean there are not others. Until you have some AC system work experience, it will be hard to guess how much refrigerant may have leaked. If you have to top a system off with a half pound of refrigerant or more, adding refrigerant is not the answer. Find the leak. Recover all of the refrigerant and repair the system. The moisture absorbing capacity of any desiccant material is limited and cannot be measured. For that reason, replace the receiver-drier or accumulator. Then evacuate the system for an hour and recharge with refrigerant. When a compressor shaft seal has leaked oil and the refrigerant charge is a little low, the shaft seal may have leaked because the air conditioner was not used. The seal can get a little out of round from the weight of the crankshaft and leak above the shaft. Running the compressor may cause the seal to swell and close up the leak. The shaft rotation exerts force all around the seal and puts life back into it. To prevent this from happening, manufacturers recommend regular AC system operation a minimum of every couple of weeks even in cool weather. Keep in mind that the compressor can cause a vacuum inside the system if there is a restriction in the system. That means it can suck air and moisture inside under some conditions. It will pull these contaminants in through the same space where refrigerant and refrigerant oil has leaked out.

Conclusion What could the air conditioning problem and it’s cause have been at the beginning of this chapter? The operator was in a hurry, but you were able to start your troubleshooting with the answers he gave you. Problems your inspection may have turned up are a very low refrigerant charge, a contaminated system or defective compressor. Those are not quick fix jobs. On the other hand, you might have found enough debris on the condenser fin surface to boost high side pressures to an abnormal level during the hottest part of the day. So the high pressure switch would cut out from high pressure—but reset itself. You cleaned the condenser, added a half pound of refrigerant and AC system pressures and function returned to normal. Service and repair took a half hour. But there was no way to tell without using your knowledge and experience. By now you are pretty familiar with AC system problems, the reasons for some of them, troubleshooting and repair.

Component Repair or Replacement • Tips on Component Repair or Replacement • Servicing the Compressor • HVAC Control System Variations—Troubleshooting • Servicing and Repairing the Heater • Summary Tips on Replacing & Repairing AC Components The following service and repair procedures are not any different than typical vehicle service work. However, AC system parts are made of soft metals (copper, aluminum, brass, etc.). The comments and tips that follow will make your job easier. CAUTION All of the service procedures described are only performed after the AC system refrigerant has been recovered. Never use regular shop oil or joint compound to lubricate or seal any AC connections. Note: To help prevent air, moisture or debris from entering an open system, cap or plug open lines, fittings or components as soon as they are disconnected. Keep all connections (also the caps or plugs you might use) clean so no debris can accidentally get inside the system. As a general rule in AC service, replace any gaskets and O-rings with new ones. Use fresh refrigeration oil to lubricate connections, gaskets and O-rings. The following parts are discussed further in this section: 1. Hoses and Fittings 2. Lines 3. Expansion Valves 4. Receiver-Drier and Accumulator 5. Compressor & Clutch

1. Hoses and Fittings When replacing hoses be sure to use the same type and ID hose you removed. When hoses or fittings are shielded or clamped to prevent vibration damage, be sure these are in position or secured. On R-134a systems make sure replacement hose has been designed for this refrigerant. Use reusable fittings on the nylon-lined hose brands such as Aeroquip FC 202.

2. Lines Always use two wrenches when disconnecting or connecting AC fittings attached to metal lines. You could be working with copper and aluminum tubing which can kink or break easily. Tube O-ring type fittings require only 18 foot pounds of torque for correct sealing. When there are grommets or clamps used to prevent line vibration, be sure these are in place and secured.

3. Expansion Valves When removing the expansion valve from the system, remove the insulation, clean the area, and disconnect the line from the receiver-drier. Remove the expansion valve from the evaporator inlet. Expansion valve service is limited. If this is the problem, replace the valve. If there is any debris in a block-type valve, replace it.

4. Receiver-Drier & Accumulator The receiver-drier and accumulator can not be serviced or repaired. They should be replaced whenever the AC system is opened for any service. If the receiver-drier or accumulator has a pressure switch to control the clutch, it should be removed and installed on the new unit.

5. Compressor & Motor The compressor can fail due to shaft seal leaks, defective valve plates, bad bearings, or problems associated with high pressure, heat or lack of lubrication. The motor can fail due to excessive heat, contaminated oil, or back pressure in the case drain line. Every AC system and compressor depends on refrigeration oil for lubrication and safe operation. Whenever an AC system is opened for service, check the compressor oil level and add clean refrigeration oil as required by manufacturer specs. This is especially important with these rotary compressors that has no oil sump. Ensure that the oil return system is clean and operational when replacing a compressor or cleaning a contaminated system. When adding oil use only Sanden SP-20. Add oil into discharge line or oil separator. Never put oil in the suction side.

Compressor Repair Vehicle down time can be very costly. For this reason, compressor service and repair is usually more costly than replacement with a new compressor. We have limited compressor service and repair coverage because each compressor make (and model) requires special tools and procedures for complete repair capability. Compressor manufacturers publish service manuals for their products. We do not use or recommend rebuilt compressors.

ÓCOPYRIGHT 2004 VISIONAIRE, INC. PORTIONS ÓCOPYRIGHT RED DOT CORP. 1993 USED BY PERMISSION

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