Water Contamination; Troubleshooting - Manitowoc Grove 5540F Service Manual

TRANSMISSION AND TORQUE CONVERTER
Possible Cause
11. Non-return valve faulty.
12. 2/4WD solenoid permanently energized

Water Contamination

Troubleshooting

Carefully inspect the gearbox oil for signs of water
contamination. Contaminated oil will contain water droplets
or be visibly emulsified. Water droplets may be visible on the
1. Water ingress during filling/topping up.
2. Missing/incorrect dipstick, damaged filler tube.
3. Machine operated in deep water.
4. Gearbox casings damaged.
5. Gearbox oil circuit pipes/hoses damaged.
6. Oil cooler failure. (Water cooled machine installations).
Gearbox faults caused typically by water contamination and
other factors related to the transmission oil:
Fault
1. Pressurization of gearbox casing -
Dipstick blows out/oil leaking from
dipstick tube.
2. Clutch Failure - Friction Lining
Separation
3. Badly worn/noisy bearings.
If the transmission cooler circuit becomes contaminated due
to the ingress of water, stop the engine immediately. Drain
7-20
Possible Cause
Water in oil combined with heat from
torque converter causes steam.
Gearbox over filled with oil.
Water ingress. Overheating.
Water ingress.
Insufficient lubrication.
Published 10-21-2010, Control# 198-04
5540F/YB5515 SERVICE MANUAL
11. Check the non-return valve
12. Check the 2/4WD relay and select switch, replace as
necessary.
dipstick or inside the filler tube. For oil analysis purposes, the
maximum permissible water content of the oil is 0.10%.
If the transmission oil has been contaminated with water,
faults or damage to the gearbox may be apparent as a result.
Before remedying, thoroughly investigate and rectify the
cause of the water contamination.
C a r r y o u t f l u s h i n g p r o c e d u r e . R e f i l l w i t h t h e
recommended grade of oil.
Renew missing/incorrect/damaged components. Carry
out flushing procedure. Refill with the recommended
grade of oil.
C a r r y o u t f l u s h i n g p r o c e d u r e . R e f i l l w i t h t h e
recommended grade of oil.
Inspect, renew damaged components. Carry out flushing
procedure. Refill with the recommended grade of oil.
Inspect, renew damaged components. Carry out flushing
procedure. Refill with the recommended grade of oil.
Inspect, renew damaged components. Carry out cooler
test procedure. Carry out flushing procedure. Refill with
the recommended grade of oil.
Possible Cause
the oil from the transmission sump and external cooler circuit
into a suitable container.
Remedy
Remedy
Remedy
Replace/renew dipstick. Carry out
flushing procedure. Refill with the
recommended grade of oil. Drain the
oil level to the correct level, see
Check Oil Level, Section 3.
Renew friction plates. Carry out
flushing procedure. Refill with the
recommended grade of oil.See Fault
Finding - Synchro Shuttle Gearbox
- Hydraulics.
Fit new bearings.
Carry out flushing procedure.
Refill with the recommended grade of
oil.