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Service Manual

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3. T16000 11 96 CLARK HURTH INGERSOLLRAND ASSEMBLY INSTRUCTIONS D Add some grease to O ring before assembly gt Add some grease to piston rings before assembly slots of piston rings is not allowed to pass bores in housings b Teflon seals must be sized prior to assembly add some grease to inner and outer dia of clutch drum before assembly Pump must be filled up with test oil prior to assembly Pump drive shaft must be installed after torque converter Fl Rev 1st and 2nd clutch 9 separator plates with inner splines 8 friction plates friction material both sides with outer splines 2 1 side friction plates fric
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5. The range clutches IE he output section T16000 11 96 5 6 CLARK HURTH Operation of the unit INGERSOLLRAND 5 The transmission controls refer to hydraulic diagram The transmission is controlled by an electronic gear selector EGS This unit has a microprocessor which receives certain inputs gear selector position speed sensor which are processed and will give output signals to the control valve The control valve has 6 solenoid 6 shift spools a pressure reducer an electronic controlled modulation valve an accumulator a pressure booster and a speed sensor p The transmission controls Operation of the valve is as follows Regulated pressure 20 bar 290 PSI is directed to the shift spools pressure booster and pressure reducer In the pressure reducer regulated pressure is reduced to 5 5 bar 80 PSI This reduced pressure is used as supply for the solenoid and electronic controlled modulation valve When activated the electronic controlled modulation valve will give an output pressure curve from 0 to 5 bar 0 to 80
6. The convertor and pump drive section T16000 11 96 5 4 CLARK HURTH Operation of the unit INGERSOLLRAND 2 The input or directional clutches The turbine shaft driven from the turbine transmits power to the forward or reverse clutches These clutches consists of a drum with splines and a bore to receive a hydraulic actuated piston The piston is oil tight by the use of sealing rings A steel disc with external splines is inserted into the drum and rests against the piston Next a friction disc with splines at the inner diameter is inserted Discs are alternated until the required total is achieved A back up plate is then inserted and secured with a span ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch To engage the clutch the control valve which is fitted on the side of the transmission will direct oil under pressure through tubes and passages to the selected clutch shafts Oil sealings are located on
7. 116000 11 96 9219 Disassembly forward low clutch Figure 77 Use bearing puller to remove front bearing and gear Figure 78 Front bearing and gear removed Figure 79 Remove gear retainer ring T16000 CLARK HURTH INGERSOLLRAND Figure 80 Use a bearing puller to remove clutch gear and outer bearing Figure 81 Clutch gear and outer bearing removed Figure 82 Hemove spacer snap ring CLARICHURTH Disassembly forward low clutch INGERSOLLRAND Figure 83 Figure 86 Remove spacer Use a bearing puller to remove clutch gear inner bearing Figure 84 Figure 87 Remove backing plate retaining ring Clutch gear inner bearing removed Figure 85 Figure 88 Remove clutch disc backing plate Remove one outer half disc T16000 11 96 9 17 CLARICHURTH Disassembly forward low clutch INGERSOLLRAND Figure 89 Figure 92 Remove inner and outer discs Compress spring to remove spring retainer snap ring Figure 90 Figure 93 Remove one outer half disc Remove spring retainer snap ring Figure 91 Figure 94 Remove clutch gear inner bearing locating ring Remove clutch piston spring retainer T16000 11 96 9 18 CLARICHURTH Dis
8. E HE S s l gu 3rd SPEED FORWARD TITTI 4th SPEED FORWARD T16000 11 96 Ss CLARK HURTH Operation of the unit INGERSOLLRAND D POWER FLOWS
9. e UL m E he input or directional clutches T16000 11 96 555 CLARICHURTH Operation of the unit INGERSOLLRAND 3 The range clutches Once a directional clutch is engaged power is transmitted to the range clutches 1st or 2nd Operation and actuation of the range clutches is similar as the directional clutches The engagement of the range clutches is also modulated to enable a smooth engagement The modulation for these clutches is achieved by means of a restrictor valve fitted in the control valve which is controlled electronically and which limits oil flow to the clutch during shifts In the clutch itself the plate before the end plates is dished to build up the c
10. T16000 11 96 9 58 CLARICHURTH Disassembly disconnect shaft INGERSOLLRAND A Figure 308 Figure 311 Use bearing puller to remove disconnect shaft front Hemove clutch hub from shaft bearing Figure 309 Figure 312 Remove front bearing Hemove clutch hub locating ring from shaft Figure 310 Remove front bearing retaining ring T16000 11 96 9 59 CLARK HURTH Reassembly disconnect shaft INGERSOLLRAND Figure 313 Figure 316 Install bushing if necessary Install front bearing retaining ring Figure 314 Figure 317 Install clutch hub locating ring Install front bearing on shaft Figure 315 Figure 318 Install clutch hub on shaft Tap bearing on shaft T16000 11 96 9 60 CLARICHURTH Disassembly pump drive shaft INGERSOLL RAND Figure 319 Figure 322 Hemove rear bearing snap ring Remove sealing ring from shaft Figure 320 Use bearing puller to remove rear bearing Figure 321 Hemove rear bearing from shaft T16000 11 96 9 61 CLARICHURTH Reassembly pump drive shaft INGERSOLLRAND Figure 3
11. PORT 42 S B PRESSURE CHECK PORT G FA 2ND CLUTCH 2 FWD 2ND FWD 4TH REV 2ND NY er D d LEI n 1 Ox PORT 47 PRESSURE CHECK PORT NE DISCONNECT CLUTCH 3 4 WHEEL DRIVE LEFT SIDE VIEW PORT 31 FILTER PLUG M22 X 1 5 THD PRESSURE CHECK PORT REGULATOR PRESSURE M ND DH m 2 f OJ Serie TOP VIEW T16000 CLARK HURTH Troubleshooting guide INGERSOLLRAND PORT 71 TEMPERATURE CHECK PORT CONVERTER OUT TO COOLER cA q 7 nmi f li L d ke um CONVERTER OUT TO COOLER J E 2 j j d Bes ALL BOTTOM VIEW Threads All pressure and temperature check ports e M10x 1 THD o ring port ISO 6149 1 All hydraulic line connection ports 1 0625 12 UN 2B SAE o ring port PORT 35 PRESSURE BEFORE FILTER RIGHT SIDE VIEW T16000 11 96 6 6 CLARK HURTH Troubleshooting guide INGERSOLLRAND C ELECTRICAL WIRING Transmission Control valve
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13. Figure 57 Remove by pass plug spring and ball T16000 11 96 9 11 CLARICHURTH Disassembly forward high clutch INGERSOLLRAND Figure 58 Figure 61 Remove clutch shaft sealing rings Remove clutch gear Figure 59 Figure 62 Remove thrust washer and thrust bearing Remove clutch gear inner needle bearing Figure 60 Figure 63 Remove clutch gear outer needle bearing Remove thrust washer and thrust bearing T16000 11 96 9 12 CLARICHURTH Disassembly forward high clutch INGERSOLLRAND Figure 64 Figure 67 Remove backing plate retaining ring Remove one outer half disc Figure 65 Figure 68 Remove clutch plate spacer Remove inner and outer discs Figure 66 Figure 69 Remove clutch disc backing plate Remove one outer half disc T16000 11 96 9 13 CLARICHURTH Disassembly forward high clutch INGERSOLLRAND Figure 70 Figure 73 Compress spring to remove spring retainer Remove clutch piston spring retainer snap ring Figure 71 Figure 74 Remove spring retainer snap ring Remove clutch piston spring Figure 72 Figure 75 Remove clutch spring spacer Remove clutch piston wear plate T16000 11 96 9 14 CLARICHURTH Disassembly forward high clutch INGERSOLLRAND Figure 76 Remove clutch piston assembly
14. OG a aw iy L d Mi G Fi pe B AE GE N D ee y rss I f J C Gr II ol EH Nu f i Id er fot p En 3 CORE d J gt BR m a Ves NOD LEE 2 Eme ji SS Cl ies L a C c ZS El jir 2nd SPEED REVERSE T16000 11 96 25 10 INGERSOLLRAND E GEAR AND CLUTCH LAY OUT 5
15. From cooler to transmission lube distributor Cooler lines specifications Minimum 19 mm internal diameter for lines and fittings e Suitable for operation from ambient to 120 C continuous operating temperature Must withstand 20 bar continuous pressure and with 40 bar intermittent surges e Conform SAE J1019 and SAE J517 100RI T16000 11 96 4 3 CLARK HURTH INGERSOLLRAND 184 0c JHASSIHd HOLATI HILNTI 193NNOOSIG HILNTI HILNTI HOLN19 H91f119 HILNTI jq 02 010 181 anz H9IH 4 M014 3unss3ud 1 LIN Jeq kl T 7 uolvinnoov eq 02 0 01S S 0 4315009 JHNSSIHA jq 0 015 JAVA NOLLWINGOW 311081502 JINOHLIJH eq G G OL d3onqdg JHNSSIHA 194 09510 NOILVINGOW 193 ONG HOIH QIONJ10S JONVH QIONJ10S QIONJ10S QIONJ10S QION31OS QIONJ1OS G JHASSIHA QIONITOS NOLLVO H8N1 3S0H 3S0H jm N 431009 Y3LY3ANOI Jo JNDHOL 14Od JUNIVHAAWAL X 1 oun 189 junssaud X uva v 39N34334IQ 3uf1SS3ud 3A1VA SSVd Ad Q39Vv5N3 HOLN19 LO3NNOOSIG HOLN19 ANZ TVHLNIN HALWJANOD INDHOL JANS 110 Na349S x lt u3ulv3ug M ul req 1 1eq ib JINIH1HHIQ JHASSIHA JA TVA SSVd Ad HOLVIND4U JHASSIHA 1eq 00 JAVA 3ufiSS3ud 9NDIOVH 289 01 3A1VA AL33VS 39nv9 39nv9 JHNLVHIAWIL JHASSIHA INAWLYVdINOO HOLVH4dAO 11 96 116000 CLARK HURTH INGERSOLLRAND
16. A NOTE Determine measure and weld part 3 after try out T16000 11 96 10 1
17. CLARK HURTH INGERSOLLRAND GROUP OUTPUT SHAFT WITH INTERNAL DISCONNECT 7 14 11 96 T16000 GROUP OUTPUT SHAFT WITH INTERNAL DISCONNECT Item oo T16000 Description Nut flange Washer flange nut O ring flange Output flange front yoke 1410 with brake disc Bearing output shaft front Ring retaining Disconnect hub Snapring gear retainer Assembly output shaft front Bushing Snapring clutch disc backing plate Spacer Plate clutch disc backing Disc outer half Disc outer Disc inner Disc outer half Ring retaining Retainer spring Spring piston return Plate spring clutch piston wear Assembly clutch piston amp seals Seal clutch piston outer Seal clutch piston inner Assembly output shaft rear drum amp plug Snapring gear retainer Gear lower output Snapring gear retainer Snap ring rear bearing Bearing output shaft rear Snap ring rear bearing Ring piston 11 96 CLARK HURTH Quantity sech wo oo sch sch sch sch sch sch NI SH HS ech sch sch ech INGERSOLLRAND CLARK HURTH INGERSOLLRAND GROUP PARKING BRAKE 7 16 11 96 T16000 GROUP PARKING BRAKE Item c OO NM N HS HS o et P O 116000 Description Screw brake mounting Assembly caliper Nut brake mounting screw Nut jam adjustment
18. Forward Low 77771 Forward High 7 1 Reverse and 1st Disconnect T16000 11 96 _ CLARK HURTH INGERSOLLRAND TROUBLESHOOTING GUIDE FOR THE T16000 TRANSMISSION The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and correct functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assembly oil cooler filter connecting lines and controls including the engine as a complete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system T16000 TRANSMISSION T16000 power shift with torque converter transmission troubles fall into three general categories mechanical hydraulic and electrical problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fl
19. T16000 11 96 955 CLARK HURTH Disassembly T16000 transmission INGERSOLLRAND Figure 25 Figure 28 Remove transmission case plug Transmission case removed all drums and shafts remain in converter housing Figure 26 Figure 29 Transmission case plug and gasket removed Remove transmission case to converter housing gasket Figure 27 Figure 30 Using spreading type snap ring plier spread ears on Remove output shaft sealing rings output shaft rear bearing retaining ring Holding snap ring open tap on output shaft and transmission case to remove case from converter housing P10 1 Lift transmission case from converter housing using lifting bracket T16000 11 96 9 6 CLARICHURTH Disassembly T16000 transmission INGERSOLLRAND Figure 31 Figure 34 Remove output shaft rear bearing retaining ring Using bearing puller to remove 2nd shaft rear bearing Figure 32 Figure 35 Use bearing puller to remove output shaft rear 2nd shaft rear bearing removed bearing Figure 33 Figure 36 Output shaft rear bearing removed Using bearing puller to remove input shaft rear bearing T16000 11 96 9 7 CLARICHURTH Disassembly T16000 transmission INGERSOLLRAND Figure 37 Figure 40 Input shaft rear bearing removed Reverse and 1st shaft rear bearing removed Figure 38 Figure 41 Remove reverse and 1st shaft sealing rings Hemove forward low and forward high shaft sealing rings Figure 39 Figur
20. a Stall procedure b Check points c Electrical wiring Sectional views and parts identification Assembly instructions Disassembly and reassembly of units Service tools T16000 CLARK HURTH INGERSOLLRAND CHAPTER 10 CLARK HURTH INGERSOLLRAND SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instruction must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with one of the same part number or with a equivalent part Do not use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended by Clark Hurth must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the unit or render it u
21. ans SPICER Off Highway Products Service Manual Powershift Transmission 116000 TSM 0030 November 1996 CLARK HURTH INGERSOLLRAND TOWING OR PUSHING Before towing the vehicle be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing Note Ifthe transmission has 4 wheel drive disconnect both front and rear drivelines Because of the design of the hydraulic system the engine cannot be started by pushing or towing Copyright Clark Equipment Company 1996 Unpublished material All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of Clark Equipment Company T16000 11 96 CLARK HURTH INGERSOLLRAND FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the CLARK HURTH COMPONENTS product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshoo
22. 32 Ring retaining 1 33 Disc outer half 1 34 Disc inner 9 33 Disc outer 8 36 Disc outer half 1 37 Modulation spring 1 38 Plate clutch disc backing 1 39 Snap ring clutch disc backing plate 1 40 Bearing clutch gear 1 41 Retaining ring clutch gear bearing 1 42 Gear 1st clutch 1 43 Retaining ring clutch gear bearing 1 44 Bearing clutch gear 1 45 Snap ring 1 46 Bearing rear Rev 1st shaft 1 47 Ring piston 3 T16000 11 96 7 11 CLARK HURTH INGERSOLLRAND GROUP 2ND SHAFT 7 12 11 96 116000 GROUP 2ND SHAFT Item oo T16000 Description Ring piston Bearing front 2nd shaft Washer bearing support Bearing clutch gear Retaining ring clutch gear bearing Gear 2nd clutch Retaining ring clutch gear bearing Bearing clutch gear Snap ring cluch disc backing plate Plate clutch disc backing Modulation spring Disc outer half Disc outer Disc inner Disc outer half Ring retaining Retainer spring Spring clutch piston return Plate spring clutch piston wear Assembly clutch piston amp seals Seal clutch piston outer Seal clutch piston inner Assembly 2nd shaft drum amp plug Snap ring gear retainer Gear lower output drive Gear upper output Bearing rear 2nd shaft Flange yoke 1410 upper output O ring flange Washer flange nut Nut flange 11 96 CLARK HURTH Quantity c c c c c c cl cl cl Il lI ol lI lI sch ech eck eck qw INGERSOLLRAND
23. Install clutch outer seal Note Ring must QD Install clutch piston return spring be sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 123 Figure 126 Install piston inner seal and install clutch Install piston return spring retainer piston in clutch drum use caution as not to damage sealing rings Figure 124 Figure 127 Install clutch piston wear plate on piston Install spring retainer spacer T16000 11 96 9 24 CLARK HURTH Reassembly forward high clutch INGERSOLLRAND Figure 128 Figure 131 Install clutch spring retainer snap ring Install one steel disc Alternate friction and steel discs until the proper amount of discs are installed first and last discs are steel Figure 129 Figure 132 Use a sleeve with the proper diameter to fit over shaft Install one outer half disc with friction material down and against retainer ring A sharp blow with a soft hammer will compress spring and seat retainer ring Be sure ring is in full position in groove Figure 130 Figure 133 Install one outer half disc with friction material away Install backing plate from the piston T16000 11 96 9 25 CLARK HURTH Reassembly forward high clutch INGERSOLLRAND Figure 134 Figure 137 Install backing plate spacer Install clutch gear inner nee
24. OPERATION OF THE UNIT The transmission and hydraulic torque converter of the power train enacts an important role in transmitting engine power to the driving wheels In order to properly maintain and service these units it is important to first understand their function and how they operate A THE HYDRAULIC CIRCUIT REFER TO HYDRAULIC DIAGRAM The transmission and torque converter function together and operate through a common hydraulic system With the engine running the transmission charging pump draws oil through the oil suction screen and directs it through the oil filter and pressure regulating valve Across the oil filter is a filter by pass valve which will open if the pressure difference becomes higher than 4 3 bar 62 PSI The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar 288 PSI Excess oil volume is bled off into the converter circuit A safety valve is fitted between the pressure regulator and converter The valve will open if pressure in this line becomes higher than 10 bar 144 PSI After entering the converter the oil is directed through the converter blade cavity and exits in the passage between the turbine shaft and pump drive shaft and flows to the cooler After leaving the cooler the oil is directed to a fitting on the transmission Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches The oil then gravity drains back to
25. Assembly pump drive shaft amp sleeve 1 25 Ring piston 1 26 Bearing pump drive shaft 1 27 onap ring 1 28 Retaining ring 1 2 Gasket permanent pump adapter cover 1 30 Cover permanent pump adapter 1 31 Lockwasher permanent pump adapter cover screw 4 32 Screw permanent pump adapter cover 4 T16000 11 96 az SL INGERSOLLRAND GROUP FWD LOW FWD HIGH SHAFT 6 CF 50 11 96 TIEG U GROUP FWD LOW FWD HIGH SHAFT Item JO 116000 Description Bearing front Fwd low Fwd high shaft Gear forward driven onap ring Bearing clutch gear Retaining ring clutch gear bearing Gear forward low clutch Ring clutch gear piston Retaining ring clutch gear bearing Bearing clutch gear Snap ring Snap ring Washer Snap ring backing plate Plate clutch disc backing Disc outer half Disc outer Disc inner Disc outer half Ring retaining Retainer spring Spring piston return Plate spring clutch piston wear Assembly clutch piston amp seals Seal clutch piston outer Seal clutch piston inner Assembly Fwd low Fwd high shaft drum amp plug Seal clutch piston inner Seal clutch piston outer Assembly clutch piston amp seals Plate spring clutch piston wear Spring piston return Retainer spring Spacer clutch spring fwd high Ring retaining Disc outer half Disc inner Disc outer Disc outer half Plate clutch disc backing Spacer clutch
26. Forward 3 Forward 2nd 1st Forward high 1st Forward 2 Forward Forward high low Forward low 2nd Forward 1 Forward Forward high low 2nd 1st Forward low 1st Heverse 1 Reverse 2nd 1st Heverse 1st Reverse 2 Reverse Reverse 2nd Disconnect off Disconnect Disconnect on Disconnect T16000 11 96 9e CLARICHURTH Operation of the unit INGERSOLLRAND D POWER FLOWS
27. connections Function Control valve common plus for direction and range modulation solenoid Transmission temperature out Range modulation solenoid Speed sensor Temp sensor ground Control valve common ground for forward reverse 1 2 high low and disconnect solenoid Direction modulation solenoid Reverse neutral solenoid Disconnect solenoid Range 1 2 solenoid Forward neutral solenoid Forward lo hi solenoid Speed sensor output CONNECTOR T16000 11 96 6 7 CLARK HURTH INGERSOLLRAND SECTIONAL VIEWS AND PARTS IDENTIFICATION T16000 11 96 fc CLARK HURTH INGERSOLLRAND GROUP CONVERTER HOUSING amp TRANSMISSION CASE 24 1 2 11 96 T16000 CLARK HURTH INGERSOLLRAND GROUP CONVERTER HOUSING amp TRANSMISSION CASE Description Quantity 1 Plug 11 2 O ring plug 11 3 O ring plug 3 4 Plug 3 5 Ball 1 6 Spring 1 7 Plug 1 8 O ring plug 1 9 Spring safety valve 1 10 Ball 1 11 O ring plug 1 12 Plug 1 13 O ring converter housing to transmission case 2 14 O ring converter hous
28. disc backing plate Fwd high Snap ring spacer Thrust washer Thrust bearing Bearing needle Gear forward high clutch Bearing needle Thrust bearing Thrust washer Bearing rear Fwd low Fwd high shaft Ring piston 11 96 CLARK HURTH Quantity ee DA sch sch cl sch sch sch sch sch ee ech ech ech INGERSOLLRAND CLARK HURTH INGERSOLLRAND GROUP REVERSE 1ST SHAFT AND GEARS 7 10 11 96 T16000 CLARK HURTH INGERSOLL RAND GROUP REVERSE 1ST SHAFT AND GEARS Item Description Quantity 1 Bearing front Rev 1st shaft 1 2 Gear reverse driven 1 3 Snap ring 1 4 Bearing clutch gear 1 9 Retaining ring clutch gear bearing 1 6 Gear forward low clutch 1 7 Ring clutch gear piston 1 8 Retaining ring clutch gear bearing 1 9 Bearing clutch gear 1 10 onap ring 1 11 onap ring 1 12 Washer 1 13 Snap ring backing plate 1 14 Plate clutch disc backing 1 15 Disc outer half 1 16 Disc outer 8 17 Disc inner 9 18 Disc outer half 1 19 Ring retaining 1 20 Retainer spring 1 21 Spring piston return 1 22 Plate spring clutch piston wear 1 23 Assembly clutch piston amp seals 1 24 Seal clutch piston outer 1 2b Seal clutch piston inner 1 26 Assembly Rev 1st shaft drum amp plug 1 27 Seal clutch piston outer 1 28 Seal clutch piston inner 1 29 Assembly clutch piston amp seals 1 30 Plate clutch piston wear 1 31 Assembly spring disc 1
29. environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination For extreme conditions judgement must be used to determine the required change intervals Every 1000 hours change oil filter Every 1000 hours drain and refill system as follows Drain with oil at 65 93 C 150 200 F Drain transmission Oil filter remove and discard install new filter Refill transmission 14 litres 3 7 Run engine at idle 600 RPM to prime converter and lines When oil temperature is at 82 93 C 180 200 F adjust oil level to full mark am Br A Note It is recommended that oil filter be changed after 100 hours of operation on new rebuilt or repaired unit T16000 11 96 3 1 CLARK HURTH Maintenance INGERSOLLRAND C SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be acc
30. follows When the range is changed oil will flow through the modulation shift spool to the chosen range clutch momentary until the friction discs are closed against the dished plate At that moment the range modulation solenoid is activated The plot pressure will move the modulation shift spool so that oil supply is fed through restrictor which is in by pass of the valve The controlled volume of oil is used to push in the dished outer plate gradually until the clutch is fully closed This will give a smooth build up of torque At that moment the range modulation solenoid is released so that the modulation shift spool return to its rest position and allowing full oil flow to the clutch The control valve also controls the front lower output disconnect clutch If the solenoid is not activated full oil pressure is fed through the disconnect shift spool to the disconnect clutch If the solenoid is activated pilot pressure will move the disconnect shift spool to block oil supply to the disconnect clutch to release it The control valve also has a speed sensor This sensor will pick up upper output gear speed This information is used in the electronic gear selector to determine shift logic Since the sensor picks up upper output gear speed the signal will be in direct relation of the turbine speed if any directional clutch is engaged C ELECTRIC SOLENOID CONTROLS Activated solenoids Activated clutches Forward 4 Forward Forward high 2nd
31. this operation Gear splines must be in full position with internal teeth of all steel discs Figure 258 Figure 261 Install clutch hub inner bearing Install clutch hub outer bearing AN Be sure that bearing shield is on the outside dr 1 TA Figure 259 Figure 262 Tap clutch gear inner bearing into place Tap outer bearing into place T16000 11 96 9 49 Resassembly 2nd clutch drum Figure 263 Install bearing washer Figure 264 Warm front bearing to 120 C 248 F install bearing Figure 265 Install clutch shaft sealing rings T16000 11 96 CLARK HURTH INGERSOLLRAND Figure 266 Install gear retaining ring Figure 267 Warm gear to 150 C 302 F install gear Figure 268 Warm upper output gear to 150 C 302 F install gear CLARK HURTH Disassembly output shaft INGERSOLLRAND Figure 269 Figure 272 Remove oil baffle screws and nuts Remove output shaft gear retaining ring Figure 270 Figure 273 Remove oil baffle Press output gear from shaft Figure 271 Figure 274 Remove output shaft sealing rings Remove output gear T16000 11 96 9 51 CLARK HURTH Disassembly output shaft INGERSOLLRAND Figure 275 Figure 278 Remove oil baffle from output shaft Remove backing plate spacer Figure 276 Figure 279 Remove gear retaining ring Remove backing plate m Figure 277 Figure 280 Hemove backing plate snap ring Remove one outer half disc
32. 2 55 CLARICHURTH Reassembly input shaft INGERSOLLRAND Figure 342 Turn shaft and install input shaft forward high gear retaining ring Figure 343 Install input shaft rear sealing ring T16000 11 96 9 66 CLARICHURTH Reassembly converter housing INGERSOLLRAND Figure 344 Figure 347 Install safety valve ball spring and plug Tap seal into place Figure 345 Figure 348 Install by pass valve ball spring and plug Install input shaft into housing and in the meantime install reverse and first shaft they have to be installed together Using caution as not to damage any of the first shaft sealing rings Figure 346 Figure 349 Install output shaft front oil seal Install forward low shaft and high shaft into housing Using caution as not to damage any sealing rings T16000 11 96 9 67 Reassembly converter housing Figure 350 Install disconnect shaft assembly into housing r rati e emm Wi d 5 hu 2 Figure 351 Open bearing retaining ring Tap shaft into place Be sure ring is in groove Figure 352 Install upper and lower output at the same time Do not force this operation be sure discs o
33. 23 Figure 326 Install sealing ring on shaft Install rear bearing retainer ring Figure 324 Install rear bearing on shaft Figure 325 Tap bearing into place T16000 11 96 9 62 CLARICHURTH Disassembly input shaft INGERSOLLRAND Figure 327 Figure 330 Remove input shaft rear sealing ring Remove input shaft front sealing ring Figure 328 Figure 331 Remove forward high gear retaining ring Use bearing puller to remove input shaft front bearing Figure 329 Figure 332 Remove forward low gear retaining ring Remove input shaft front bearing T16000 11 96 9 63 CLARICHURTH Disassembly input shaft INGERSOLLRAND Figure 333 Remove input shaft front bearing retaining ring Figure 334 Remove forward low gear retaining ring Figure 335 Press forward low gear from shaft T16000 11 96 9 64 CLARK HURTH Reassembly input shaft INGERSOLLRAND Figure 336 Figure 339 Install forward low gear retaining ring Install input shaft front bearing retaining ring Figure 337 Figure 340 Warm gear to 150 C 302 F install gear Install input shaft front sealing ring Figure 338 Figure 341 Install forward low gear retaining ring Warm input shaft front bearing to 120 C 248 F install bearing T16000 11 96
34. 5 Position parking brake install mounting Position wiring connector in valve protection cover screws See packing brake adjustment Figure 393 Figure 396 Install by pass valve spool into solenoid housing and Install gasket and valve protection cover spring into transmission case position control valve mounting screws and tighten screws to on transmission case specified torque Figure 394 Figure 397 Install control valve mounting screws and Install air breather and tighten to 34 41 Nm lockwashers tighten screws to specified 25 30 Ibft torque T16000 11 96 9 9 CLARICHURTH Reassembly T16000 transmission INGERSOLLRAND Figure 398 Install wiring connector nut and tighten to 6 8 Nm 4 4 5 9 Ibft T16000 11 96 9 76 CLARK HURTH INGERSOLLRAND SERVICE TOOLS 1 LIFTING BRACKET TE i Y 1 1 i 45 i 0190 0126 255 A 579 04 Y Yo 2 Holes 013 010 2 x 30 lt Y Y 7 gt a 15 TG 1500 676 1 piece Material ST37
35. 9 Spool stop 1 10 Separator plate 1 11 1st 2nd spool 1 12 Pilot spool spring 1 13 Spool stop 1 14 Separator plate 1 15 Range modulation spool 1 16 Pilot spool spring 1 17 Accumulator spring 1 18 Accumulator spool 1 19 Booster spool 1 20 Reverse spool 1 21 Pilot spool spring 1 22 Forward spool 1 23 Spool stop 1 24 Separator plate 1 25 Fwd low Fwd high spool 1 26 Pilot spool spring 1 27 Spool cover 1 28 Spool cover screw 11 29 Check port plugs 4 30 Spool body to solenoid plate screw 9 31 Spacer plate 1 32 Bypass valve spool 1 33 Bypass valve spring 1 34 Solenoid plate 1 35 Plug 6 36 Solenoid 6 37 Electronic controlled modulation valve 1 38 Solenoid clamp 1 39 Solenoid clamp screw 6 40 Wiring strap 6 41 Speed sensor 1 42 Speed sensor ring 1 43 Jam nut O ring 1 44 Jam nut 1 45 Wiring harness rings and speed sensor assembly 1 46 Wiring clamp 1 47 Clamp screw lockwasher 1 48 Clamp screw 1 T16000 11 96 T2 CLARK HURTH INGERSOLLRAND ASSEMBLY INSTRUCTIONS
36. 96 9 92 CLARICHURTH Disassembly reverse clutch INGERSOLL RAND Figure 171 Figure 174 Remove inner and outer discs Compress spring to remove spring retainer snap ring Figure 172 Figure 175 Remove one outer half disc Remove spring retainer snap ring Figure 173 Figure 176 Remove inner bearing locating ring Remove clutch piston spring retainer T16000 11 96 9 33 Disassembly reverse clutch Figure 177 Remove clutch piston spring Figure 178 Remove clutch piston wear plate Figure 179 Remove clutch piston assembly T16000 11 96 CLARK HURTH INGERSOLL RAND CLARK HURTH Reassembly reverse clutch INGERSOLLRAND Figure 180 Figure 183 Install clutch piston outer seal Note Ring must QD Install clutch piston spring be sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 181 Figure 184 Install clutch piston inner seal Install clutch Install clutch piston spring retainer piston in clutch drum use caution as not to damage sealing rings Figure 182 Figure 185 Install piston wear plate on piston Install clutch sp
37. ENT AND ADJUSTMENT OF PARKING BRAKE ASSEMBLY 1 Loosen two adjustment locking nuts 4 amp 5 enough to slide each torque plate 16 amp 18 away from disc far enough to provide clearance to remove old carrier and lining assemblies and install new ones It may be necessary to remove one or both nuts 2 Collapse lining retraction spring 21 and remove from brake head assembly 3 Slide torque plates 16 amp 18 away from disc move carrier and lining assemblies 17 out of pockets and remove from the brake head assembly from the side 4 Install new carrier and lining assemblies 17 in each torque plate 16 amp 18 5 Install lining retention spring 21 into brake head assembly Be sure spring s in holes in both lining carrier assemblies 17 feet are positioned properly 6 Tighten inner adjusting nut 5 until firm contact is made with the disc by the linings Torque to 100 Ibs in 11 Nm make certain lever is in proper operating position for application 7 Back off inner adjusting nut 4 5 to 5 flats and check that disc is free to move total clearance 0 8 1 1 mm 0 031 0 043 8 Tighten outer locking nut 4 against inner adjusting nut to lock adjustment bolt in place Torque to 45 to 55 lb ft 61 75 Nm T16000 11 96 de CLARK HURTH INGERSOLLRAND INSTALLATION DETAILS A CONVERTER DRIVE COUPLING Measure the A dimension bolt circle diameter and order drive plate kit listed below Note
38. ND TECHNICAL SPECIFICATIONS ELARICHURTE gt COMPONENTS A IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number B WEIGHT DIMENSIONS OIL CAPACITY Weight dry 290 kg 639 Ib Maximum length 705 3 mm 27 8 Maximum width 465 mm 19 3 Maximum height 648 mm 25 35 Cil capacity 141 8 7 US Gallon without cooler and hydraulic lines Consult operators manual on applicable machine for system capacity T16000 11 96 CLARICHURTH _ Technical specifications INGERSOLLRAND C TIGHTENING TORQUE S Torque table for bolts Based in VDI 2230 u 0 14 and 1 standard All threads must be lubricated before assembly Class 8 8 Grade 5 5 6 M5 0 8 4 4 8 x 1 25 14 7 18 4 M10 x 1 5 29 5 36 8 35 4 44 2 112 140 82 5 103 2 Torque tables for pipe plugs bf M22 x 1 5 35 4 44 2 0 1250 27 9 13 6 6 9 6 UNI 7707 NPTF Output flanges 339 407 Nm 250 300 Ibft Filter torque 30 38 Nm 22 1 28 Ibft Control valve Connector nut to cover 6 8 Nm 4 4 5 9 Ibft T16000 11 96 2 2 CLARICHURTH Technical specifications INGERSOLLRAND D PRESSURE AND TEMPERATURE SPECIFICATIONS Normal operating temperature 70 120 C 158 248F measured at temperature check port to cooler port 71 e Maximum allowed transmission temperature 120 C 248 F e Transmission regulator pre
39. NGERSOLLRAND First clutch springs concave side of first disc spring to be placed against clutch piston wear sleeve Remaining 10 springs to be stacked alternately reversed as shown Shipping strap Only used during shipment of the individual transmission NOTE Check if safety valve and valve block are tested before assembly Heat gears up to 150 C 302 F before assembling Parking brake Mounting Tighten locking nuts with 0 25 to 1 25 mm clearance between nuts and sleeves Adjustment loosen the 2 adjustment locking nuts 1 and 2 Put lever in correct position Tighten inner adjustment nut 2 with 11 Nm Back off inner adjustment nut 2 with 4 or 5 flats Tighten outer locking nut 1 against inner adjustment nut 2 Clearance must be from 0 8 to 1 1 mm T16000 11 96 8 3 CLARICHURTH Disassembly T16000 transmission INGERSOLL RAND AN Warning For disassembly and reassembly of this unit you will need besides normal workshop tools and the special tools mentioned in the last chapter of this manual a press capable of minimum 20 tons and an induction heater of minimum 3 5 kW to heat gears up to 150 C 302 F T16000 11 96 9 1 CLARICHURTH Disassembly T16000 transmission INGERSOLL RAND Figure 4 Remove drive plate screws Figure 1 Remove oil filter Figure 2 Figure 5 Remove filter adapter screws Remove drive plates Figure 3 Figure 6 1 Remove filte
40. Nut adjustment Washer hardened Washer stainless steel Washer trust Lever Boot Cam Id seal Ball bearing Plastic retainer Cam Torque plate front Carrier and lining assembly Torque plate rear Sleeve mounting Bolt Adjusting Spring 11 96 CLARK HURTH Quantity N eck sch eck eck sch eck c P INGERSOLLRAND CLARK HURTH INGERSOLLRAND GROUP MOUNTING ELECTRIC CONTROL VALVE co e Uum A e S NV aan Ly LO N e V T16000 11 96 CLARK HURTH INGERSOLLRAND GROUP MOUNTING ELECTRIC CONTROL VALVE Item Description Quantity 1 Control valve assembly 1 2 Control valve mounting screws 17 3 Control valve protection cover gasket 1 4 Control valve protection cover 1 5 Protection cover screw 20 6 Air breather 1 T16000 11 96 7 19 CLARK HURTH INGERSOLLRAND GROUP ELECTRIC CONTROL VALVE ASSEMBLY T16000 11 96 YO aa e 4 a N 30 G g 20 CLARK HURTH INGERSOLL RAND GROUP ELECTRIC CONTROL VALVE ASSEMBLY Item Description Quantity 1 Spool body 1 2 Pressure reducer spool 1 3 Pressure reducer spring 1 4 Separator plate 1 5 Pressure regulator spring 1 6 Pressure regulator spool 1 7 Pilot spool spring 1 8 Disconnect spool 1
41. PSI This pressure curve is multiplied in the booster so that a curve from 1 20 bar 0 to 290 PSI is available for the directional clutches Between the electronic modulation valve and the booster is an accumulator to damper any hydraulic vibration When forward is selected the electronic modulation valve and the forward solenoid are activated The pilot pressure of the forward solenoid will move the shift spool so that a forward clutch can be fed with modulated pressure If the high low solenoid is not activated the forward high clutch is engaged if it is activated the forward low clutch is engaged When reverse is selected the electronic modulation valve and the reverse solenoid are activated the pilot pressure of the reverse solenoid will move the shift spool so that the reverse clutch can be fed with modulated pressure The shift spools from forward and reverse are located against each other with a return spring in between this is to make sure that only one direction can be selected Range is selected as follows If the range solenoid 2nd 1st is not activated regulated pressure is fed through the modulation shift spool and through the 2nd 1st shift spool to the 2nd clutch If the range solenoid 2nd 1st is activated the pilot pressure will move the shift spool so that 1st clutch is fed T16000 11 96 Sur CLARK HURTH INGERSOLLRAND Operation of the unit The range clutches also have modulation which operates as
42. SSION CASE 24 7 4 11 96 T16000 CLARK HURTH INGERSOLLRAND GROUP CONVERTER HOUSING amp TRANSMISSION CASE Description Quantity 50 Plug 1 o1 Plug 11 52 O ring plug 11 53 Seal upper output 1 54 Screw converter housing to transmission case 5 55 Lockwasher converter housing to transmission case screw 5 56 Plug magnetic drain 1 57 Snapring output shaft rear bearing 1 58 Plug output shaft bore 1 59 Sealing ring plug 1 60 Plug 1 61 Plug 1 62 Plug 1 T16000 11 96 f CLARK HURTH INGERSOLLRAND GROUP INPUT SHAFT TORQUE CONVERTER PUMP DRIVE INTERNAL CHARGING PUMP AND DRIVE PLATE 7 6 11 96 T16000 CLARK HURTH INGERSOLLRAND GROUP INPUT SHAFT TORQUE CONVERTER PUMP DRIVE INTERNAL CHARGING PUMP AND DRIVE PLATE Description Quantity 1 Screw drive plate mounting 6 2 Lockwasher drive plate mounting screw 6 3 Ring drive plate 1 4 Plate drive 2 5 Assembly drive plate 1 6 Bushing converter pilot 1 7 Assembly torque converter 1 8 Oil seal charging pump 1 9 Screw pump mounting 6 10 Seal washer pump mounting screw 6 11 Assembly charging pump 1 12 O ring charging pump 1 13 Ring piston 1 14 Bearing input shaft front 1 19 onap ring 1 16 onap ring 1 17 Gear forward low amp reverse drive 1 18 onap ring 1 19 Shaft input 1 20 Snap ring 1 21 Gear forward high drive 1 22 Bearing input shaft rear 1 23 Ring piston 1 24
43. T16000 11 96 9 52 CLARK HURTH Disassembly output shaft INGERSOLLRAND Figure 231 Figure 284 Remove inner and outer discs Remove spring retaining ring Figure 282 Figure 285 Remove one outer half disc Remove spring retainer Figure 283 Figure 286 Compress spring to remove spring retaining ring Remove clutch piston spring T16000 11 96 9553 CLARICHURTH Disassembly output shaft INGERSOLLRAND Figure 287 Remove piston wear plate Figure 288 Remove piston assembly T16000 11 96 9 54 CLARICHURTH Reassembly output shaft INGERSOLLRAND Figure 289 Figure 292 Install piston outer seal Note Ring must be ob Install clutch piston spring sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 290 Figure 293 Install clutch piston inner seal Install spring retainer Install clutch piston in clutch drum Use caution as not to damage sealing rings Figure 291 Figure 294 Install piston wear plate on piston Install spring retainer snap ring Use
44. Y 1 Remove disassemble and rebuild converter assembly Replace Fill to proper level Clean cooler Se Change cooler lines REMEDY 1 Replace 2 A complete disassembly will be necessary to determine what bearing is faulty REMEDY 1 Tune engine check governor 2 Make corrections as explained in Overheating CLARK HURTH Troubleshooting guide INGERSOLLRAND B CHECK POINTS DIPSTICK HOLE 1 3125 12UN 2B THD SAE O RING PORT FRONT VIEW PORT 44 PRESSURE CHECK PORT FWD HI CLUTCH FWD 3RD AND FWD 4TH PORT 33 PRESSURE CHECK PORT FROM COOLER LUBE PRESSURE PORT 45 PRESSURE CHECK PORT FWD LOW CLUTCH FWD 1ST AND FWD 2ND PORT 11 TO COOLER PORT 46 PRESSURE CHECK PORT REV CLUTCH REV 1ST AND REV 2ND PORT 41 PRESSURE CHECK PORT 1ST CLUTCH FWD 1ST FWD 3RD REV 1ST PORT 12 FROM COOLER OIL LEVEL PLUG M10 X1 MAGNETIC DRAIN PLUG M22 X 1 5 REAR VIEW T16000 11 96 6 4 CLARK HURTH Troubleshooting guide INGERSOLLRAND 2 2 PORT 34 PRESSURE CHECK PORT CONVERTER IN 1 al PORT 11 i A TO COOLER To Laon
45. a sleeve with the proper inner diameter to fit over shaft and against snap ring A sharp blow of a soft hammer will compress spring and seat retainer ring Be sure ring is in full position in groove T16000 11 96 999 CLARICHURTH Reassembly output shaft INGERSOLLRAND Figure 295 Figure 298 Install one outer half disc with friction material away Install backing plate from the piston Figure 296 Figure 299 Install one steel disc Alternate friction and steel Install backing plate spacer discs until the proper amount of discs are installed First and last discs are steel Figure 297 Figure 300 Install one half disc with friction material down Install backing plate snap ring T16000 11 96 95b Reassembly output shaft Figure 301 Install oil baffle on output shaft Figure 302 Install output gear retaining ring Figure 303 Warm gear to 150 C 302 F install gear T16000 CLARK HURTH INGERSOLLRAND Figure 304 Install output gear retaining ring Figure 305 Install output shaft sealing rings Figure 306 Install rear oil baffle on output shaft CLARICHURTH Reassembly output shaft INGERSOLLRAND Figure 307 Install oil baffle mountng screws washer and nuts and tighten nuts to specified torque Use Loctite 243
46. ach reassembly Smontaggio di particollari ingombranti Remove obstruction parts Togliere mettere la sicura Unlock lock e g split pin locking plate etc Montaggio di particollari ingombranti Reinstall remount parts which had obstructed disassembly Mettere la sicura incollare mastice liquido Lock adhere liquid sealant Attenzione indicazione importante Attention important notice Evitare danni ai materiali danni ai pezzi Guard against material damage damage to parts Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc Marchiari prima dello smontaggio per il montaggio Mark before disassembly observe marks when reasembl T Attrezzature speciali Pagina T Special tool P Page Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc Rispettare direzione di montaggio Note direction of installation Scarricare olio lubrificante Drain off oil lubricant Controllare esaminare controllo visuale Visual inspection Tendere Tighten clamp tightening a clamping device Eventualimente riutilizzable sostituire se necessario Possibly still serviceable renew if necessary 11 96 Insere pressione nel circuito idraulico Apply pressure into hydraulic circuit Pulire To clean CLARK HURTH INGERSOLLRA
47. aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner A CAUTION Care should be exercised to avoid inhalation of vapours and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time After inspection dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed T16000 11 96 1 1 CLARK HURTH INGERSOLLRAND Cleaning and inspection OIL SEALS GASKETS ETC Replacement of spring load oil seals O rings metal sealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Fur
48. aling rings Figure 224 Figure 227 Press gear from 2nd shaft Use bearing puller to remove clutch hub and front bearing Figure 225 Figure 228 Remove gear retaining ring Remove clutch shaft front bearing T16000 11 96 9 43 CLARICHURTH Disassembly 2nd clutch drum INGERSOLLRAND Figure 229 Figure 232 Remove bearing washer Remove clutch hub inner bearing Figure 230 Figure 233 Remove clutch hub and outer bearing Remove backing plate snap ring Figure 231 Figure 234 Use a bearing puller to remove clutch hub inner Remove backing plate bearing T16000 11 96 9 44 CLARICHURTH Disassembly 2nd clutch drum INGERSOLLRAND Figure 235 Figure 238 Remove modulation spring Remove one outer half disc Figure 236 Figure 239 Remove one outer half disc Compress spring to remove spring retaining ring Figure 237 Figure 240 Remove inner and outer discs Remove spring retaining ring T16000 11 96 9 45 Disassembly 2nd clutch drum Figure 241 Remove spring retainer Figure 242 Remove clutch piston return spring Figure 243 Remove piston wear plate T16000 CLARK HURTH INGERSOLLRAND 11 96 Figure 244 Remove clutch piston assembly CLARK HURTH Resassembly 2nd clutch drum INGERSOLLRAND Figure 245 Figure 248 Install piston outer seal Note Ring must be Install piston return spring sized before installing in clutch drum Sizing is best accomplished
49. assembly forward low clutch INGERSOLLRAND Figure 95 Remove clutch piston spring Figure 96 Remove clutch piston wear plate Figure 97 Remove clutch piston assembly T16000 11 96 9 19 Reassembly forward low clutch Figure 98 Install clutch piston outer seal Note Ring must CD be sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 99 Install clutch piston inner seal Install clutch piston in clutch drum use Caution as not to damage sealing rings D Figure 100 Install clutch piston wear plate on piston 116000 11 96 CLARK HURTH INGERSOLLRAND Figure 101 Install clutch piston spring Figure 102 Install clutch piston spring retainer Figure 103 Install clutch spring retainer snap ring CLARICHURTH Reassembly forward low clutch INGERSOLLRAND Figure 104 Figure 107 Use a sleeve with the proper diameter to fit over shaft Install one outer half disc with friction material down and against retainer ring A sharp blow with a shoft hammer will compress spring and seat retainer ring Be sure ring is in full
50. ate discs until the proper amount of discs are installed First and last discs are steel Figure 212 Figure 215 Install one outer half disc with friction material down Install backing plate snap ring T16000 11 96 9 40 CLARICHURTH Reassembly first clutch INGERSOLLRAND Figure 216 Figure 219 Install clutch disc hub inner bearing Install clutch hub outer bearing Be sure that bearing shield is on the outside Figure 217 Figure 220 Tap inner bearing into place Tap outer bearing into clutch hub Figure 218 Figure 221 Install clutch hub bearing locating rings Install clutch Install outer bearing retaining ring gear in clutch drum Align splines on clutch gear witch internal teeth of steel discs Do not force this operation Gear splines must be in full position with internal teeth of all steel discs T16000 11 96 9 41 CLARICHURTH Reassembly first clutch INGERSOLLRAND Figure 222 Install clutch shaft sealing rings T16000 11 96 9 42 CLARICHURTH Disassembly 2nd clutch drum INGERSOLL RAND Figure 223 Figure 226 Press upper output gear from 2nd shaft Remove clutch shaft se
51. by rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 246 Figure 249 Install clutch piston inner seal D Install spring retainer Install clutch piston in clutch drum Use caution as not to damage sealing rings Figure 247 Figure 250 Install piston wear plate Install spring retainer snap ring T16000 11 96 9 47 Resassembly 2nd clutch drum Figure 251 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress spring and seat retainer ring Be sure ring is in full position in groove Figure 252 Install one outer half disc with friction material away from the piston Figure 253 Install one steel disc Alternate friction and steel discs until the proper amount of discs are installed First and last discs are steel T16000 11 96 CLARK HURTH INGERSOLLRAND Figure 254 Install one outer half disc with friction material down Figure 255 Install modulator spring with large diameter up to the backing plate Figure 256 Install backing plate CLARK HURTH Resassembly 2nd clutch drum INGERSOLLRAND Figure 257 Figure 260 Install backing plate retainer ring Install clutch hub bearing locating rings Install clutch gear in clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force
52. d turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication in function of the balding impeller turbine and reaction member and the converter output speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing In the impeller cover a splined shaft is fitted which runs inside and through the turbine shaft to drive a hydraulic pump which is fitted at the back of the transmission Since the shaft is connected to the centre of the impeller cover the pump speed will be the same as engine speed The rear side of the impeller cover has a tanged drive which drives the transmission charging pump located in the converter housing The transmission charging pump speed is also the same as the engine speed
53. dle bearing Figure 135 Figure 138 Install backing plate spacer retainer ring Install clutch gear in clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs Figure 136 Figure 139 Install thrust washer and thrust bearing Install clutch gear outer needle bearing T16000 11 96 9 20 CLARK HURTH Reassembly forward high clutch INGERSOLLRAND Figure 140 Install thrust washer and thrust bearing Figure 141 Install clutch shaft sealing rings T16000 11 96 9 27 CLARICHURTH Disassembly first clutch INGERSOLLRAND Figure 142 Figure 145 Remove clutch shaft sealing rings Clutch gear and outer bearing removed Figure 143 Figure 146 Remove clutch gear bearing retainer ring Remove backing plate retainer ring Figure 144 Figure 147 Use a bearing puller to remove clutch gear and outer Remove backing plate bearing T16000 11 96 9 28 CLARICHURTH Disassembly first clutch INGERSOLLRAND Figure 148 Figure 151 Remove modulation spring Remove one outer half disc Figure 149 Figure 152 Use beari
54. e 42 Using bearing puller to remove reverse and 1st shaft Using bearing puller to remove forward low and rear bearing forward high shaft rear bearing T16000 11 96 9 8 Disassembly T16000 transmission Figure 43 Forward low and forward high shaft rear bearing removed Figure 44 Use bearing puller to remove forward high gear from the input shaft Figure 45 Forward high gear removed T16000 CLARK HURTH INGERSOLLRAND Figure 46 Remove baffle plates screws remove baffle plates Figure 47 Remove oil baffle to converter housing Screws do not remove oil baffle from output shaft il a uM ftl Figure 48 Remove output shaft 2nd shaft and oil baffle m at the same time CLARICHURTH Disassembly T16000 transmission INGERSOLL RAND i 7 Figure 49 Figure 52 Loosen suction tube retainer screw Remove suction tube O ring and washer Figure 50 Figure 53 Remove suction tube retainer screw and lockwasher Remove output shaft front bearing retainer ring Figure 51 Figure 54 Remove suction tube retainer ring Remove output shaft front assembly T16000 11 96 9 10 CLARICHURTH Disassembly T16000 transmission INGERSOLLRAND Figure 55 1 Remove input shaft reverse and forward ES shaft at the same time Figure 56 Remove safety valve plug spring and ball
55. e drive plate locating stud 7 Install drive plate attaching screw and washer Snug screw but do not tighten Some engine fivwheel housings have a hole located on the flywheel housing circumference in line with the SPECIAL STUD WASHER AND drive plate screw access hole A screwdriver or SELF LOCK NUT FURNISHED pry bar used to hold the drive plate against the a flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed torque one 26 to 29 Ibft torque 35 39 Nm This will require tightening each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened to specified torque IMPELLER COVER INTERMEDIATE H DRIVE PLATES 8 Measure engine crankshaft end play after transmission has been completely installed on engine flywheel This value must be within 001 0 025 mm of the end play recorded in step No 2 Does not apply to units having 3 intermediate drive plates See fig 4 T16000 11 96 4 2 CLARK HURTH INGERSOLLRAND C EXTERNAL PLUMBING To cooler from converter Transmission cooler gt
56. e operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications T16000 11 96 6 1 CLARICHURTH Troubleshooting guide INGERSOLLRAND Hydraulic check Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the converter and its fluid circuit lines must be fully charged filled at all times See NOTE below A NOTE The transmission fluid must be at operating temperature of 82 93 C 180 200 F to obtain correct fluid level and pressure readings DO NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with converter at stall Refer to converter stall procedure A CAUTION Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall R P M A CONVERTER STALL PROCEDURE 1 Put the vehicle against a solid barrier such as a wall and or apply the parking brake and block the wheels 2 Put the directional control lever in FORWARD or REVERSE as applicable 3 Select the highest speed With the engine running slowly increase engine speed to app
57. f disconnect are in full position Using caution as not to damage any of the lower shaft sealing rings T16000 11 96 CLARK HURTH INGERSOLLRAND Figure 353 Install baffle plate mounting screws washers and nuts Tighten nuts to specified torque Use Loctite 243 ax Figure 354 Install baffle plate mounting screws washers and nuts Tighten nuts to specified torque Use Loctite 243 Figure 355 Install oil baffle mounting screws and washers Tighten screws to specified torque Use Loctite 243 CLARICHURTH Reassembly converter housing INGERSOLLRAND Figure 356 Figure 359 Install O ring spacer and snap ring on Install output shaft rear bearing retaining ring suction tube Install suction tube into housing Be sure ring is in groove FN Figure 357 Figure 360 Install suction tube retainer mounting screw and Warm forward high gear to 150 C 302 F lockwasher Use Loctite 243 install gear Figure 358 Figure 361 Tighten mounting screw to specified torque Warm upper output rear bearing to 120 C 248 F install bearing T16000 11 96 9 59 CLARICHURTH Reassembly converter housing INGERSOLLRAND Figure 362 Figure 365 Warm reverse and 1st shaft rear bearing to 120 C Warm lower output shaft rear bearing to 120 C 248 F install bearing 248 F install bearing Figure 363 Figure 366 Warm input shaft rear bearing to 120 C 248 F Install ou
58. gure 378 Install upper output flange O ring washer and nut and tighten nut to 339 407 Nm 205 300 Ibft rg ji uc e A N j 2 d Figure 379 Install pump drive shaft assembly into housing CLARICHURTH Reassembly T16000 transmission INGERSOLLRAND Figure 380 Figure 383 Install pump drive shaft rear bearing retaining ring Install pump and O ring into converter housing Figure 381 Figure 384 Install pump hole cover gasket screws and Install pump mounting screws and lockwashers lockwashers and tighten screws to specified torque i j LASA Figure 382 Tighten pump hole cover screws to specified torque Figure 385 Install convertor assembly on input shaft T16000 11 96 9 73 CLARICHURTH Reassembly T16000 transmission INGERSOLLRAND Figure 386 Figure 389 Install drive plates on converter Tighten screws to specified torque Figure 387 Figure 390 Install drive plates screws and lockwashers Install oil filter and tighten to 30 38 Nm and tighten screws to specified torque 22 1 28 Ibft Figure 388 Figure 391 Install filter adapter O ring lockwashers and Instal output shaft front flange O ring mounting screws washer and nut Tighten nut to 339 407 Nm 250 300 Ibft T16000 11 96 9 74 CLARK HURTH Reassembly T16000 transmission INGERSOLLRAND Figure 392 Figure 39
59. ing to transmission case 2 15 Gasket converter housing to tranmission case 1 16 Housing converter 1 17 Lockwasher converter housing to transmission case screw 14 18 Screw converter housing to transmission case 14 19 ring filter adaptor 1 20 ring filter adaptor 1 21 Filter adaptor 1 22 Lockwasher filter adaptor screw d 2d Screw filter adaptor 3 24 Assembly filter 1 25 Oil seal output shaft front 1 26 Screw converter housing to transmission case 1 27 Lockwasher converter housing to transmission case screw 1 28 Screw converter housing to transmission case 5 29 Lockwasher converter housing to transmission case screw 5 30 Clip suction tube 1 31 Lockwasher suction tube screw 1 32 Screw suction tube 1 33 O ring suction tube 1 34 Retainer suction tube 1 39 Assembly tube amp screen 1 36 Baffle oil 1 37 Lockwaher oil baffle mountng screw 3 38 Screw oil baffle mounting 3 39 Nut oil baffle mounting screw 5 40 Lockwasher oil baffle mounting screw 5 41 Baffle oil 1 42 Screw oil baffle mounting 5 43 Plate oil baffle 1 44 Plate oil baffle 1 45 Pin transmission case to converter dowel 2 46 Lockwasher converter housing to transmission case screw 4 47 Screw converter housing to transmission case 4 48 Case transmission 1 49 O ring plug 1 T16000 11 96 7 3 CLARK HURTH INGERSOLLRAND GROUP CONVERTER HOUSING amp TRANSMI
60. ith solvent FLYWHEEL HOUSING MOUNT 2 Check engine flywheel amp housing for DIAL INDICATOR conformance to standard SAE No 3 per SAE J927 and J1033 tolerance specifications for pilot bore size pilot bore runout and mounting face ENGINE flatness Measure and record engine crankshaft end play FLYWHEEL mE PILOT BORE 3 Install two 2 50 63 500 mm long transmission to flywheel housing guide studs in the engine flywheel housing as shown Rotate the engine FLYWHEEL flywheel to align a drive plate mounting screw hole with the flywheel housing access hole 54 Install a 4 00 101 60 mm long drive plate locating stud 3750 24 fine thread in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 Locate transmission on flywheel housing FLYWHEEL HOUSING CONVERTER HOUSING 4 STUD Aligning drive plate to flywheel and transmission to flywheel housing guide studs install transmission to flywheel housing screws Tighten screws to specified torque Remove transmission to engine guide studs Install remaining screws FLYWHEE of DRIVE and tighten to specified torque 2 ALIGNING STUDS i 6 Remov
61. lamping force of the clutch gradually 4 The output section With a range clutch engaged power is finally transmitted to the output shafts The T16000 transmission can have an upper output or lower output at the rear side of the unit and a lower output at the front side Output rotation of the rear upper output is opposite the engine rotation when the forward clutch is engaged while output rotation of the lower rear output and the front output is the same as the engine rotation with the forward clutch engaged Ration between upper and lower output is 0 951 1 The lower front output has an axle disconnect clutch to enable 4 wheel drive The clutch is similar as the other clutches except that it has no modulation The disconnect is controlled electronically Without an electrical signal the clutch is always engaged Ug
62. ng puller to remove clutch gear inner Remove inner and outer discs bearing Figure 150 Figure 153 Clutch gear inner bearing removed Remove one outer half disc T16000 11 96 9 29 CLARICHURTH Disassembly first clutch INGERSOLLRAND Figure 154 Figure 157 Compress clutch piston belleville washer spring Remove clutch piston wear sleeve Remove spring snap ring AN Note Force of disc spring is 3 280N LS Figure 155 Figure 158 opring retainer ring removed Remove clutch piston assembly Figure 156 Remove disc belleville washer spring T16000 11 96 9 30 CLARICHURTH Disassembly reverse clutch INGERSOLLRAND Figure 159 Figure 162 Use a bearing puller to remove gear and front Use a bearing puller to remove clutch gear and bearing clutch gear outer bearing Figure 160 Figure 163 Gear and front bearing removed Clutch gear and outer bearing removed Figure 161 Figure 164 Remove clutch gear bearing retaining ring Hemove spacer snap ring T16000 11 96 9 91 CLARICHURTH Disassembly reverse clutch INGERSOLL RAND Figure 165 Figure 168 Remove spacer Use a bearing puller to remove clutch gear inner bearing Figure 166 Figure 169 Remove backing plate retaining ring Clutch gear inner bearing removed Figure 167 Figure 170 Remove clutch disc backing plate Remove one outer half disc T16000 11
63. nsafe It is also important to understand that these Cautions and Notices are not exhaustive because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions T16000 11 96 CLARK HURTH INGERSOLLRAND CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned A CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapours when using solvent type cleaners BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearing to avoid spinning Do not spin bearings when drying Bearings may be rotated slowly by hand to facilitate drying process HOUSINGS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will
64. omplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter elements cleaning out filter cases thoroughly 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes 5 Reassemble all components and use only type oil recommended for lubrication section Fill transmission through filler opening until fluid comes up to the oil level check port Run engine 2 minutes at 500 600 R P M to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 R P M Add quantity necessary to bring fluid level to oil level check port Hecheck with hot oil 180 200 F 82 93 C 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary T16000 11 96 3 2 CLARK HURTH Maintenance INGERSOLLRAND D INSTRUCTIONS FOR LINING REPLACEM
65. position in groove lia P Figure 105 Figure 108 Install one outer half disc with friction material away Install backing plate from the piston Figure 106 Figure 109 Install one steel disc Alternate friction and steel Install backing plate snap ring discs until the proper amount of discs are installed First and last discs are steel T16000 11 96 9 21 CLARICHURTH Reassembly forward low clutch INGERSOLLRAND Figure 110 Figure 113 Install spacer Install clutch gear inner bearing Figure 111 Figure 114 Install spacer snap ring Tap inner bearing into place Figure 112 Figure 115 Install inner bearing snap ring Install clutch gear bearing locating rings T16000 11 96 9 22 CLARICHURTH Reassembly forward low clutch INGERSOLLRAND Figure 116 Figure 119 Install clutch gear sealing ring Install clutch gear in Install outer bearing snap ring clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs Ste Figure 117 Figure 120 Install clutch gear outer bearing Warm gear to 150 C 302 F install gear Be sure that bearing shield is on the outside Figure 118 Figure 121 Tap outer bearing into place Warm front bearing to 120 C 248 F install bearing T16000 11 96 9 23 CLARK HURTH Reassembly forward high clutch INGERSOLLRAND Figure 122 Figure 125
66. r adapter with O ring Remove torque converter as an assembly L T16000 11 96 9 2 CLARICHURTH Disassembly T16000 transmission INGERSOLLRAND Figure 7 Figure 10 Remove charging pump screws Remove parking brake mounting screws Figure 8 Figure 11 t Use a bearing puller to remove charging pump Remove parking brake as an assembly L Figure 9 Figure 12 Hemove charging pump as an assembly bil Remove upper output nut washer O ring and flange remove O ring 116000 11 96 gu CLARK HURTH Disassembly T16000 transmission INGERSOLLRAND Figure 13 Figure 16 Remove air breather Remove control valve protection cover and gasket Figure 14 Figure 17 Remove control valve protection cover mounting Remove control valve mounting screws Screws mma gr al Figure 15 Figure 18 C Remove wiring connector mounting nut Remove control valve as an assembly remove 4 bypass valve spool and spring in the meantime T16000 11 96 9 4 CLARICHURTH Disassembly T16000 transmission INGERSOLL RAND Figure 19 Figure 22 Remove auxiliary pump hole cover screws Remove pump drive shaft and bearing as an L assembly Figure 20 Figure 23 Remove auxiliary pump hole cover and gasket Hemove upper output nut washer O ring and flange d a 4 li m Figure 21 Figure 24 Hemove pump drive shaft rear bearing locating ring Remove converter housing to transmission case screws and lockwashers
67. ring retainer snap ring T16000 11 96 2535 CLARICHURTH Reassembly reverse clutch INGERSOLLRAND K Figure 186 Figure 189 Use a sleeve with the proper diameter to fit over shaft Install one outer half disc with friction material down and against retainer ring A sharp blow with a soft hammer will compress spring and seat retainer ring Be sure ring is in full position in groove Figure 187 Figure 190 Install one outer half disc with friction material away Install backing plate from the piston Figure 188 Figure 191 Install one steel disc Alternate friction and steel Install backing plate snap ring discs until the proper amount of discs are installed First and last discs are steel T16000 11 96 9 36 CLARK HURTH Reassembly reverse clutch INGERSOLL RAND Figure 192 Figure 195 Install spacer Install clutch gear inner bearing Figure 193 Figure 196 Install spacer snap ring Tap inner bearing into place Figure 194 Figure 197 Install inner bearing snap ring Install clutch gear bearing locating rings T16000 11 96 9 37 Reassembly reverse clutch Figure 198 Install clutch gear sealing ring Install clutch gear in clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs Figure 199 Install clutch gear outer bearing A Be sure that bearing shield is on the o
68. roximately one half throttle and hold until transmission converter outlet oil temperature reaches the operating range A CAUTION Do not operate the converter at stall condition longer than 30 seconds at one time shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached Excessive temperature 120 C 250 F maximum will cause damage to transmission clutches fluid converter and seals T16000 11 96 6 2 Troubleshooting guide TROUBLESHOOTING GUIDE CLARK HURTH INGERSOLLRAND Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles LOW CLUTCH PRESSURE CAUSE 1 Low oil level 2 Clutch pressure regulating valve stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings LOW CHARGING PUMP OUTPUT CAUSE 1 Low oil level 2 Suction screen plugged 3 Defective charging pump OVERHEATING CAUSE 1 Worn oil sealing rings 2 Worn charging pump 3 Low oil level 4 Dirty oil cooler 5 Restriction in cooler lines NOISY CONVERTER CAUSE 1 Worn charging pump 2 Worn or damaged bearings LACK OF POWER CAUSE 1 Low engine R P M at converter stall 2 See Overheating and make same checks T16000 11 96 REMEDY 1 Fill to proper level 2 Clean valve spool and housing 3 Replace pump 4 Replace sealing rings REMEDY 1 Fill to proper level 2 Clean section pump 3 Replace pump REMED
69. ssure neutral 2nd speed port 31 at 600 RPM min 16 5 bar 239 PSI at 2200 RPM 19 6 23 1 bar 284 335 PSI e Pump flow at 2200 RPM in neutral 2nd speed 64 9 l min minimum 17 1 GPM at 2200 RPM in reverse 1st 2 nd forward 1st 2nd maximum 3 l min 0 8 GPM less than in neutral 2nd at 2200RPM in forward 3rd and 4th maximum 5l min 1 3 GPM less than in neutral 2nd Clutch pressures 1st clutch port 41 2nd clutch port 42 forward high clutch port 44 forward low clutch port 45 reverse clutch port 46 disconnect clutch port 47 at 2200 RPM 18 1 21 5 bar 263 312 PSI clutch activated 0 0 2 bar 0 3 PSI clutch released Filter bypass valve set at 4 1 5 bar 59 73 PSI measured between port 31 and 35 Lube pressure port 33 0 3 0 5 bar 4 3 7 3 PSI at 47 l min 12 4 GPM pump flow 1800 RPM e Internal leakage 1 5 3 0 l min 0 4 0 8 GPM for each clutch Max total leakage 6 8 l min 1 8 GPM clutch leakage dir range converter leak valve leak without disconnect clutch e Safety valve cracking pressure 9 5 10 5 bar 138 152 PSI measured at port 34 cooler converter out pressure port 32 2 bar min 29 PSI at 2000 RPM and max 5 bar 73 PSI at no load governed speed Converter by pass valve set at 5 7 bar 73 102 PSI measured bet
70. the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit When the clutch is released a return spring will push the piston back and oil will drain back via the control valve into the transmission sump The T16000 transmission has one reverse clutch and two forward clutches forward low and forward high This in combination with the two range clutches result in the transmission having 4 forward speeds and 2 reverse speeds The engagement of the directional clutches is modulated which means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive The modulation is controlled electronically in the control valve
71. the transmission sump Across the converter and oil cooler is a converter by pass valve which will open if the pressure difference is higher than 4 bar 58 PSI during start up from cold or at high RPM T16000 11 96 gez CLARK HURTH Operation of the unit INGERSOLLRAND B THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies 1 L The converter and pump drive section 2 B The input or directional clutches E The range clutches d The output section D Xp The transmission controls T16000 11 96 S CLARK HURTH Operation of the unit INGERSOLLRAND 1 The converter and pump drive section Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump in that it picks up fluid at its centre discharges at its outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft or directional clutch shaft This element receives fluid at its outer diameter and discharges at its centre The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller an
72. ther loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lip of seal seriously impairs its efficiency When assembling new metal type sealing rings same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recommended type Automatic Transmission Fluid before assembly GEARS AND SHAFTS If magna flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or splines twisted and that shafts are true HOUSING COVERS ETC Inspect housings covers and bearing caps to be certain they are thoroughly clean and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures Legend symbols Smontaggio di sottogruppi Disassembly of assembly groups Montaggio di sottogruppi Reassemble to from assembly group Sostituire con ogni montaggio Renew at e
73. ting and adjustments it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Clark Hurth Components approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Clark Hurth Components does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied by or approved by Clark Hurth Components A Important Always furnish the Distributor with the serial and model number when ordering parts T16000 11 96 TABLE OF CONTENTS Foreword Safety precautions Cleaning and inspection legend symbols Technical specifications Identification of the unit Weight oil capacity dimensions Tightening torques Pressure and temperature specifications Electrical specifications Hydraulic cooler lines cn OG OO Maintenance a Oil specification b Maintenance intervals c Servicing machine after components overhaul d Parking brake adjustment Installation details a Converter drive coupling b Components to engine installation c External plumbing Operation of the unit Hydraulic circuit Transmission assembly Electric solenoid control Power flows Gear and clutch lay out ooocp Troubleshooting
74. tion material 1 side with outer splines Start with one 1 side friction plate metal against piston then alternately separator and friction plate End with a 1 side friction plate metal side against end plate or disc spring Be sure disc spring is mounted as shown Clearance Forward low and Reverse min clearance 2 79 mm max clearance 5 21 mm If clearance is more than 4 79 mm add one separator plate upon last separator plate for carbon plates Clearance First and second min clearance 2 54 mm max clearance 5 41 mm If clearance is more than 4 54 mm add one separator plate upon last separator plate for carbon plates gt Fh clutch 4 separator plates 3 friction plates and two 1 side friction plates Assembly see gt Clearance min clearance 1 24 mm nac dearnose Arm Kran gt Disconnect clutch 12 separator plates 11 friction plates and two 1 side friction plates Assembly see b Clearance min clearance 3 66 mm max clearance 6 78 mm If clearance is more than 5 66 mm add one separator plate upon last separator plate for carbon plates A CAUTION Installation force of disc spring is 3280 Be sure that shielded and sealed bearings are mounted as shown Seals must be pressed in perpendicular upon shaft axis from bearing side Except lower rear output VVV V Plug to be screwed in and torqued but without Loctite T16000 11 96 9 2 y CLARK HURTH I
75. tput shaft rear bearing retaining ring install bearing b ort E die MN 2 Figure 364 Figure 367 Warm forward low and high shaft rear bearing to Install gasket and clutch pressure O rings 4 120 C 248 F install bearing into O ring grooves T16000 11 96 9 70 CLARICHURTH Reassembly T16000 transmission INGERSOLLRAND Figure 368 Figure 371 Hemove lower output bore plug Position Install transmission case to converter transmission case on converter housing 101 housing mounting screws and lockwashers using lifting bracket Tighten mounting screws to specified torque 1 i Sa i a u z ta KA i Figure 369 Figure 372 Using spreading type snap ring pliers spread ears Using spreading type snap ring plier spread ears on output on output shaft rear bearing retaining ring Holding shaft rear bearing retaining ring Hold snap ring open pry or snap ring open Tap transmission case into place lift output shaft Be sure retaining ring is complete in bearing groove Using a lifting eye or screw M12 Figure 370 Figure 373 Tap dowel pin in transmission case and converter Install hole plug and gasket housing T16000 11 96 9 71 Reassembly T16000 transmission Tighten plug to 13 6 20 3 Nm 10 15 Ibft Position lower output bore plug and tap bore plug Position upper output seal CLARK HURTH INGERSOLLRAND Figure 377 Tap seal into place Fi
76. two 2 kits have 2 intermediate drive plates and one 1 drive plate and weld nut assembly Two 2 kits with three intermediate drive plates 1 DRIVE PLATE AND WELD NUT ASSEMBLY BOLT CIRCLE DIA BOLT CIRCLE DIA BACKING RING 2 INTERMEDIATE DRIVE PLATES BACKING RING 3 INTERMEDIATE DRIVE PLATES A Dimension Bolt circle diameter A Dimension Bolt circle diameter 13 125 333 38 mm diameter 13 125 333 38 mm diameter Kit No 802424 Kit No 802426 e 13 500 342 90 mm diameter e 13 500 342 90 mm diameter Kit No 802425 Kit No 802427 Each kit will include the following parts Kit will include the following parts e 2 Intermediate drive plates e Intermediate drive plates 1 Drive plate and weld nut assembly e 1 Backing ring e 1 Backing ring 6 Mounting screws e G Mounting screws e 6 Lock washers e Lock washers e 1 Instruction sheet 4 1 Instruction sheet Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter Align intermediate drive plates and backing ring with holes in torque converter assembly A Note Two dimples 180 apart in backing ring must be out Toward the engine flywheel Install cap screws and washers Tighten 26 to 29 Ibft torque 35 39 Nm T16000 11 96 4 1 CLARK HURTH INGERSOLLRAND B TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1 Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface w
77. uid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components TROUBLESHOOTING PROCEDURES Stall Test Use a stall test to identify transmission converter or engine problems Transmission pressure checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure may also be measured Mechanical and electrical checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and electrical checks should be made e Check the parking brake for correct adjustment e Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points The controls are actuated electrically Check the wiring and electrical components Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary e he engine must b
78. utside Figure 200 Tap outer bearing into place T16000 11 96 CLARK HURTH INGERSOLLRAND Figure 201 Install outer bearing snap ring Figure 202 Warm gear to 150 C 302 F install gear Figure 203 Warm front bearing to 120 C 248 F install bearing CLARICHURTH Reassembly first clutch INGERSOLLRAND Figure 204 Figure 207 Install clutch piston outer seal Note Ring must CD Install piston return disc springs First spring with be sized before installing in clutch drum Sizing is best large diameter of bevel toward wear sleeve accomplished by rotating piston while holding a round object Alternate eleven 11 springs against the new sealing ring Rotate piston until sealing ring is flush with outer diameter of piston Figure 205 Figure 208 Install piston inner seal Install clutch piston CD Install disc belleville washer spring retainer ring in clutch drum Use caution as not to damage sealing rings Figure 206 Figure 209 Install clutch piston wear sleeve Compress spring to install spring retainer ring Be sure ring is in full position in groove T16000 11 96 3 39 CLARICHURTH Reassembly first clutch INGERSOLLRAND Figure 210 Figure 213 Install one outer half disc with friction material away Install modulation spring with large diameter up to from the piston the backing plate Figure 211 Figure 214 Install one steel disc Alternate friction and steel Install backing pl
79. ween port 33 and 34 All pressures and flows to be measured with oil temperature of 82 93 C 180 200F Refer to section troubleshooting for check port identification T16000 11 96 2 3 CLARICHURTH Technical specifications INGERSOLLRAND E ELECTRICAL SPECIFICATIONS e Solenoid forward reverse high low 2nd 1st modulation disconnect coil resistance 28 Q 2 Q 20 C e Electronic controlled modulation valve coil resistance 3 55 Ohm 0 25 Ohm at 20 C 68F e Speed sensor type magneto resistive sensor with 7 14 mA current loop frequency 0 25000 Hz sensing distance 0 2 5 mm Temperature sensor in speed sensor resistance versus temp see table Hesistance Hesistance F HYDRAULIC COOLER LINES SPECIFICATIONS e Minimum 19 mm internal diameter for lines and fittings e Suitable for operation from ambient to 120 C continuous operating temperature e Must withstand 20 bar continuous pressure and with 40 bar intermittent surges Conform SAE J1019 and SAE J517 100RI T16000 11 96 2 4 CLARK HURTH INGERSOLLRAND MAINTENANCE A OIL SPECIFICATION ATF oil only which meets following specifications ATF Elfmatic G3 A MAINTENANCE INTERVALS Daily Check oil level daily with engine running at idle 600 RPM and oil at 82 93 180 200 F Maintain oil level at full mark Normal drain period Normal drain period and oil filter change are for average

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