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
CTM147 (16JUL98) 00-05-1 DF Series 150 and 250
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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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