John Deere DF Series 150 250 Transmissions Technical Manual (05-JUN-98) – PDF DOWNLOAD

Description

John Deere DF Series 150 250 Transmissions Technical Manual (05-JUN-98) – PDF DOWNLOAD

DESCRIPTION:

CTM147 (05 JUN98)

John Deere DF Series 150 250 Transmissions Technical Manual (05-JUN-98) – PDF DOWNLOAD

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

This 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.

WARNING 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

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

TABLE OF CONTENTS:

John Deere DF Series 150 250 Transmissions Technical Manual (05-JUN-98) – PDF DOWNLOAD

Contents 1
DF Series 150 and 250 6
Safety 6
Safety messages 6
HANDLE FLUIDS SAFELY—AVOID FIRES 6
PREPARE FOR EMERGENCIES 6
AVOID HIGH-PRESSURE FLUIDS 7
SUPPORT MACHINE PROPERLY 7
WEAR PROTECTIVE CLOTHING 8
SERVICE MACHINES SAFELY 8
WORK IN VENTILATED AREA 8
WORK IN CLEAN AREA 9
REMOVE PAINT BEFORE WELDING OR HEATING 9
AVOID HEATING NEAR PRESSURIZED FLUID LINES 9
ILLUMINATE WORK AREA SAFELY 10
USE PROPER LIFTING EQUIPMENT 10
PRACTICE SAFE MAINTENANCE 10
USE PROPER TOOLS 11
DISPOSE OF WASTE PROPERLY 11
LIVE WITH SAFETY 12
PARK MACHINE SAFELY 12
STAY CLEAR OF ROTATING DRIVELINES 12
PREVENT MACHINE RUNAWAY 12
General Information 14
IDENTIFICATION AND SERIAL NUMBER PLATES 16
RECOMMENDED LUBRICANTS 17
COLD WEATHER STARTUP 18
COLD WEATHER OPERATION 19
FILL THE TRANSMISSION WITH OIL 20
CHECK AND SERVICE TRANSMISSION REGULARLY 21
INTERVALS FOR CHANGING TRANSMISSION OIL AND FILTERS 22
OIL ANALYSIS 23
OIL TEMPERATURE WARNING SIGNAL 23
TOWING THE VEHICLE 24
PUT TRANSMISSION IN STORAGE 24
REMOVE TRANSMISSION FROM STORAGE 25
INSTALL TRANSMISSION TO THE ENGINE 26
CONVERTER-TO-ENGINE FLYWHEEL DIMENSIONS 27
ENGINE TO TORQUE CONVERTER SPECIFICATIONS 28
SUGGESTED WRENCHING TORQUE FOR TAPERED PIPE THREAD 29
SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS 30
SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS 31
CHECK OIL LINES AND FITTINGS 32
METRIC BOLT AND CAP SCREW TORQUE VALUES 33
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES 34
Torque Converter 36
REMOVE TORQUE CONVERTER AND DRIVE PLATE ASSEMBLY 36
DISASSEMBLE AND ASSEMBLE DRIVE PLATE GROUP 37
DISASSEMBLE DRIVE PLATE GROUP 37
ASSEMBLE DRIVE PLATE GROUP 38
Charge Pump 39
DISASSEMBLE SUCTION TUBE GROUP 40
REMOVE SUCTION TUBE ASSEMBLY 41
ASSEMBLE SUCTION TUBE GROUP 42
INSTALL SUCTION TUBE 43
CHARGE PUMP GROUP 44
REMOVE CHARGE PUMP GROUP 45
REMOVE DRIVEN GEAR AND BEARING ASSEMBLY 45
DISASSEMBLE AND ASSEMBLE CHARGE PUMP GROUP WITH AUXILIARY PUMP DRIVE DISCONNECT 46
DISASSEMBLE AUXILIARY PUMP DRIVE DISCONNECT 47
ASSEMBLE AUXILIARY PUMP DRIVE DISCONNECT 48
INSTALL DRIVEN GEAR AND BEARING ASSEMBLY (CHARGE PUMP) 50
INSTALL CHARGE PUMP TO FRONT COVER 51
Control Valve 53
REMOVE AND INSTALL WIRING HARNESS 53
REMOVE CONTROL VALVE GROUP 54
DISASSEMBLE AND ASSEMBLE CONTROL VALVE 55
INSTALL CONTROL VALVE GROUP 56
CAP SCREW TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS 57
PIPING DIAGRAM, CONVERTER DRIVEN TRANSMISSION, (WITHOUT WET BRAKE) 58
PRESSURE AND TEMPERATURE CHECK PORTS (WITHOUT WET BRAKE) 59
Brake Group 61
DISC BRAKE GROUP 61
DISASSEMBLE DISC BRAKE 62
ASSEMBLE DISC BRAKE 64
Special Tools 67
GROUP 99 67
ASSEMBLY STAND PLATE 68
ASSEMBLY STAND PLATE 69
FRONT COVER LIFTING TOOL 70
Test and Troubleshooting 71
SUCTION LEAK TEST 71
SOLENOID VALVE OPERATION 72
CLUTCH SOLENOID VOLTAGE REQUIREMENTS 73
TEST SOLENOIDS 73
4-4 DF POWER FLOW FORWARD SPEEDS 74
4-4 DF POWER FLOW REVERSE SPEEDS 75
8-4 DF POWER FLOW FORWARD SPEEDS 76
8-4 DF POWER FLOW FORWARD SPEEDS (CONTINUED) 77
8-4 DF POWER FLOW REVERSE SPEEDS 78
8-4 DF POWER FLOW REVERSE SPEEDS (CONTINUED) 79
TROUBLESHOOT TRANSMISSION SYSTEM MALFUNCTIONS 80
POWERSHIFT TROUBLESHOOTING-INTERNAL DISCONNECT MODELS ONLY 84
Transmission Control Unit 85
TROUBLE SHOOTING INTRODUCTION 85
THEORY OF OPERATION 86
SYSTEM COMPONENTS 86
COMPONENT FUNCTIONS 87
CLUTCH CALIBRATION FOUR FORWARD SPEEDS AND FOUR REVERSE 92
CLUTCH CALIBRATION EIGHT FORWARD SPEEDS AND FOUR REVERSE 93
SYSTEM REQUIREMENTS 96
CONNECTOR PINOUTS 96
J2 CONNECTOR 97
J3 CONNECTOR 97
PROPORTIONAL VALVES 99
SYSTEM ERRORS100
ANALOG ERROR CODES101
GLOSSARY110
ABBREVIATIONS USED IN TCU GROUP111
Index 1
A 48
Auxiliary pump drive disconnect 48
Assemble 48
Disassemble 47
C 51
Charge pump 51
Install pump to front cover 51
Assemble pump drive disconnect 48
Assemble suction tube group 42
Auxiliary pump drive disconnect 46
Charge pump group drawing 44
Disassemble pump drive disconnect 47
Disassemble suction tube drawing 40
Driven gear assembly 45
Install driven gear assembly 50
Install suction tube 43
Remove charge pump group 45
Remove suction tube 41
Suction tube drawing 42
Control valve 57
Cap screw tightening sequence 57
Control valve group drawing 56
Direction and speed ports 60
Disassemble and assemble 55
Piping diagram 58
Control Valve 14
Pressure and Flows 14
Control valve 59
Pressure and temperature ports 59
Remove control valve group 54
Remove wiring harness 53
D 37
Drive plate 37
Assemble drive plate group 38
Disassemble drive plate group 37
F 0
Front Cover 70
drawing, lifting tool 70
I 16
Identification plate 16
ID plate location 16
L 17
Lubricant, transmission 17
M 0
Metric torque values 33
O 30
O-ring boss fittings 30
Oil 17
Air Temperature Range 17
Check and service 21
Cold weather operation 19
Cold weather startup 18
Fill with oil 20
Hot weather operation 19
Lines and fittings 32
Oil analysis 23
Oil and filter change intervals 22
Oil specifications 17
Oil temp warning signal 23
Operating Conditions 14
Preheat 19
Pressure and Flows 14
Oil filter bypass 18
Cold weather startup 18
Filter bypass indication 22
Oil lines and fittings 32
P 14
Pressure 14
Clutch 14
S 0
Solenoid 73
Test 73
Valve operation 72
Voltage requirements 73
Suction leak test 71
Suction tube 40
Disassemble 40
Drawing 42
Install suction tube 43
Remove suction tube 41
T 14
Temperature 14
Maximum Operating 14
Test 73
Solenoids 73
Suction leak 71
Torque converter 1275 0
Drive plate assembly drawing 37
Install drive plate 38
Remove drive plate group 37
Remove from transmission 36
Torque value 31
Flat face O-ring seal fitting 31
O-Ring boss fitting 30
Torque values 34
Inch 34
Metric 33
Towing 24
Towing the vehicle 24
Transmission 21
Check and service 21
Cold weather startup 18
Fill with oil 20
ID plate location 16
Install transmission to engine 26
Oil analysis 23
Oil and filter change intervals 22
Oil specifications 17
Oil temp warning signal 23
Stalling torque converter 18
Storing the transmission 24
Troubleshooting 80
Transmission Control Unit 91
Calibration 91
Clutch Calibration 92
Clutch Calibration 93
Component Functions 87
Connector Pinouts, J1 J2 J3 96
Cylinder Speed MPU 88
Glossary 110
Inching Pedal 94
Input Function Switches 95
Optional Components 94
Output Speed MPU 89
Proportional valves 99
Shift Handle 90
System Components 86
System errors 100
System Requirements 96
Theory of operation 86
Trouble shooting introduction 85
Transmission Stand 68
drawing, assembly stand plate 68
drawing, assembly stand plate 69
Troubleshooting 80
Transmission 80
U 34
Unified inch torque values 34
V 72
Valve 72
Solenoid, operation 72
Solenoid, voltage requirements 73
Valve, control 57
Cap screw tightening sequence 57
Control valve group drawing 56
Direction and speed ports 60
Disassemble and assemble 55
Piping diagram 58
Pressure and temperature ports 59
Remove and install wiring harness 53
Remove control valve group 54
W 14
Weight 14
Transmission 14
Wiring harness 53
Remove and install 53
PAGE NUMBERS 1
SECTION 00 6
GROUP 05 6
00- 05-0001 6
00- 05-0002 7
00- 05-0003 8
00- 05-0004 9
00- 05-0005 10
00- 05-0006 11
00- 05-0007 0
00- 05-0008 13
GROUP 10 14
00- 10-0001 14
00- 10-0002 15
00- 10-0003 16
00- 10-0004 17
00- 10-0005 18
00- 10-0006 19
00- 10-0007 20
00- 10-0008 21
00- 10-0009 22
00- 10-0010 23
00- 10-0011 24
00- 10-0012 25
00- 10-0013 26
00- 10-0014 27
00- 10-0015 28
00- 10-0016 29
00- 10-0017 30
00- 10-0018 31
00- 10-0019 32
00- 10-0020 33
00- 10-0021 34
00- 10-0022 35
GROUP 20 36
00- 20-0001 36
00- 20-0002 37
00- 20-0003 38
GROUP 25 39
00- 25-0001 39
00- 25-0002 40
00- 25-0003 41
00- 25-0004 42
00- 25-0005 43
00- 25-0006 44
00- 25-0007 45
00- 25-0008 46
00- 25-0009 47
00- 25-0010 48
00- 25-0011 49
00- 25-0012 50
00- 25-0013 51
00- 25-0014 52
GROUP 35 53
00- 35-0001 53
00- 35-0002 54
00- 35-0003 55
00- 35-0004 56
00- 35-0005 57
00- 35-0006 58
00- 35-0007 59
00- 35-0008 60
GROUP 55 61
00- 55-0001 61
00- 55-0002 62
00- 55-0003 63
00- 55-0004 64
00- 55-0005 65
00- 55-0006 66
GROUP 99 67
00- 99-0001 67
00- 99-0002 68
00- 99-0003 69
00- 99-0004 70
GROUP 100 71
00- 100-0001 71
00- 100-0002 72
00- 100-0003 73
00- 100-0004 74
00- 100-0005 75
00- 100-0006 76
00- 100-0007 77
00- 100-0008 78
00- 100-0009 79
00- 100-0010 80
00- 100-0011 81
00- 100-0012 82
00- 100-0013 83
00- 100-0014 84
GROUP 105 85
00- 105-0001 85
00- 105-0002 86
00- 105-0003 87
00- 105-0004 88
00- 105-0005 89
00- 105-0006 90
00- 105-0007 91
00- 105-0008 92
00- 105-0009 93
00- 105-0010 94
00- 105-0011 95
00- 105-0012 96
00- 105-0013 97
00- 105-0014 98
00- 105-0015 99
00- 105-0016100
00- 105-0017101
00- 105-0018102
00- 105-0019103
00- 105-0020104
00- 105-0021105
00- 105-0022106
00- 105-0023107
00- 105-0024108
00- 105-0025109
00- 105-0026110
00- 105-0027111
00- 105-0028112

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JOHN DEERE DF SERIES 150 250 TRANSMISSIONS TECHNICAL MANUAL (05-JUN-98) – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.M