FUNK DF250 Manuals

Manuals and User Guides for FUNK DF250. We have 1 FUNK DF250 manual available for free PDF download: Manual

FUNK DF250 Manual (242 pages)

Transmissions (ANALOG)

Brand: FUNK | Category: Microphone system | Size: 4 MB

Introduction
3
Contents
4
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
Stay Clear of Rotating Drivelines
12
General Information
14
Specifications
14
Identification and Serial Number Plates
16
Recommended Lubricants
17
Ambient Air Temperature Chart
17
Cold Weather Startup
18
Stalling the Torque Converter
18
Cold Weather Operation
19
Alternate Warm-Up Procedure
19
Hot Weather Operation
19
Fill the Transmission with Oil
20
Check and Service Transmission Regularly
21
Check the Oil Level Daily
21
Oil Level
21
Intervals for Changing Transmission Oil and Filters
22
First Oil and Filter Change
22
Routine Oil and Filter Maintenance
22
Oil Analysis
23
Oil Temperature Warning Signal
23
Towing the Vehicle
24
Put Transmission in Storage
24
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
Tapered Pipe Thread with Sealant Chart
29
Tapered Pipe Thread Without Sealant Chart
29
Service Recommendations for O-Ring Boss Fittings
30
Straight Fitting
30
Angle Fitting
30
Straight Fitting or Special Nut Torque Chart
30
Service Recommendations for Flat Face O-Ring Seal Fittings
31
Flat Face O-Ring Seal Fitting Torque
31
Check Oil Lines and Fittings
32
Metric Bolt and Cap Screw Torque Values
33
Unified Inch Bolt and Cap Screw Torque Values
34
Use Proper Lifting Equipment
36
Transmission Lifting Procedure
36
Transmission Repair Stand
37
Mounting Df Series Transmission to Repair Stand
37
Safety Precautions
38
Torque Converter
40
Specifications
40
Remove Torque Converter and Drive Plate Assembly
40
Other Material
40
Disassemble and Assemble Drive Plate Group
41
Disassemble Drive Plate Group
41
Assemble Drive Plate Group
42
Remove Front Cover
45
Remove and Install Bearing in Front Cover
45
Remove Turbine Assembly
45
Remove Stator Assembly
46
Disassemble and Assemble Fixed Stator Assembly
46
Disassemble Fixed Stator Assembly
47
Stator Front and Back Side Identification
48
Assemble Fixed Stator Assembly
49
Disassemble and Assemble Free Stator Assembly
50
Disassemble Free Stator Assembly
51
Assemble Free Stator Assembly
52
Free Stator Clutch Assembly
54
Disassemble Converter Impeller
55
Assemble Converter Impeller and Hub
56
Assemble Stator to Impeller
58
Assemble Turbine to Stator
59
Assemble Front Cover to Turbine and Impeller
60
Other Material
62
Specifications
62
Disassemble Suction Tube Group
63
Remove Suction Tube Assembly
64
Assemble Suction Tube Group
65
Install Suction Tube
66
Charge Pump Group
67
Remove Charge Pump Group
68
Remove Driven Gear and Bearing Assembly
68
Disassemble Auxiliary Pump Drive Disconnect
70
Assemble Auxiliary Pump Drive Disconnect
71
Install Charge Pump to Front Cover
74
Other Material
76
Specifications
76
Disassemble Front Cover Group
77
Remove Front Cover and Input Assembly
78
Disassemble Input Assembly
81
Disassemble Front Cover
82
Remove and Disassemble Driven Gears
83
Assemble Driven Gears and Bearings
84
Remove Idler Gears and Disassemble
84
Assemble Idler Gears
85
Remove Magnetic Pickup
85
Assemble Input Assembly
86
Install Oil Seal and Ball Bearing
87
Install Idler Gears and Bearing Assemblies
88
Install Idler Shafts
89
Alternate O-Ring Installation Procedure
89
Install Driven Gear Assembly
91
Assemble Front Cover Group
94
Assemble Converter Input Shaft and Stator Tube
95
Install Front Cover Assembly to Main Case Front Housing
97
Remove and Install Wiring Harness
98
Remove Wiring Harness
98
Install Wiring Harness
98
Specifications
98
Remove Control Valve Group
99
Disassemble and Assemble Control Valve
100
Install Control Valve Group
101
Cap Screw Tightening Sequence and Torque Specifications
102
Piping Diagram, Converter Driven Transmission, (Without Wet Brake)
103
Pressure and Temperature Check Ports (Without Wet Brake)
104
Operating Conditions
104
Main Case Front Housing
106
Remove and Install Dipstick Assembly
107
Remove Output Yoke
108
Remove Internal Disconnect
108
Disassemble and Assemble Ground Driven Pump
117
Disassemble and Assemble Front Housing
121
Install Bore Sleeves
126
Remove Lube Relief Valve
127
Install Lube Relief Valve
127
Remove Bearing Cup
127
Install Bearing Cup
128
Remove Oil Seal
128
Install Oil Seal
128
Install Front Housing to Rear Housing
129
Remove Magnetic Pickup from Rear Housing
132
Specifications
132
Remove Output Group
133
Disassemble Output Group (no Disconnect) and Oil Trough
134
Disassemble and Assemble Output Group (with Internal Disconnect)
135
Disassemble Output Group with Internal Disconnect
136
Remove All Clutch Stage Assemblies
142
First Stage Shaft Assembly
144
Second Stage Clutch Assembly (Df150)
145
Third Stage Clutch Assembly (Df150)
146
Fourth Stage Clutch Assembly
147
Fifth Stage Clutch Assembly
148
Disassemble Clutch Stage Assembly
149
Sizing Seal Rings
166
Install Stage Assemblies into Rear Housing
167
Gear Ratio Group
168
Install Output Group (no Disconnect) and Oil Trough
170
Install Output Group and Oil Trough
171
Specifications
172
Rear Housing Component Identification (Df250)
173
First Stage Cover Group
174
Remove First Stage Cover Group
175
Install First Stage Cover Group
176
Remove Bearing Retainer
177
Setting End Play of Output Group
182
Install Output Yoke
182
Disc Brake Group
186
Disassemble Disc Brake
187
Assemble Disc Brake
189
Special Tools Used in this Manual
192
Assembly Stand Plate
193
Front Cover Lifting Tool
195
Suction Leak Test
196
Solenoid Valve Operation
197
Clutch Solenoid Voltage Requirements
198
Test Solenoids
198
Df Power Flow Forward Speeds
199
Df Power Flow Reverse Speeds
200
Troubleshoot Transmission System Malfunctions
205
Transmission Control Unit
210
Trouble Shooting Introduction
210
Theory of Operation
211
System Components
211
Required Components
211
Component Functions
212
Basic Components
212
Transmission Control Unit (TCU)
212
Engine Speed Magnetic Pickup
213
Cylinder Magnetic Pickup Sensor
213
Connector Pinouts
213
Output Speed Magnetic Pickup Sensor
214
Connector Pinouts
214
Bump Shift Handle
215
Calibration
216
Reasons to Calibrate
216
Clutch Calibration Four Forward Speeds and Four Reverse
217
Clutch Calibration Eight Forward Speeds and Four Reverse
218
Gear/Diagnostic Indicator
219
Inching Pedal
219
Park Pressure
220
Park Brake
220
System Requirements
221
J1 Connector
221
J2 Connector
222
J3 Connector
222
Function of Proportional Valves
223
Proportional Valves
224
System Errors
225
Analog Error Codes
226
Glossary
235
Abbreviations Used in Tcu Group
236
Index
238

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FUNK DF250 Manual (242 pages)

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