FUNK DF Series User manual

DF Series
150 and 250
Transmissions (ANALOG)
Funk Manufacturing Company
CTM147 (16JUL98)
LITHO IN U.S.A.
ENGLISH

DF Series 150 and 250 Transmissions (Analog) CTM147 (16JUL98)

FOREWORD
Component Technical Manuals (CTM) are concise
service guides for specific components. Component
technical manuals are written as stand-alone manuals
covering multiple machine applications.
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.
NThis is the safety-alert symbol. When you see
this symbol in the manual or on the machine,
be alert to the potential for personal injury.
NWARNING VEHICLE RUNAWAY HAZARD
Avoid serious or fatal injury. This transmission is
not a braking system. Install it only if there is a
braking system capable of stopping vehicle with
dead engine, disengaged transmission, or loss
of hydrostatic retardation. Otherwise, vehicle
may roll freely, resulting in loss of control.
IMPORTANT: Important warns of possible damage
to transmission.
NOTE: To make special mention of or to record in
writing useful information about the
transmission.
Use this component technical manual in conjunction
with the machine technical manual. See the machine
technical manual for information on component
removal and installation, and gaining access to the
components.
This manual is divided in three parts; general
information, repair, and troubleshooting and tests:
• General information group offers component
identification with specification information about the
transmission.
• Repair groups contain necessary instructions to
repair the component.
• Troubleshooting and test groups help you identify
the majority of routine failures quickly and then allows
you to perform certain tests.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable service equipment and tools, other
materials needed to do the job, specifications, and
torque values.
YZ,CTM147,IFC -19-05MAY98
Introduction
CTM147 (16JUL98) DF Series 150 and 250
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Page
DF Series 150 and 250
Group 05—Safety messages
Group 10—General Information
Group 15—Transmission Mounting
Group 20—Torque Converter
Group 25—Charge Pump
Group 30—Front Cover
Group 35—Control Valve
Group 40—Main Case Front Housing
Group 45—Gear Ratio Group
Group 50—Main Case Rear Housing
Group 55—Brake Group
Group 99—Special Tools
Group 100—Test and Troubleshooting
Group 105—Transmission Control Unit
Index
COPYRIGHT© 1998
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION® Manual
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.
CTM147-19-16JUL98
Contents
CTM147 (16JUL98) iDF Series 150 and 250
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Contents
CTM147 (16JUL98) ii DF Series 150 and 250
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NWARNING VEHICLE RUNAWAY HAZARD Avoid
serious or fatal injury. This transmission is not a
braking system. Install it only if there is a braking
system capable of stopping vehicle with dead
engine, disengaged transmission, or loss of
hydrostatic retardation. Otherwise, vehicle may roll
freely, resulting in loss of control.
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. TS227 -UN-23AUG88
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.
TS291 -UN-23AUG88
YZ,WARN -19-10MAR98
DX,FLAME -19-04JUN90
DX,FIRE2 -19-03MAR93
Group 05
Safety messages
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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.
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 & Company Medical Department in
Moline, Illinois, U.S.A.
X9811 -UN-23AUG88
SUPPORT 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.
TS229 -UN-23AUG88
DX,FLUID -19-03MAR93
DX,LOWER -19-04JUN90
Safety messages
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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.
TS206 -UN-23AUG88
SERVICE MACHINES SAFELY
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228 -UN-23AUG88
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.
TS220 -UN-23AUG88
DX,WEAR -19-10SEP90
DX,LOOSE -19-04JUN90
DX,AIR -19-04JUN90
Safety messages
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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.
T6642EJ -UN-18OCT88
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose
of paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
TS220 -UN-23AUG88
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized 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.
TS953 -UN-15MAY90
DX,CLEAN -19-04JUN90
DX,PAINT -19-03MAR93
DX,TORCH -19-03MAR93
Safety messages
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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.
TS223 -UN-23AUG88
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
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow
machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
machine.
TS218 -UN-23AUG88
DX,LIGHT -19-04JUN90
DX,LIFT -19-04JUN90
DX,SERV -19-03MAR93
Safety messages
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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.
TS779 -UN-08NOV89
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil,
fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
TS1133 -UN-26NOV90
DX,REPAIR -19-04JUN90
DX,DRAIN -19-03MAR93
Safety messages
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LIVE WITH SAFETY
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231 -19-07OCT88
PARK MACHINE SAFELY
Before working on the machine:
• Lower all equipment to the ground.
• Stop the engine and remove the key.
• Disconnect the battery ground strap.
• Hang a “DO NOT OPERATE” tag in operator station.
TS230 -UN-24MAY89
STAY CLEAR OF ROTATING DRIVELINES
Entanglement in rotating driveline can cause serious
injury or death.
Keep tractor master shield and driveline shields in place
at all times. Make sure rotating shields turn freely.
Wear close fitting clothing. Stop the engine and be sure
PTO driveline is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
TS1644 -UN-22AUG95TS177 -UN-11JAN89
DX,LIVE -19-15APR98
DX,PARK -19-04JUN90
DX,PTO -19-12SEP95
DX,BYPASS1 -19-10MAR98
Safety messages
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Safety messages
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SPECIFICATIONS
Item Measurement Specification
• DF-150 Weight 567 Kg (1250 lbs)
• DF-150 Input-to-Output 500 mm (19.69 in)
• DF-150 Rating (Depending on Input power (maximum) - 142 kW (190
application) SAE hp)
Input no load speed (maximum) - 3000
rpm
Turbine torque (maximum) - 1288 N·m
(950 lb-ft)
• DF-250 Weight 703 Kg (1550 lbs)
• DF-250 Input-to-Output 550 mm (21.65 in)
• DF-250 Rating (Depending on Input power(maximum) - 224 kW (300
application) SAE hp)
Input no load speed (maximum) - 3000
rpm
Turbine torque (maximum) - 1898 N·m
(1400 lb-ft)
• DF-150/250 Mountings Available Engine
Midship
Remote
• DF-150/250 Torque Converters Available 298.5 mm (11.75 in)
323.8 mm (12.75 in)
355.6 mm (14.00 in)
• DF-150/250 Clutches Fully modulated, oil cooled, multidisc,
hydraulic actuated and self-adjusting.
• DF-150/250 Gearing Constant mesh, in line, high contact
ratio ground gears. Up to eight speeds
forward and four speeds reverse.
• DF-150/250 Oil Hydraulic transmission fluid.
• DF-150/250 Filter Remote mounted spin-on type filter.
Continued on next page
Group 10
General Information
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Item Measurement Specification
Transmission Operating Conditions Maximum Input Speed 3000 rpm
Test Input Speed 2000 rpm
Minimum Operating Temperature -40˚C (-40˚F)
Maximum Continuous Operating 110˚C (230˚F)
Temperature
Maximum intermittent Operating 121˚C (250˚F)
Temperature
Normal Operating Temperature 38—93˚C (100—200˚F)
Pressures and Flows at Control Pump Pressure 1758—1965 kPa (255—285 psi)
Valve Pump Flow 87—102 L/min (23—27 gpm)
Clutch Pressure 1655—1931 kPa (240—280 psi)
Lube, In Pressure 138—414 kPa (20—60 psi)
Weights will vary depending on installed options.
YZCTM147,10,SPC-19-05MAY98
General Information
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IDENTIFICATION AND SERIAL NUMBER
PLATES
The identification plate is located on the engine side
and/or opposite engine side of the transmission main
case housing. The exact location varies depending on
installed options and model number. Earlier version of
the DF series transmission had three lines of information.
Later DF series transmission will have four lines of
information on identification plate. All information on
identification plate is needed when contacting FUNK
concerning transmission.
Contact:
Funk Manufacturing Company
Attention: Parts Department
Industrial Park, Highway 169 North
P.O. Box 577
Coffeyville, Kansas 67337-0577
Telephone: Area Code (800)-844-1337
Ask for Parts Department
FAX:[phone]
YZ1502 -UN-24APR98
YZ1503 -UN-01MAY98
YZ,CTM147,10,13-19-07MAY98
General Information
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RECOMMENDED LUBRICANTS
AMBIENT AIR TEMPERATURE CHART
Select an oil viscosity, from the chart, based on the
air temperature range expected between oil changes.
NOTE: The words “oil”, “fluid” and “transmission fluid”
are used in this manual to mean,
HYDRAULIC TRANSMISSION FLUID, the
operating and lubricating oil for this
transmission.
Standard and Low viscosity HY-GARD®Transmission
fluids are available through the John Deere dealer
network worldwide. Other oils may be used if they
meet one of the following:
John Deere Standard JDM J20 C
John Deere Standard JDM J20 D
Some fluids that contain the following additive
packages have been shown to meet the specification
requirements of J20 C and/or J20 D. Inclusion of the
following additive packages does not constitute
blanket approval of the oil for these applications.
Supplier Additive
Chevron Ornite OLOA 9725X
Lubrizol Lubrizol 9990
HY-GARD is a registered trademark of Deere & Company.
YZ1500 -UN-23APR98
YZ,CTM147,10,3 -19-05MAY98
General Information
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COLD WEATHER STARTUP
Cold starts will sometimes cause the oil filter bypass
signal to activate, indicating the oil is bypassing the filter.
This should be an intermittent condition and should not
continue after the transmission oil has reached 38˚ C
(100˚ F) operating temperature.
IMPORTANT: Transmission oil should be warm
before operating the transmission. If
the transmission (converter out) oil
temperature remains below the normal
operating range after a reasonable
warm-up period, stop the machine and
warm the oil by stalling the torque
converter.
If necessary to maintain the
recommended oil temperature, operate
the machine in a higher gear.
STALLING THE TORQUE CONVERTER:
NOTE: This procedure should not be used on 14 inch
AAD torque converters.
• Park vehicle away from personnel and obstacles.
• Set brakes.
• Shift transmission to the highest gear.
IMPORTANT: Do not operate transmission at full
governed engine rpm for more than 30
seconds. Do not allow converter out oil
temperature to exceed 121˚C (250˚F).
• Run engine for a maximum of 30 seconds at full
governed engine speed.
• Stop the stall procedure when oil temperature is in the
normal operating range. Do not allow oil temperature to
exceed 121˚C (250˚F) at anytime.
YZ,CTM54,10,19 -19-07MAY98
General Information
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COLD WEATHER OPERATION
IMPORTANT: Viscosity grade selection is critical for
cold weather operation of the
transmission. Preheat and proper
start-up procedures are required when
operating transmission below the oil’s
MINIMUM critical temperature which is
viscosity grade dependant.
NOTE: Refer to AIR TEMPERATURE RANGE chart for
the MINIMUM transmission operating temperature
viscosity grades.
PREHEAT TRANSMISSION FLUID WITH AUXILIARY
SOURCE
• Preheat the transmission fluid to the MINIMUM
temperature before operating.
ALTERNATE WARM-UP PROCEDURE:
• Operate transmission in neutral for approximately 20
minutes or until oil is warmed to the MINIMUM
temperature.
HOT WEATHER OPERATION
Use higher viscosity grades (Refer to AIR
TEMPERATURE RANGE chart) for:
• Ambient temperatures consistently above 30˚C (86˚F).
• Frequent stop-and-go driving in hot weather.
• High grade climbing in hot weather.
YZ,CTM147,10,3A-19-05MAY98
General Information
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FILL THE TRANSMISSION WITH OIL
AFTER INSTALLING TRANSMISSION IN VEHICLE:
• Park machine on level surface.
• Engage parking brake, block wheels.
• Put transmission in neutral.
• Remove dipstick, the dipstick tube is the normal oil fill
location.
• Begin filling operation by adding 19 liters (5 gal) of
recommended oil.
• Start the engine, run at idle speed to fill the converter
and oil lines.
• Check oil level on dip stick with engine running at idle
speed.
IMPORTANT: Do not overfill transmission. This will
cause overheating. Damage to the
transmission will result.
• Fill transmission to the full mark on dipstick with engine
running at idle speed.
• Check oil level again when the transmission has
reached normal operating temperature 38—93˚C
(100—200˚F).
YZ,CTM147,10,2 -19-05MAY98
General Information
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