HM D 23000 Series Transmission
Contents
1. 201 10MAYOS 05 6 HMD 23000 Series Transmission 051105 PN 12 Group 10 Ganaral Information Specification 10 1 Measurement Specification Oil Specifications Maximum operating oil Temperature 107 C 225 F temperature Oil First time fill Approximately 3 quarts Oil type Recommended Lubricants Must conform to MIL L 2105C or API GL 5 specifications Oil change First time After 500 hours Normal operating conditions Every six months of operation Ambient temperature 23 C 10 F 75W Ambient temperature 22 C 37 C 10 F 100 F 80W 90W Ambient temperature Above 37 C Above 100 F 85W 140W Input adapter cap Torque 144 Nem 106 lb ft screw to housing DPSG YZ07927 181 19 245 99 1 1 Abbreviations and Acronyms CTM Component Technical Manual HMD Hydraulic Motor Driven Attn Attention Spec Specification C Degrees Celsius 1 unit is 1 100th of the difference between the temperature of melting ice and boiling water at standard temperature and pressure e F Degrees Fahrenheit 1 unit is 1 80th of the difference between the temperature of melting ice and boiling water at standard temperature and pressure FEPM Funk Engineering Procedures Manual RTV Room Temperature Vulcanizing DPSG YZ07927 209 19 200 99 1 1 CTM201 10 05 10 1 HMD 23000 Series Transmission 051105 PN 132. General Information Parts Ordering Instructions Should repair parts be required please specify the model specification and serial numbers of your unit as well as the name and number of the parts accompanying your purchase order This information tag is attached to your unit You may write to Funk Manufacturing Company Attn Parts Department Industrial Park Hwy 169 N P O Box 577 Coffeyville KS 67337 0577 or Telephone e Area Code 316 251 3400 or 800 844 1337 Ask for Customer Service Representative Fax 316 252 3252 FUNK MANUFACTURING COMPANY MODEL S JO COFFEYVILLE KANSAS U S A YZ1503 01 98 Identification Tag DPSG YZ07927 195 19 285 99 1 1 Description The series 23000 is a three or four speed non syncronized mechanical shift transmission The gear ranges are selected by means of sliding shift collars The power from the engine is transmitted to the series 23000 by means of drive line components or a hydrostatic transmission 0 86 207927 182 19 245 99 1 1 CTM201 10 05 10 2 HMD 23000 Series Transmission 051105 PN 14 General Information Operation Like all mechanical equipment the 23000 will need oil cleanliness The type of service and operating attention and servicing Routine checks will help conditions shall determine the maintenance interval prevent down time Beca
3. Lock washer 1 Mount the brake band anchor 5 with cap screws 8 Slide brake band 13 over drum 1 and lock washers 7 8 in the center holes at the 9 Insert anchor spring 16 between brake band right edge of the rear face of the transmission anchor 5 and brake band Install anchor bolt 17 gt housing abut do not completely tighten 2 Mount the brake bracket 6 with cap screws and 10 Insert a brake adjustment spring 21 on each side lock washers 7 8 in the center holes at the left of the brake bracket 6 Install brake adjustment edge of the rear face of the transmission housing bolt lock washer and jam nuts 18 19 20 do not 3 Mount the brake link anchor 9 with a bolt nut and fully tighten at this point lock washer 10 11 12 in the upper left corner of 11 Install screw lock washer and jam nuts the rear face of the transmission housing The 22 23 24 brake link anchor 9 must be installed so that the 12 With the transmission in neutral rotate the brake tab points toward the input end of the transmission drum 1 at the same time tightening the anchor 4 Mount the brake drum 1 on the output flange with bolt 17 until a slight drag is felt Secure the bolt four bolts nuts and lock washers 2 3 4 by wiring through the head and brake band 5 Remove brake adjustment bolt adjustment springs 13 Continue rotating the brake drum tighten screw jam nuts and lock washer 18 19 20 21 24 until a slight drag on the
4. TS220 UN 23AUG88 19 23AUG88 1 1 Work in Clean Area Before starting a job Clean work area and machine Make sure you have all necessary tools to do your job Have the right parts on hand Read all instructions thoroughly do not attempt shortcuts e T6642EJ UN 18OCT88 DX CLEAN 19 04JUN90 1 1 Illuminate Work Area Safely Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed by a wire cage The hot filament of an accidentally broken bulb can ignite spilled fuel or oil 75223 UN 23AUG88 DX LIGHT 19 04JUN90 1 1 Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual TS226 UN 23AUG88 DX LIFT 19 04JUN90 1 1 201 10MAYOS 05 2 HMD 23000 Series Transmission 051105 PN 8 Safety Use Proper Tools Use tools appropriate to the work Makeshift tools and procedures can create safety hazards Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches Use only service parts meeting John Deere specifications Using
5. 111 82 117 9 16 12 144 106 149 9 16 18 160 118 5 8 18 165 316 233 3 4 10 258 365 3 4 16 7 8 9 mug 408 589 7 8 14 460 649 1 8 848 625 1199 884 1 12 928 684 1312 967 Applies to non lubricated plain or zinc plated fasteners 151162 19 04 91 DPSG YZ07927 20 19 11MAY99 1 1 201 10MAYOS 10 9 HMD 23000 Series Transmission 051105 21 General Information Suggested Wrenching Torque Pipe Thread For Tapered FEPM TORQUE SPECIFICATIONS 14 4 TAPERED PIPE THREAD WITH SEALANT CHART Thread Size m Nem 1 16 27 UNF 1 8 27 UNF 1 4 18 UNF 3 8 18 UNF 1 2 14 UNF 3 4 14 UNF 60 45 1 11 1 2 UN 75 55 1 1 4 11 1 2 UN 95 70 1 1 2 11 1 2 UN 110 80 2 11 1 2 UN 130 95 FEPM TORQUE SPECIFICATIONS 14 4 TAPERED PIPE THREAD WITHOUT SEALANT CHART 1 1 16 27 UNF 20 1 8 27 UNF 25 1 4 18 UNF 35 3 8 18 UNF 45 3 4 14 UNF 75 1 11 1 2 UN 90 1 1 2 11 1 2 UN 130 2 11 1 2 UN 160 SUGGESTED WRENCHING TORQUE FOR TAPERED PIPE THREAD charts meet Funk Engineering Procedures Manual Torque Specifications FEP 14 4 201 10 5 10 10 Ib ft DPSG YZ07927 8 19 30 99 1 1 HMD 23000 Series Transmission 051105 PN 22 Group 15 Major Component Groups O
6. D 4 To assemble reverse the disassembly procedure 2 Drive the input shaft D from inside the adapter housing B outward 5 207927 189 19 275 99 1 1 201 10 05 25 1 HMD 23000 Series Transmission 051105 PN 27 Shift Cap Group Shift Cap Assembly cocking 2 140 799 YZ0052 Locking Shift Cap Continued on next page DPSG YZ07927 191 19 275 99 1 2 201 10MAYOS 30 2 HMD 23000 Series Transmission 051105 PN 30 Shift Cap Group 1 Shift cap 10 Expansion plug 2 Shift lever 11 3 Cotter pin 12 Switch 4 Clevis pin 13 Shift shaft 5 Shift fork 14 6 Detent bail 15 Spacer 7 Detent spring 16 Washer 8 Shaft rail 17 9 Roll pin LOCKING HMD MODELS 2315 2325 and 2326 1 Remove cap 22 035 Extract spring 26 and piston 25 O ring 27 and 28 will come out with piston Remove switch 12 and washer 32 Remove roll pins 9 Dislodge one expansion plug 10 with a punch Drive the shaft rail 8 to dislodge the other expansion plug 10 A CAUTION When removing the rail the opening in the shift fork should be shielded as the detent spring 7 will propel the detent ball 6 18 26 Spring 19 27 20 Plug 28 21 29 22 Cap 30 23 31 24 32 Washer 25 Piston 33 Spring washer 7 Ro
7. drum is felt The 6 Remove anchor bolt and anchor spring 16 17 same procedure is to be used on the brake 7 Remove screw jam nuts and lock washer adjustment bolt 18 22 23 24 14 Tighten jam nuts 19 22 DPSG YZ07927 201 19 07 99 2 2 201 10 05 45 3 HMD 23000 Series Transmission 051105 PN AK Index Page Page A Abbreviation Oil 651 ee AC hs ag REOR 10 1 Ambient 10 4 FERM NEM E 10 1 CHONG pes dh ea qus ated 19 S SP E ends 1041 Maintenance tans en eas 10 4 RTV ener i fenes itera d Pe EU 2 10 1 recommendation 10 4 SCIVICO elke 10 4 10 1 dederat ga RR RAT pei on 10 1 B Warning tag Ordering Service 10 2 Brake 45 2 Ordering 10 2 Cleaning Machine 15 1 R Repair G Ordering i2 hake Se Ba 10 2 Gasket S us ess ee p SERRE aet 15 1 Shift Cap 22 9 ru REL BE odo 30 2 H Non Locking ell ERR eh 30 4 Specification Tag E RE EMPRESA Eit 10 2 HMD23000 Sto
8. rail the 6 Remove the cotter pin 7 and withdraw the clevis opening in the shift fork should be shielded pin 6 through the fill hole as the detent spring will propel the detent 7 Drive the shift shaft 5 from the serrated end ball dislodging the plug 13 The shift shaft is now withdrawn This frees the shift lever for removal Rotate the shift rail 11 approximately 90 and 8 For assembly the disassembly procedure is withdraw it from the shift cap 1 reversed 4 The shift fork 3 is now free and can be removed from the shift cap Be sure to retrieve the ball 10 and spring 9 DPSG YZ07927 202 19 110CT99 2 2 201 10 05 30 5 HMD 23000 Series Transmission 051105 PN 33 Shift Cap Group Shift Cap Group FRONT FOR LEFT HAND MOUNT FRONT FOR RIGHT HAND MOUNT 2 8 2 2 5 HMD Model 2355 1 Shift cap 6 Shift shaft 11 Shift rail 16 Handle 2 7 Clevis pin 12 Inhibitor pin 17 Cotter pin 3 Shift lever 8 Shift forks 13 Retainer ring 18 Bolt 4 Pin 9 Detent spring 14 Roll pins 19 Nut 5 Roll pin 10 Detent bail 15 Expansion plugs 20 Reducer bushing HMD MODEL 2355 1 Remove nut 19 bolt 18 and handle 16 Continued on next page DPSG YZ07927 203 19 110 199 1 2 201 10 05 30 6 HMD 23000 Series Transmission 051105 PN 34 Shift Cap Group Remove reducer bushi
9. ERVATION CTM201 10 05 B 1 Dip spray or brush ALL exposed unpainted surfaces with NOX RUST X 110 This includes shafts flanges seals etc NOX RUST X 110 meets MIL C 16173 Grade 4 specifications Nox Rust is purchased from e Daubert Chemical Company 1200 Jorie Boulevard Oak Brook IL 60521 312 990 4600 RESTORING UNITS TO SERVICE 1 Wash off ALL external grease with solvent 2 Remove covers or tape from all openings 3 Fill the unit with Funk Manufacturing approved transmission fluid DPSG YZ07927 186 19 27SEP99 1 1 10 5 HMD 23000 Series Transmission 051105 PN 17 General Information Installation Side View 6 20058 UN 190CT99 Hmd23000 Side View A 3 8 N P T Oil level check B 1 4 N P T Magnetic drain C Mounting face 4 5 8 plug plug Diameter holes DPSG YZ07927 207 19 190 199 1 1 201 10MAYO5 10 6 HMD 23000 Series Transmission 051105 PN 18 General Information Installationgear view 150 500 PSI 42 CU IN Required to retract locking piston B Breather amp Oil Fill Handle Length 76 2 mm 3 in 101 6 4 in HMD23000 Rear View B 0 4 Ok 24 6 20059 19 99 BP inches Inches 23 37 mm 92 in 34 80 mm 1 37 in 30 99 mm 1 22 in 46 48 mm 1 83
10. HMD 23000 Series Transmission COMPONENT TECHNICAL MANUAL HMD 23000 Series Service Manual CTM201 10 05 ENGLISH John Deere Power Systems LITHO IN U S A DCT CTM201 Introduction Io This manual is written for an experienced technician Essential tools required in performing certain service work are identified in this manual and are recommended for use Live with safety Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual A This is the safety alert symbol When you see this symbol on the machine or in this manual be alert to the potential for personal injury Information is organized groups for the various components requiring service instruction At the beginning of each group are summary listings of all applicable essential tools service equipment and tools other materials needed to do the job specifications wear tolerances and torque values Component Technical Manuals CTM are concise guides for specific machines They are on the job guides containing only the vital information needed for diagnosis analysis testing and repair DX TMIFC 19 22MAY92 1 1 Warning Tag NOTE This service manual contains data referred to by warning tag on each transmission it is for your protection and should not be removed until the unit has been properly serviced under the instructions of t
11. N 40 Gear and Case Group 1 Main case 7 Counter shaft drive gear 13 Rear support bearing 19 Output flange 2 Front support bearing 8 Main shaft 14 Rear cover 20 Gasket 3 Counter shaft 9 Shift gears 15 21 Washer 4 10 Needie rollers 16 Gasket 22 0O ring 5 Snap ring 11 Output gear 17 Washers 23 Nut 6 Center gear 12 Thrust washer 18 Cap screw 24 pin HMD Model 2315 2325 2326 1 Remove the cotter pin 24 nut 23 washer 21 gasket 20 O ring 22 and output flange 19 6 7 Remove the rear support bearing 13 by driving it from the inside of the main housing outward Remove the snap ring 5 on the input side of the center gear 6 on the counter shaft 3 2 Remove the cap screws 18 and washers 17 that 8 Drive the counter shaft 3 from the input side of the attach the rear cover 14 to the main housing 1 main housing toward the output side until it is free 3 Remove the rear cover 14 and rear cover gasket of the front support bearing 2 It should be 16 expected that the front support bearing 2 will 4 Drive the main shaft 8 from the output end become dislodged from its bore in the housing through the rear support bearing 13 Care must be Allowing the center gears 6 to rest against the taken to prevent damage to the threads on the back wall of the main housing The counter shaft main shaft Remove the
12. Special Tools Faulty or broken tools can result in serious injury When constructing tools use proper quality materials and good workmanship Do not weld tools unless you have the proper equipment and experience to perform the job 21 4 11111 LX1016749 201 10 5 05 3 75779 08 89 DX REPAIR 19 04JUN90 1 1 LX1016749 UN 01JUL97 Special Tools DPSG YZ07927 121 19 06JUL99 1 1 HMD 23000 Series Transmission 051105 PN 9 Safety D Machine Properly Always lower the attachment or implement to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not support the machine on cinder blocks hollow tiles or props that may crumble under continuous load Do not work under a machine that is supported solely by a jack Follow recommended procedures in this manual 75229 UN 23AUG88 DX LOWER 19 04 90 1 1 Handle Fluids Safely Avoid Fires When you work around fuel do not smoke or work near heaters or other fire hazards Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Make sure machine is clean of trash grease and debris Do not store oily rags they can ignite and burn spontaneously 15227 UN 23AUG88 DX FLAME 19 04 90 1 1 P
13. g Instructions 10 2 Description HUP Xe Mode aa a d a 10 2 Operation xac 10 3 Rules of Operation 10 3 tae REM eS OES 10 4 Extended Storage 10 5 Installation sideview 10 6 InstallatiOngss veon c feared a ee os eo dd 10 7 Metric Bolt And Cap Screw Torque Values 10 8 Unified Inch And Cap Screw Torque Values 10 9 Suggested Wrenching Torque For Tapered Pipe 10 10 Group 15 Major Component Groups Other Materials 15 1 Specifications 15 1 HMD23000 Major Component Groups 15 2 Group 25 Input Adapter Group Remove and Assemble Input Adapter ASSOMDIY 00 580 eee a 25 1 Group 30 Shift Cap Group Shift Cap Assembly Locking 2 30 2 Shift Cap Assembly Non Locking 30 4 Shift Cap Group vs sm o 30 6 Group 20 Gear and Case Group Gear and 935 20 2 Gear and 2315 2325 2226 20 4 Group 45 Brake Assembly Brake Assembly and Adjustment 45 2 CTM201 10 05 1 HMD 23000 Series Transmission 051105 PN 1 Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in
14. his manual 201 10 05 The above tag is attached to each unit when it is shipped DO NOT OPERATE THIS TRANSMISION DOES NOT CONTAIN LUBRICATION TO PREVENT DAMAGE FILL WITH OIL WHICH MEETS OR EXCEEDS EP GEAR LUBRICATION SPEC MIL L 2105C OR API CLASSIFICATION GL 5 PER RECOMMENDATIONS OUTLINED IN SERVICE MANUAL 20007 UN 06OCT99 Warning Tag DPSG YZ07927 196 19 28SEP99 1 1 HMD 23000 Series Transmission 051105 2 Contents HMD 23000 Transmission Group 05 Safety Group 10 General Information Group 15 Major Component Groups Group 25 Input Adapter Group Group 30 Shift Cap Group Group 20 Gear and Case Group Group 45 Brake Assembly All information illustrations and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 1999 2005 DEERE amp COMPANY Moline Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Ecl 201 10 05 HMD 23000 Series Transmission 051105 PN 1 HMD 23000 Transmission Contents Page Group 05 Safety 05 1 Group 10 General Information Specification Metu ec ra det ches 10 1 Abbreviations and 10 1 Parts Orderin
15. in C 12 V DC 5 AMP 24 V DC 3 AMP mechanical normally open or normally closed switch for out of gear indicator Length of Shift Throw 304 8 mm 12 in CTM201 10 05 93 22 mm 3 67 in 406 4 16 in 124 21 mm 4 89 in 186 18 mm 7 33 in 139 45 mm 5 49 in D 7 16 diameter bolt 4 places 95 25 mm 3 750 BCD ref 10 7 E 5 8 drill 4 holes DPSG YZ07927 208 119 190CT99 1 1 HMD 23000 Series Transmission 051105 PN 19 General Information 7 Metric Bolt And Cap Screw Torque Values 8 Metric Applies to non lubricated plain or zinc plated fasteners FEPM METRIC TORQUE SPECIFICATIONS 14 1 Class 8 8 Class 10 9 M5 i 54 NOTE Torque tolerance is 20 METRIC BOLT AND CAP SCREW TORQUE VALUES chart meets Funk Engineering Procedures Manual Do not use these values if a different torque value or FEPM Torque Specifications tightening procedure is given for a specific application DPSG YZ07927 14 19 0 99 1 1 CTM201 10MAYOS 10 8 HMD 23000 Series Transmission 051105 PN 20 General Information Grade and Head Markings Markings Unified Inch And Cap Screw Torque Values FEPM INCH TORQUE SPECIFICATIONS 14 2 Size Grade 5 Grade 8 1 4 20 114 16 11 6 1 4 28 12 8 18 ee ee 57 42 1 2 20
16. ized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area 15 90 53 UN TS9 0 DX TORCH 19 03MAR93 1 1 201 10MAYOS 05 5 HMD 23000 Series Transmission 051105 PN 11 Safety Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids 9811 UN 23AUG88 If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A DX FLUID 19 03 9 1 1 Live With Safety Before returning machine to customer make sure machine is functioning properly especially the safety Systems Install all guards and shields SAFETY live with it TS231 19 07OCT88 DX LIVE 19 25SEP92 1 1
17. loration or strong odor vehicle installation and or after repair the unit is to 3 When changing the oil the dirty oil should be be filled to the level check plug Approximately drained while the unit is warm and examined for three quarts 2 84 1 will be required contamination 4 Clean magnetic drain plug before replacing IMPORTANT Do not overfill To do so will result in 5 Refill using clean oil from clean containers overheating and will shorten the life of the transmission 2 Use only lubricants that conform to MIL L 2105C or API GL 5 specifications The following must be adhered to DPSG YZ07927 185 19 245 99 1 1 CTM201 10MAYOS 10 4 HMD 23000 Series Transmission 051105 PN 16 General Information Extended Storage PRESERVATION OF TRANSMISSION AND RELATED COMPONENTS This procedure applies to those transmissions and components that have been tested according to Funk Manufacturing test specifications and have had the fluid drained from them prior to shipment The following will protect the unit or component from internal rust and or corrosion damage for approximately one 1 year provided they are stored under shelter INTERNAL PRESERVATION 1 Seal ALL openings with moisture proof covers or tape 2 Spray 4 ounces of atomized NOX RUST VCI No 10 oil into drain hole This fluid is covered and approved per MIL P 46002 and 1 23310 EXTERNAL PRES
18. main shaft by passing it 3 can be withdrawn from the main housing through the output gear 11 shift gears 9 and the 9 The front support bearing 2 counter shaft drive input side of the main case 1 gear 7 and the center gears 6 can now be 5 The shift gears 9 and output gear 11 are now removed from the main housing loose and can be removed from the main housing Care must be taken to retrieve all thirty nine needle rollers 10 and the thrust washer 12 10 For assembly the disassembly procedure is reversed DPSG YZ07927 205 19 110 199 2 2 CTM201 10MAYOS 20 5 HMD 23000 Series Transmission 051105 41 Brake Assembly Brake Assembly and Adjustment A lt a Fi iA 1 TYP 4P E 2 2 i e e N gt Brake Assembly Continued on next page DPSG YZ07927 201 19 07 99 1 2 201 10MAYOS 45 2 HMD 23000 Series Transmission 051105 PN 44 Brake Assembly 1 Brake drum 7 Cap screw 13 Brake band 19 Adjustment springs 2 Bolt 8 Lock washer 14 20 Jam nut 3 Nut 9 Brake link anchor 15 21 Lock washer 4 Lock washer 10 Bolt 16 Anchor spring 22 Screw 5 Brake band anchor 11 Nut 17 Anchor bolt 23 Jam nut 6 Brake bracket 12 Lock washer 18 Brake adjustment bolt 24
19. ng 20 Remove roll pins 14 Remove expansion plugs 15 one at each end of the shift rail 11 Remove the plugs by dislodging one with a punch and then driving the shift rail 11 to dislodge the other Position both the shift rail 11 so that approximately 1 2 inch protrudes outside the shift cap 1 Position both shift forks 8 in a neutral detent The inside faces of the forks will be approximately 1 1 2 inches apart when they are positioned correctly Remove retainer ring 13 from the inhibitor pin 12 Insert a drift or punch in the protruding end of the shift rail 11 Rotate the shift rail 11 slightly at the same time withdrawing the inhibitor pin 12 A CAUTION When removing the shift rail the exposed opening the shift fork 8 should be shielded as the detent spring 9 will propel the detent ball 10 The shift rail can now be withdrawn Remove shift forks 8 Remove the cotter pin 17 and clevis pin 7 The clevis pin should drop through the hole in top of the shifter cap The shift shaft 6 can now be withdrawn from the shift lever 3 and both parts removed from the shift cap 1 The shift lever can be further disassembled by driving out roll pins 5 and removing pins 4 To assemble the disassembly procedure is reversed DPSG YZ07927 203 19 110CT99 2 2 CTM201 10 05 30 7 HMD 23000 Series T
20. r group A from the transmission case and refer to group 25 for further disassembly of the input adapter group A 2 Remove the cap screws that attach the shift cap group B to the gear and case group Specification Shift control assembly cap screw to gear and case group Torque esses eene reete 41 Nem 30 Ib ft Lift the shifter cap group off the main case Refer to section 3 for disassembly of the shifter cap group 3 The gear and case group ref 1 is now ready for disassembly Refer to section 4 for this procedure 4 If the unit is supplied with a parking brake refer to section 5 for assembly and adjustment procedure 5 Prior to assembling the component groups into a complete transmission the mating surfaces of the main case and motor adapter housing should be cleaned with a non hydrocarbon solvent such as Loc Tite Safety Solvent A thin bead of RTV 732 Silicon sealant is then applied to the main case DPSG YZ07927 187 19 275 99 2 2 CTM201 10 5 15 3 HMD 23000 Series Transmission 051105 PN 25 Group 25 Input Adapter Group Remove and Assemble Input Adapter Assembly 5 8 Input Adapter Assembly A Snap Ring C Bearing D Input Shaft E Pilot Bearing B Input Adapter group All HMD23000 Models 3 Remove snap ring A from input shaft and pull the bearing C from the input shaft 1 Slide pilot bearing E from input shaft
21. rage 1 5 10 6 10 7 External preservation 10 5 Internal preservation 10 5 Restore to 10 5 M Main Case Model 2355 20 2 Tag Others cu Sait a qe etd 20 4 10 2 Maintenance Warning GIU MR C 10 4 Temperature Metric bolt Oil MAXIMUM sep S eoe REX EVE 10 3 Torque 10 8 Torque Motor adapter assembly Cap screw 10 9 Assemble sie vetet amie ace ee ded 25 1 Cap screw 10 8 REMOVE codo s ERR ea re aerea 25 1 Companion flange cap screw 15 1 CTM201 10 05 Index 1 HMD 23000 Series Transmission 051105 PN 1 Index Unified inch Torque values CTM201 10 05 Major component groups Motor adapter Motor adapter cap screw Shift control assembly cap screw Tapered pipe thread values Unified Index 2 HMD 23000 Series Transmission 051105 PN 2
22. ransmission 051105 PN 35 Gear and Case Group Gear and 2355 2 DHT m A H3 18 AS REQ D 3 9 6 D E Model 2355 Gear and Case Continued on next page 56 207927 204 19 110CT99 1 2 CTM201 10MAYOS 20 2 HMD 23000 Series Transmission 051105 PN 38 Gear and Case Group 1 Main case 8 Counter shaft drive gear 15 Rear support bearing 21 Output flange 2 Front support bearing 9 Main shaft 16 Rear cover 22 Gasket 3 Counter shaft 10 Shift gear 17 23 Washer 4 11 Shift gear 18 Rear cover gasket 24 0 ring 5 Center gear 12 Needle rollers 19 Washer 25 Nut 6 Center gear 13 Output gear 20 Cap screw 26 Cotter pin 7 Snap ring 14 Thrust washer HMD Model 2355 6 Remove the rear support bearing 15 by driving it from the inside of the main housing outward 1 Remove the cotter pin 26 nut 25 washer 23 7 Remove the snap ring 7 from the counter shaft gasket 22 O ring 24 and output flange 21 3 Drive the counter shaft 3 from the input side 2 Remove the cap screws 20 and washers 19 that of the main housing toward the output side until it is attach the rear cover 16 to the main housing 1 free of the front support bearing 2 It should be 3 Remove the rear cover 16 and rear cover gasket expected that the front suppor
23. revent Battery Explosions Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 C 60 F TS204 UN 23AUG88 OX SPARKS 19 03MAR93 1 1 201 10MAYOS 05 4 HMD 23000 Series Transmission 051105 PN 10 Safety Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripping electrolyte Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 quarts 3 Get medical attention immediately TS203 UN 23AUG88 DX POISON 19 21APR93 1 1 1 Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressur
24. t bearing 2 will 18 become dislodged from its bore in the housing 4 Drive the main shaft 9 from the output end Allowing the center gears 5 6 to rest against the through the rear support bearing 15 Care must be back wall of the main housing The counter shaft taken to prevent damage to the threads on the 3 can be withdrawn from the main housing main shaft Remove the main shaft by passing it 8 The front support bearing 2 counter shaft drive through the output gear 13 shift gears 10 11 gear 8 and the center gears 5 6 can now be and the input side of the main case 1 removed from the main housing 5 The shift gears 10 11 and output gear 13 are 9 For assembly the disassembly procedure is now loose and can be removed from the main reversed housing Care must be taken to retrieve all thirty nine needle rollers 12 and the thrust washer 14 OPSG YZ07927 204 19 110 99 2 2 CTM201 10 05 20 3 HMD 23000 Series Transmission 051105 PN 39 Gear and Case Group Gear and 2315 2325 2326 9 gt DO 6 Ol WO 2 2 WEE nO 19 AJON j 24 LLL TORA Patek 15 1605 _ 23 HOP TET TI ut posa 7 2 16 AS REQ D HMD2315 2325 2326 Gear and Case Group CTM201 10MAYOS 20 4 DPSG YZ07927 205 9 110 799 1 2 HMD 23000 Series Transmission P
25. tate the shift rail 8 approximately 90 and withdraw it from the shift cap 1 8 The shift fork 5 is now free and can be removed from the shift cap Be sure to retrieve the ball 6 and spring 7 9 Remove plug 20 10 Remove the cotter pin 3 and clevis pin 4 11 Drive the shift shaft 13 from the serrated end toward the cup plug The shift shaft 13 may now be withdrawn This frees the shift lever 2 and the spring washer 33 for removal The washer 16 and spacer 15 may be removed as well 12 To assemble reverse the disassembly procedure DPSG YZ07927 191 19 275 99 2 2 CTM201 10 05 30 3 HMD 23000 Series Transmission 051105 PN 31 Shift Cap Group Shift Cap Assembly Non Locking 20053 UN 14O0CT99 Non Locking Shift Cap 1 Shift cap 5 9 Spring 13 Expansion plug 2 6 Clevis pin 10 Ball 14 Plug 3 Shift lever 7 Cotter pin 11 Shift rail 15 Breather 4 8 12 Roll pin NON LOCKING HMD MODELS 2315 2325 and 2326 2 Dislodge one expansion plug 13 with a punch 3 Drive the shift rail 11 to dislodge the other 1 Remove roll pin 12 expansion plug Continued on next page DPSG YZ07927 202 19 11 99 1 2 201 10 5 30 4 HMD 23000 Series Transmission 051105 PN 32 Shift Cap Group L 5 Remove the breather 15 and fill plug 14 A CAUTION When removing the
26. ther Materials Number Name Use U S Loctite safety solvent Preparing surface for jointing U S RTV 732 For jointing oil retaining surfaces DPSG YZ07927 199 19 040 799 1 1 Specifications Item Measurement Specification Torque Values Input adapter group cap Torque 65 Nem 48 lb ft Screw to gear and case group Shift control assembly cap Torque 41 Nem 30 Ib ft Screw to gear and case group Companion flange cap Torque 65 Nem 48 Ib ft Screw to gear and case group DPSG YZ07927 197 19 305 99 1 1 201 10MAYOS 15 1 HMD 23000 Series Transmission 051105 PN 23 Major Component Groups HMD23000 Major Component Groups WA in 9 3 i E 8 5 Major Component Groups A Input Adapter Group C Shifter Cap cap D Park Brake Group F Gear and Main Case Group B Shift Cap Group screw to main case E Input Adapter Group screw to main case The models HMD2315 HMD2325 HMD2326 and 1 Remove the cap screws that attach the input HMD2355 may be disassembled into major component adapter group A to the main case group groups as follows Continued on next page DPSG YZ07927 187 19 275 99 1 2 201 10MAY05 15 2 HMD 23000 Series Transmission 051105 PN 24 Major Component Groups Specification Input adapter group cap screw io gear and case group Torque 144 Nem 106 Ib ft Separate the input adapte
27. this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine CTM201 10MAYOS 05 1 Group 05 Safety 1389 UN 07DEC88 T8 DX ALERT 19 070 88 1 1 75291 UN 23AUG88 OX FIRE2 19 03MAR93 1 1 PLS TS206 UN 23AUG88 DX WEAR 19 10SEP90 1 1 HMD 23000 Series Transmission 051105 PN 7 05 1 Safety Work In Ventilated Area Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area
28. use the unit operates in oil most of the maintenance is concerned with oil replenishment and OPSG YZ07927 183 19 24SEP99 1 1 Rules of Operation 1 Check the oil level weekly Clean the area around 3 The maximum operating oil temperature is 107 C the check plug before removing 225 F CAUTION Gear range shifts must not be attempted when the vehicle is moving DPSG YZ07927 184 19 245 99 1 1 201 10 05 10 3 23000 Series Transmission 054105 PN 15 General Information Service AIR TEMPERATURE RANGE Prevailing Ambient TemperatureOil Spec Oil Spec Below 23 C 10 F 75W Below 23 C 37 8 C 10 F 100 F 80W 90W Above 37 8 C 100 F 85W 140W The type of service and operating conditions will 1 It is recommended that the oil be changed after the determine the maintenance interval However it is first 500 hours of service recommended that the oil level be checked weekly at 2 Thereafter and under normal operating conditions the same time checking for oil leaks Because the it is recommended that the oil be changed after lubrication system is the hear of the unit it is every six months of operation The oil should be especially important that the oil be kept clean changed whenever the oil shows traces of dirt or effects of high temperature evidenced by 1 When servicing the unit for the first time after disco
Download Pdf Manuals
Related Search