Service Manual. Eaton Hydraulic Launch Assist (HLA) TRSM1200 June 2012

Transcription

1 Service Manual Eaton Hydraulic Launch Assist (HLA) TRSM1200 June 2012

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3 Table of Contents Warnings and Cautions Definitions Hydraulic Launch Assist (HLA) Warnings and Cautions Emergency Procedures Accumulator Stored Energy Drain Procedure Towing General Information How to Use This Manual HLA System Identification Serial Tag Location Hydraulic Hybrid Overview Driver Display Module Startup Procedure Bootstrapping Operation Accumulator Inspection Accumulator Nitrogen Precharge Typical Installation and Configuration HLA Hybrid Components and Connector Locations Maintenance General Maintenance Tips Service and Maintenance Shutdown Procedure Accumulator Stored Energy Drain Procedure Manual Relief Valve Drain Procedure Inspection Procedures Maintenance and Inspection Intervals Warning Label Positions HLA System Oil Regular Maintenance Oil Sample Procedure HLA System Filter Maintenance HLA System Oil Fill Accumulator Precharge Procedure Transfer Case Service Procedures Service and Maintenance Shutdown Procedure Accumulator Stored Energy Drain Procedure System Overhaul Swash Carrier Assembly Charge Pump Replacement Transfer Case Replacement Transfer Case Warnings and Cautions Model Identification General Information Installation Instructions Repair and Rebuilding Instructions Cleaning and Inspection Instructions Reassembly Instructions Assembly of Shift Mechanism Preventative Maintenance Oil Capacity Recommended Oil Type General Information Input Shaft Seal Replacement Accumulator Replacement Accumulator Bladder Repair Electrical Enclosure Electronic Control Unit Replacement Splice Packs Wire Harness Connectors Reservoir Replacement Reservoir Cover Main Filter Assembly Replacement Return Manifold Replacement Cooler Replacement Hose Assemblies Replacement Standard Reservoir Design Offset Reservoir Design Suction Hose Case/Cooler Hose High Pressure Hose Low Pressure Return Hose Sensors Replacement Swash Sensor Accumulator Foot Valve Proximity Sensor Accumulator Pressure Sensor Transfer Case Engagement Proximity Sensor Speed Sensor Filter Pressure Delta Sensor i

4 Table of Contents Level Sensor Pump Temperature Sensor Reservoir Temperature Sensor Valves Replacement Mode Valve Directional Control Valve Bypass Valve (Main Stage) Charge Pump Bypass Valve Bypass Valve Pilot Cartridge Isolation Valve Manual Relief Valve Pneumatic Clutch Valve Wiring Repair Instructions Vehicle Harness Routing Proper Routing Techniques Improper Routing Techniques Wiring Schematic Hydraulic System OEM Electrical Circuit.. 89 Appendix Fault Codes Nitrogen Gas Precharge Pressure Chart.. 94 HLA High Performance Hydraulic Fluid Data Sheet Physical Characteristics Chemical Characteristics Hose Chart Sub-System Weights Special Tools Torque Specifications Connector List HLA Maintenance Check Sheet Real Time Warranty Pre-Call Checklist ii

5 Warnings and Cautions Warnings and Cautions Definitions Throughout this manual there are sections that are marked Warning, Caution or Important. These special paragraphs contain specific safety information and must be read, understood and heeded before continuing the procedure or performing the step(s). WARNING Warning indicates you will be severely Injured or Killed if you do not follow the indicated procedure. CAUTION Warnings and Cautions Caution indicates an Immediate Hazard, which could result in Severe Personal Injury if you do not follow the indicated procedure. IMPORTANT Important indicates Vehicle or Property Damage could occur if you do not follow the indicated procedure. Note: Note indicates additional detail that will aid in the service or repair of component or system. Hydraulic Launch Assist (HLA) Warnings and Cautions WARNING Improper service and maintenance will cause vehicle damage or personal injury. Do not repair, service or maintenance the HLA system without the service manual or proper training and tools. HLA system will not stop vehicle. Driver must be prepared to apply brakes anytime the HLA system is in regenerative braking. Do not operate HLA system without body installed. HLA system is not designed for no-load operation. Wheel skid may occur. Do not check accumulator precharge with key on and stored oil in accumulator. Do not use liquid nitrogen, oxygen or compressed shop air to charge accumulator. In the event of an accident, the accumulator should be removed for inspection and replacement. 1

6 Warnings and Cautions High pressure accumulator under high pressure reaches 5000 psi. Follow venting and drain procedures to relieve pressure. High pressure accumulator has both stored oil and nitrogen gas under pressure. Nitrogen gas remains under pressure even when stored oil has drained. Do not cut, hammer or weld to the accumulator shell, high pressure tube, hose assembly or pressure fittings attached to the accumulator. Failure to properly install the thermal relief fuse cap could result in an accumulator burst event if the accumulator becomes overheated. Avoid suffocation. Nitrogen asphyxiates. Move to ventilated area upon opening the vent. See MSDS for more information on nitrogen gas. Do not use automotive type valve cores in high pressure hydraulic accumulator gas port. Do not push or unscrew gas valve core with nitrogen gas precharge. CAUTION IMPORTANT For proper operation. Use only dry industrial grade nitrogen to charge accumulator. Read the entire manual before operating HLA system. Battery (+) and (-) must be disconnected prior to any type of welding on any Hybrid equipped vehicle. Do not use HLA mounting frame or components as a jack support. Driveshaft behind the transfer case or axles must be removed before towing vehicle. Use only original Eaton HLA replacement parts and fluids. Emergency Procedures Use the relief valve manual release to relieve any pressurized oil in the HLA system. See Manual Relief Valve Drain procedure. Do not cut, hammer or torch accumulator shell. Accumulator maintains gas pressure when HLA pressurized oil is removed. Wear hearing protection. Venting accumulator nitrogen gas may make a loud whistle noise. Vent accumulator nitrogen gas precharge prior to servicing accumulator. Follow Venting Nitrogen Gas from Accumulator procedure. Prior to any work on the HLA system, perform the HLA service and maintenance shutdown procedure and lockout/ tagout in accordance with local facility. Vent accumulator nitrogen gas in a well ventilated area. Before servicing the HLA system, allow accumulator to depressurize for five minutes minimum with the key off. Thermal relief fuse cap must be in good condition and properly installed. HLA components and surfaces get hot during operation. Avoid contact. May cause burn and/or other injury. Escaping nitrogen gas is extremely cold and may freeze skin. Avoid skin contact with the nitrogen gas to prevent freezing damage to skin tissues. 2

7 Warnings and Cautions Accumulator Stored Energy Drain Procedure 1 Turn ignition switch to OFF. OFF WARNING High pressure accumulator has both stored oil and nitrogen gas under pressure. Nitrogen gas remains under pressure even when stored oil has drained. 2 Wait 5 minutes. Warnings and Cautions Note: System allows controlled drain of accumulator through START ON 5 Min Fluid Bladder 3 Verify pressure has drained accumulator following these (3) methods: a. Turn ignition switch to ON and check state of charge bar on driver display. b. Connect ServiceRanger to check accumulator pressure bar. c. Open manual relief valve. See Manual Relief Valve Drain Procedure. OFF START ON Manual Relief Valve Protective Cap 3

8 Warnings and Cautions Towing When towing vehicle, do not allow output shaft of the HLA system to spin or turn. If vehicle is towed with drive wheels still in contact with road surface, remove or disconnect vehicle axle shafts or driveline. WARNING Serious internal transmission damage and damage to HLA system can result from improper vehicle towing. Prefered Must remove driveshaft between HLA transfercase and rear axle 4

9 General Information General Information How to Use This Manual For parts and technical support visit roadranger.com or call the Roadranger call center at HELP. HLA System Identification Serial Tag Location Hydraulic Pump Tag General Information Serial Tag Information The HLA system serial tag contains very useful information and is the first place to look to identify the system. Being able to read the tag can help determine which service manual to use and the date the system was manufactured. HLA System Tag Information Line 1 Information Line 2 2D Data- Matrix Bar Code XXXXXXXXXXXXX Part Number with Revision/ Model Code 12-Digit Unique Serial Number Reservoir Tag Model Number: Identifies factors such as configuration and design level. Serial Number: Identifies number of build. Product Serialization/Unique Identifier 12 Digit Serial Number SPMHMMDDYY@XX SP = common identifier for Spencer plant H = common identifier for hybrids MM = two (2) digit month code DD = two (2) digit date code YY = two (2) digit year = unit build shift identifier (2, 3, 4) XX = unique subsystem number in shift (01, 02, 03, etc.) Shift Identifier 2 = second shift 7:00 am to 3:00 pm 3 = third shift 3:00 pm to 11:00 pm 4 = fourth shift 11:00 pm to 7:00 am Cooler Tag Transfer Case Tag Accumulator Tag (SN# on shell and Fab# on tag) 5

10 General Information Hydraulic Hybrid Overview Parallel Hydraulic Hybrid Architecture The Hydraulic Launch Assist (HLA) is a hybrid system designed to increase fuel economy and increase vehicle brake life in vehicles with heavy start-stop drive cycles, such as refuse trucks. The system does this by capturing energy during braking and then reusing the energy to launch the vehicle (braking regeneration). HLA is a parallel system which means both the engine and the HLA pump can turn the drive axle (together or independently). The parallel architecture allows the vehicle to continue driving if the HLA shuts down. The HLA attaches to existing drivelines and does not replace entire existing transmissions. It can be installed at any point during vehicle build and may be retro-fitted. System Specifications 10-year design life Ambient operating temperature ranges Full function range: -22 F to 122 F (-30 C to 50 C) Annual service - System oil - Main filter - Point of use filter - Reservoir breather Maximum rated pressure bar psi System oil volume - 80 liters - 21 gallons Typical peak power per cycle kw HP Pump maximum revolutions per minute 3000 RPM Driver Display Module The driver display module is mounted in the dashboard as a visual aid for the driver and is used to monitor the HLA system operation. At key on, all lights will flash as self-check. Only those applicable will remain illuminated. Two-digit fault code indicator. Either SERVICE or STOP will also light. HLA System E SOC F OFF ECON PROD SERVICE STOP State of Charge Bar: 0 bars = empty 8 bars = full Operational Mode Diagnostic Code The fault number indicator will present a two-digit code that can be referenced in the troubleshooting manual. The display is blank when no fault is present and the system is functioning properly. Any fault code will disengage the HLA system. State of Charge Bar (SOC) The state of charge bar has eight (8) segments which represent the current amount of stored energy. All eight segments are illuminated at maximum stored energy. The illuminated portion of the bar will: Decrease when accelerating Increase when decelerating Optimum use of the HLA system will occur when the state of charge indicator goes from empty to full during each braking event of the cycle. Operational Mode One of three lights will be lit to indicate the state of the system: OFF, ECON, or PROD (productivity). These states can only be changed using a service tool and are not a driver option. Service When the amber service light is lit, it means the HLA system has been disabled a fault code will appear. The HLA system requires service, but the vehicle may be driven. Record the fault number and conditions at time of fault. 6

11 General Information Stop When the red stop light is lit, it means the HLA system malfunctioned a fault code will appear. The transfer case is not disengaging as commanded, causing a mission stopping fault. This fault will put the engine in limp mode, not allowing the vehicle to exceed 7 mph. Do not drive the vehicle. Tow the vehicle to a service center. The rear driveshaft must be removed prior to towing the vehicle. Startup Procedure 1. Turn ignition key to ON to power HLA system and start engine. ECU does internal memory check. 2. Check driver display module for any fault codes. 3. Apply service brake. 4. Select drive gear on shift console. 5. Release service brake and apply accelerator. Bootstrapping IMPORTANT HLA System E SOC F OFF ECON PROD SERVICE STOP Bootstrapping is the process of turning the pump shaft by driving the vehicle. This generates pump flow which pushes against the accumulator bladder, generating pressure used to control the system. It occurs automatically when the vehicle is turned on. During the initial pump rotation after startup, oil is pushed into the accumulator. This small amount of oil is used to shift valves and pistons to control the system. Operation The following section describes how the HLA functions during different states of operation. Driving Hydraulic Launch Assist is automatic and will be active within the system parameters without driver interaction. The transfer case will only engage when: Engine is running. Vehicle is in drive. Vehicle is stopped (0 mph). No faults are present. HLA will function only within these parameters: Vehicle speed is between 3-22 mph. No faults are present. Storage is available for pumping/regeneration. Stored energy is available for motoring/launch assist. Note: HLA will only assist acceleration when accelerator pedal is pressed and there is stored energy available in the accumulator. HLA will disengage when: Cruise control is on. Vehicle is not in drive. ABS sets a fault. Vehicle speed exceeds 25 mph. Monitor the driver display module for HLA system operation or fault codes. Coast Feature HLA will slow the vehicle once the accelerator pedal is released. Lightly holding the accelerator pedal allows the vehicle to coast by keeping HLA regeneration on standby. Note: If the vehicle speed exceeds HLA system limits, the system will disengage. The transfer case will not reengage until the vehicle has come to a complete stop unassisted by HLA. The speed of disengagement will vary depending on gear ratio. Disengagement is typically set at 25 mph. General Information 7

12 General Information Note: HLA is not active in Reverse. HLA will disengage when not in drive, with cruise control on or with parking brake set. These vehicle conditions are monitored by the ECU over the J1939 data link. Vehicle Braking/Regeneration The HLA system on the vehicle uses regenerative braking to capture and store energy in the hydraulic accumulator. When the accelerator pedal is released, regenerative braking will start when HLA is active, has no faults and has available oil storage capacity. The regeneration will feel as if the brake pedal is being lightly applied. During regeneration, oil is being pumped into the accumulator, capturing the vehicle s kinetic energy. The load on the pump helps slow the vehicle. The full power of the service brake is always available to the driver. IMPORTANT The HLA system will automatically shut off regenerative braking in the following situations. Driver must always be ready to apply service brake. When the accumulator is fully charged. If a system fault occurs. During an ABS (anti-lock brake) event; i.e. skidding on black ice while trying to brake the vehicle. CAUTION Pump Over Speed Protection The HLA system will disengage if the pump exceeds 3,000 rpm. Typically this pump speed occurs between mph, depending on tire size and final drive ratio. At 3,000 rpm, the ECU will command the transfer case to disengage. The ECU will compare pump speed to vehicle speed to confirm disengagement. If disengagement is not confirmed, the pump will over speed and a diagnostic code will occur. The red stop lamp will illuminate on the driver display. The ECU will command the engine to limp mode and the vehicle will need to be towed for service. Note: The driveshaft must be removed prior to towing. Power Down 1. Select N (neutral) on shift control. 2. Set vehicle parking brakes. 3. Turn ignition key to OFF and allow engine to shutdown. Note: Any oil stored in the accumulator as HLA energy will drain back to the reservoir once ignition is turned off. Shutdown The HLA system automatically drains the stored energy when the vehicle is turned off. No operator action is required. The high-pressure oil is automatically drained from the accumulator to the reservoir. Be prepared to apply the service brakes any time HLA is in regenerative braking. Pumping/Regeneration (Slowing) Releasing the accelerator pedal or pressing the brake pedal activates regeneration energy storage. Vehicle coasts by holding or pressing the accelerator pedal at 10% of travel or less, or about 3/4 (20 mm) down. Vehicle retardation rate for HLA regeneration is set with system diagnostic and service tool. The rate of vehicle deceleration to HLA pump torque is applied to the driveline through the transfer case. Motoring/Launch Assist Pressing the accelerator pedal sends a torque request command to the ECU. The ECU commands the swash to motoring and the mode valve to open which turns the pump, providing torque to the driveline. Within normal operating parameters, the HLA system will supply torque until normal energy is depleted. The ECU will command the swash to neutral when stored energy is gone. 8

13 General Information Accumulator Inspection Visually inspect accumulator for: Thermal cap installation Secure straps Damage Accumulator Nitrogen Precharge Requires nitrogen charging kit. Follow the Accumulator Precharge Procedure on page 25. General Information 9

14 General Information Typical Installation and Configuration Secondary Filter (Point of Use) Pump/Motor Filter Reservoir Transfer Case Breather Sight Level Gauge Cooler Accumulator ECU Gas Port 10

15 General Information HLA Hybrid Components and Connector Locations Speed Sensor Swash Sensor 1 Directional Control Valve Isolation Valve Bypass Valve Pilot Cartridge Level Sensor General Information Engagement Proximity Sensor Front of Vehicle Charge Pump Bypass Valve Fan Relay OEM Connection Electronic Control Unit 11

16 General Information Reservoir Temperature Sensor Filter Pressure Delta Sensor Mode Pilot Valve Fill Pump Temperature Sensor Pneumatic Clutch Valve Drain Front of Vehicle Pressure Sensor Oil Sample Valve Foot Valve Proximity Sensor Relief Valve Swash Sensor 2 12

17 Maintenance Maintenance General Maintenance Tips All parts must be clean, dry and free of chips and burrs prior to assembly. All moving contact surfaces of components should be lubricated at the time of assembly with Roadranger HLA High Performance Hydraulic Fluid. A thin covering of lubricant, such as petroleum jelly or Eaton silicon lube (part #71203), must be used on O-rings to assist in assembly. Gaskets should be assembled dry. Service and Maintenance Shutdown Procedure 1. Park vehicle in safe area on level ground. 2. Select N (neutral) on shift control and set vehicle parking brakes. 3. Turn ignition key to OFF. Allow accumulator to depressurize 5 minutes. Oil from accumulator will drain to the reservoir. See Accumulator Stored Energy Drain Procedure. 4. Allow accumulator temperature to stabilize when checking nitrogen gas precharge. 5. Use wheel chocks to block forward and reverse movement. 6. Prior to any work on HLA Electronic Control Unit (ECU), disconnect battery power to HLA system. 7. Check that accumulator pressure has vented completely. Use ServiceRanger diagnostic tool or manual relief valve to check system pressure. See Manual Relief Valve Drain Procedure. 8. Lockout and tag vehicle under repair in accordance with your local policy. 9. Drain vehicle air system when working on pneumatic clutch valve or transfer case. Maintenance 13

18 Maintenance Accumulator Stored Energy Drain Procedure WARNING High pressure accumulator has both stored oil and nitrogen gas under pressure. Nitrogen gas remains under pressure even when stored oil has drained. 1 Turn ignition switch to OFF. OFF 2 Wait 5 minutes. Note: System allows controlled drain of accumulator through START ON 5 Min Fluid Bladder 3 Verify pressure has drained accumulator following these (3) methods: a. Turn ignition switch to ON and check state of charge bar on driver display. b. Connect ServiceRanger to check accumulator pressure bar. c. Open manual relief valve. See Manual Relief Valve Drain Procedure. OFF START ON Manual Relief Valve Protective Cap 14

19 Maintenance Manual Relief Valve Drain Procedure Inspection Procedures Use the system manual relief valve to drain any pressurized oil from the accumulator to the reservoir. 1. Follow Service and Maintenance Shutdown Procedure. 2. Using a 1/2 wrench, remove protective cap from manual relief valve. 3. Using a 1/8 hex wrench, slowly back out O-ring plug. Note: Plug does not need to be removed from port. If plug is removed, shims must be kept in place. 4. If present, pressurized oil will be audible as it drains to tank. Allow accumulator to drain for 5 minutes minimum. 5. Tighten plug into port with shims in place. Torque to 5 ft-lb. See appendix Torque Specifications. 6. Install protective cap. Inspect HLA System Daily Inspect HLA system daily during vehicle pre-trip inspection. The following is a list of routine checks. Check reservoir oil level with ignition key off. Check reservoir breather indicator. Check for oil leaks under vehicle. Check for loose or low hanging hoses or wires. Check accumulator thermal relief cap is installed. Maintenance Check Cooler Screen and Clean/Remove any Debris Check driver display for faults. Note: Report and correct any defects prior to operation of HLA system. Additional inspections are listed in the appendix and Maintenance and Inspection Intervals table. Manual Relief Valve Protective Cap 15

20 Maintenance Check Reservoir for HLA System Oil Level Note: Check oil level daily. 1. Warm up system to normal operating temperature. Check at end of shift if possible. 2. Follow Service and Maintenance Shutdown Procedure. 3. Visually inspect reservoir oil level. Level should be within specified range. Note: System must be keyed off for proper oil level reading. Note: Overfilling reservoir or topping off reservoir with accumulator full will cause an oil spill. Breather Reservoir Breather Check and Replacement Inspect breather cleanliness indicator on top of housing. When filter is clogged, indicator will show red. Replace breather if indicator is red or during regular maintenance schedule. 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove breather from fill port by hand. 3. Visually inspect O-ring condition. Replace if damaged. 4. Install new breather and tighten against O-ring by hand. Clear Filter Clogged Filter Oil Level 4. To top off oil, reservoir may be filled from the breather port. Note: When changing system oil, fill using the pump quick disconnect following the HLS System oil fill procedure. 16

21 Maintenance Maintenance and Inspection Intervals Regular maintenance is important for safe and reliable operation of the HLA system. A preventive maintenance (PM) schedule should be set up as indicated below. Component Maintenance Note In Service (PDI) Hose Visually inspect for hose abrasion or wear Check for low hanging or loose hose Pre-trip Inspection PM Interval (Hours) T-Case Oil Check oil level X X Sub-Frame System Reservoir Breather Fittings System Change transfer case oil (75W-90 Synthetic, 1.9 gallons) Visually inspect mounting frame and check for cracks in welds Inspect mounting bolts, retorque as needed Inspect absorbers for wear Inspect pump and components for leakage Inspect warning labels, replace if damaged or missing Check for driver display module function and no codes Check breather indicator; replace if red FE 75W-90 Synthetic Replace breather Part # Check for loose fittings, hose and connections Record Component Serial Number and submit to Real Time Warranty (RTW) X X X X X X X X X X X X X X X X X X X Maintenance 17

22 Maintenance Component Maintenance Note In Service (PDI) HLA System Oil Check oil level in reservoir X X X Capture oil sample and Kit # analysis Change oil) HLA Oil (21 gal) RRHLADR (55 gal) RRHLAPA (5 gal) Filter Change system oil filter Part # Accumulator Cooler Change secondary (POU) oil filter Check dry nitrogen precharge Part # X Visually inspect accumulator X Replace bladder X X Mark bladder service tag with in service date X Check thermal relief cap installation and condition Check intake screen and fan for debris and blockage; clean as needed Pre-trip Inspection X X X X PM Interval (Hours) X X X X X X 18

23 Maintenance Warning Label Positions Maintenance 19

24 Maintenance HLA System Oil Regular Maintenance Add Oil to Reservoir (Top-off Only) Note: Only use Roadranger HLA High Performance Hydraulic Fluid. Contact Roadranger Call Center to order oil, U.S. and Canada: Follow Service and Maintenance Shutdown Procedure. 2. Use filter cart to clean oil before adding to reservoir. 3. Remove reservoir breather to access oil fill port. 4. Add oil and fill to mid-range on sight level gauge. (1" = 1 gallon of oil) Breather Oil Level Oil Sample Procedure Note: Regular oil sampling in accordance with the maintenance schedule is a good practice procedure. CAUTION Oil sample valve may be hot from operation. Use thermal protection. 1. Obtain Eaton Fluid Analysis Kit (part #894276). Contact Eaton Hydraulics or your local Eaton distributor. See Note: Do not open sample bottle until ready to fill. 2. Fill out Test Sample Data Form as instructed on sheet: Include vehicle number/identifier, date, mileage and hours. Include your contact information, phone number and address for the analysis report. 3. Ensure system is at normal operating temperature by cycling HLA system for ten cycles minimum. 4. Follow Service and Maintenance Shutdown Procedure. 5. Place recycle pan under return manifold sample valve. 5. Replace breather on reservoir. See Replace Reservoir Breather. 6. Recheck oil level after short period of operation. Return Manifold Oil Sample Valve 20

25 Maintenance 6. Clean around sample valve with parts cleaner. 7. Remove dust cover on discharge port. 8. Flush valve: Turn knurled knob ¼ turn right. Bleed approximately 250 ml [about 1 cup] of oil into recycle pan. 9. Place open sample bottle into oil stream and flush with oil. 10. Place sample bottle into oil stream and fill approximately ¾ full. Note: Make sure bottle stays clean. 11. Cap sample bottle. 12. Release knurled knob. Valve will close automatically. 13. Replace dust cover. 14. Properly dispose of oil from recycle pan. 15. If system oil level has dropped below minimum level mark on reservoir, add Roadranger HLA High Performance Hydraulic Fluid. See Add Oil to Reservoir. 16. Send oil sample to: 4. Use 14mm hex socket to remove drain plug from reservoir. Allow reservoir to fully drain into recycle pan. Drain Plug (9/16" Hex Socket) Maintenance Eaton Corporation Innovation Center Vickers Fluid Analysis Service Northwestern Hwy Southfield, MI Drain and Replace HLA System Oil (Oil Change) Note: System filters should be changed during any system oil drain. 1. Follow Service and Maintenance Shutdown Procedure. 2. Verify accumulator has depressurized for 5 minutes minimum. 3. Place 25-gallon drain recycling container under reservoir. 5. Remove suction hose split flange and support suction hose from work area. 6. Remove filter assembly. 7. Inspect and clean inside of reservoir. 8. Check suction port and diffuser for debris; clean as needed. 9. Check magnet for debris and clean. 10. Install new filter element. See Change Main System Filter." 11. Reassemble filter assembly. 12. Reinstall suction hose and split flange. Torque flange bolts to 85 ± 6 ft-lb. See appendix Torque Specifications. 13. Use filter cart to fill with oil through pump case port. See Fill HLA System Oil. 14. Fill to mid-range on sight level gauge. 15. Operate system to normal system temperature and recheck oil level. See Check Reservoir for HLA System Oil Level. 21

26 Maintenance HLA System Filter Maintenance Offset Reservoir Design Return Block Contamination Bonnet Reservoir Filter Housing Filter Element Cover Plate Standard Reservoir Design Change Main System Filter Note: The main filter replacement should be combined with the PM oil change. The filter is integral to the reservoir, which must be drained in order to replace the filter element. 1. Follow Service and Maintenance Shutdown Procedure. 2. Verify accumulator has depressurized for 5 minutes minimum. 3. Place 25-gallon drain recycling container under reservoir. 4. Use 14mm hex socket to remove drain plug from reservoir. Allow reservoir to fully drain into recycle pan. 5. Remove filter housing cover plate bolts. 6. Remove cover plate. 7. Use handle to pull out filter element. 8. Remove contamination bonnet and retain. 9. Clean contamination bonnet and housing. Check threads. 10. Examine sealing surfaces inside housing for damage. 11. Check O-rings on clogging indicator and cover plate. Replace parts as necessary. 12. Check magnet for debris and clean. 13. Lubricate with Roadranger HLA High Performance Hydraulic Fluid: Sealing surfaces and thread on cover plate and housing O-rings on cover plate and filter element 14. Fit old contamination bonnet onto new filter element by turning clockwise. 15. Insert filter element with bonnet into housing. 22

27 Maintenance Note: Location spigot and element handle position must align. 16. Reinstall filter housing cover plate and hand tighten cover plate bolts. 17. Tighten bolts alternately and torque to 30 ft-lb. See appendix Torque Specifications. 18. Reinstall support hose and suction hose flange. Torque flange bolts to 85 ± 6 ft-lb. See appendix Torque Specifications. 19. Use filter cart to fill with oil through pump case port. See Fill HLA System Oil. 20. Fill to specified mid-range level on sight level gauge. 21. Operate system to normal system temperature and recheck oil level. See Check Reservoir for HLA System Oil Level. Change Point of Use Filter Maintenance Filter Block Filter Bowl Filter Element 1. Follow Service and Maintenance Shutdown Procedure. 2. Place drain pan under filter. 3. Use 15/16 wrench to remove filter bowl. 4. Remove filter element. 5. Clean filter bowl. 6. Lubricate seal of new filter element. 7. Install new filter element onto filter block. 8. Install filter bowl. Torque bowl to 60 ± 5 ft-lb. See appendix Torque Specifications. 23

28 Maintenance HLA System Oil Fill Fill HLA System Oil 1. Follow Service and Maintenance Shutdown Procedure. 2. Use HLA filter cart to clean oil added to system. 3. Attach quick disconnect from filter cart to pump quick disconnect. 4. Use filter cart to fill system with oil. 5. For oil change and pump service, fill with oil to top of sight level gauge. Note: Oil level will drop to mid-range level after start-up. 6. Disconnect filter cart quick disconnect. Note: System must be keyed off for proper oil level reading. Air Bleed Procedure 1. After filling the system, it is necessary to bleed air from the pump. 2. Push down on pump quick disconnect check valve seat to relieve air from system before start-up. 3. Install protective cap on pump quick disconnect. Alternate Air Bleed Method 1. Tap -4 O-ring plug with hammer and drift punch prior to removal. 2. Use 3/16 hex bit to remove -4 O-ring plug from back of charge pump housing. Push to Relieve Air -4 O-Ring Plug Quick Disconnect 3. Allow air to vent for one minute minimum. 4. Reinstall -4 O-ring plug. Torque to 9 ± 1 ft-lb. See appendix Torque Specifications. 5. Recheck oil level after short period of operation. Oil level will be lower after initial operation and should be maintained at mid-range of sight level gauge. 24

29 Maintenance Accumulator Precharge Procedure High Pressure Accumulator Warnings and Cautions WARNING Do not use oxygen or air for charging the accumulator. Explosion may result. Failure to properly install thermal relief fuse cap could result in an accumulator burst event if accumulator becomes overheated. Accumulator Identification Bladder tag should be marked with date of in service. BLADDER SERVICE DATE TAG INSTRUCTION: INDENT YEAR & MONTH WHEN BLADDER IS PLACED INTO SERVICE YEAR: MONTH: Maintenance IMPORTANT Use only dry industrial grade nitrogen to charge the accumulator. Accumulator Components Nitrogen Cap/ Thermal Fuse Anti-Extrusion Ring Pressure Sensor Shell Fluid Port Gas Valve Foot Valve Foot Valve Proximity Sensor Nitrogen Cap Bladder Tag Gas Port 25

30 Maintenance Accumulator Nitrogen Precharge Process Note: The best time to measure accumulator pressure is at start of shift or after vehicle and accumulator cool down to ambient temperature. For most accurate measurement, allow a minimum of 4 hours between operation and checking gas precharge. 1. Follow Service and Maintenance Shutdown Procedure. 2. Check temperature of the accumulator to get the correct setting from the chart. 3. Clean dirt and debris from gas valve protective cap area of accumulator. 4. Remove gas valve protective cap to expose gas valve port. 5. Check for damage to the gas valve by looking for a bent valve core. 6. Before applying the charge kit, verify the stem is in good condition. 7. While the cap is off from the accumulator, check the thermal fuse pin for good condition. 8. Securely attach nitrogen charge kit gauge assembly to gas valve port. 9. Open pressure gauge valve per kit manufacturer s instructions and read pressure. 10. Based on the measured temperature, compare pressure to pressure chart. See Nitrogen Gas Precharge Pressure Chart. 11. Add or vent nitrogen until pressure reaches level prescribed in chart. 12. Close pressure gauge valve. 13. Remove nitrogen charge kit gauge assembly from gas valve port. 14. Securely attach thermal relief fuse and gas valve protective cap. Torque to 15 ft-lb. See appendix Torque Specifications. Nitrogen Gas Precharge Pressure Chart Note: Nitrogen gas pressure is affected by temperature and volume. After HLA system has been used, some oil will remain trapped inside accumulator. Precharge Gas Pressure PSI [bar = PSI* ] Fahrenheit ( F) Temperature Celsius ( C) lb/in 2 (PSI) Pressure The formula for precharge pressure to temperature: P = 4.4(T)+1500 Bar P = Gas Pressure (psi) T = Gas Temperature* ( F) *Gas pressure is most accurate after a long (4hrs+) down time allowing the gas temperature to equalize with the room air temperature. 26

31 Maintenance WARNING Failure to properly install thermal relief fuse cap could result in an accumulator burst event if accumulator becomes overheated. Avoid suffocation. Nitrogen asphyxiates. Move to ventilated area upon opening the vent. See MSDS for more information on nitrogen gas. CAUTION Escaping nitrogen gas is extremely cold and may freeze skin. Avoid skin contact with the nitrogen gas to prevent freezing damage to skin tissues. Vent Nitrogen Gas from Accumulator 1. Follow Service and Maintenance Shutdown Procedure. 2. Clean dirt and debris from gas valve protective cap area of accumulator. 3. Remove gas valve protective cap to expose gas valve port. 4. Check for damage to the gas valve by looking for a bent valve core. 5. Securely attach nitrogen charge kit gauge assembly to gas valve port. 6. Open pressure gauge valve per kit manufacturer s instructions. 7. Vent nitrogen pressure to required level. 8. Close pressure gauge valve. 9. Remove nitrogen charge kit gauge assembly from gas valve port. 10. Securely attach thermal relief fuse and gas valve protective cap. Torque to 15 ft-lb. See appendix Torque Specifications. WARNING Avoid suffocation. Nitrogen asphyxiates. Move to ventilated area upon opening the vent. See MSDS for more information on nitrogen gas. Do not cut, hammer or weld to the accumulator shell or high pressure fitting attached to the accumulator. Do not use automotive type valve cores in high pressure hydraulic accumulators. CAUTION Escaping nitrogen gas is extremely cold and may freeze skin. Avoid skin contact with the nitrogen gas to prevent freezing damage to skin tissues. Wear hearing protection. Venting accumulator nitrogen gas may make a loud whistle noise. Maintenance IMPORTANT Add dry nitrogen slowly for first 7 bar (100 psi) to new or rebuilt accumulator. Do not exceed 2 bar (30 psi) per minute. Bladder damage may result if rapidly inflated. Improper nitrogen gas pressure will result in reduced HLA system performance. Precharge Accumulator with Nitrogen Gas (Adding Gas) Note: Nitrogen gas pressure is affected by temperature and volume. After HLA system has been used, some oil will remain trapped inside accumulator. 1. Follow Service and Maintenance Shutdown Procedure. 2. Clean dirt and debris from gas valve protective cap area of accumulator. 27

32 Maintenance 3. Remove gas valve protective cap to expose gas valve port. 4. Remove O-ring and bladder service date tag. 5. Securely attach nitrogen charge kit gauge assembly to gas valve port. Typical Nitrogen Charge Kit 6. Open pressure gauge valve per kit manufacturer s instructions and read pressure. 7. Add dry nitrogen until pressure reaches level prescribed in chart. See Nitrogen Gas Precharge Pressure Chart : For new or rebuilt accumulators, add nitrogen slowly for first 7 bar (100 psi). Do not exceed 2 bar (30 psi) per minute. For all other accumulators, add nitrogen at any convenient rate. Note: Accumulator will become warm during filling process. 8. Allow gas temperature to stabilize before reading pressure. 9. Close pressure gauge valve. 10. Remove nitrogen charge kit gauge assembly from gas valve port. 11. Securely attach thermal relief fuse and gas valve protective cap. Torque to 15 ft-lb. See appendix Torque Specifications. 28

33 Maintenance Transfer Case Breather Maintenance Oil Fill Plug (1" NPT) Drain Plug (¾" NPT) Oil Level Plug (½" NPT) Check Transfer Case Oil Level and Fill Note: Use only Roadranger FE 75W-90 or equivalent synthetic gear oil in transfer case. 1. Remove oil level plug and check oil level. 2. To fill transfer case: Remove oil fill plug and oil level plug. Add new clean oil through fill plug port until oil reaches bottom threads of oil level plug. Reinstall all plugs using thread sealer and tighten. Change Transfer Case Oil Note: Use only Roadranger FE 75W-90 or equivalent synthetic gear oil in transfer case. 1. Remove drain plug, oil fill plug and oil level plug. 2. Check for metal chips on drain plug magnet. Clean as required. 3. Allow oil to drain. 4. Reinstall drain plug using thread sealer and torque to 50 ft-lb. See appendix Torque Specifications. 5. Add new clean oil through fill plug port until oil reaches bottom threads of oil level plug (7.25 quarts/ 1.9 gallons). 6. Reinstall all plugs using thread sealer and tighten. 29

34 Maintenance Replace Transfer Case Breather Note: The breather is located on front side (opposite hydraulic pump) of transfer case. Removal and Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Using a 3/4 open end wrench, carefully remove breather. 3. Remove any dried thread sealant from mounting surface using putty knife or gasket scraper. Use care to keep debris out of port. 4. Apply thread sealant onto threads of new breather. 5. Thread new breather into mounting hole (3/8 NPT) and tighten securely. 30

35 Service Procedures Service and Maintenance Shutdown Procedure 1. Park vehicle in safe area on level ground. 2. Select N (neutral) on shift control and set vehicle parking brakes. 3. Turn ignition key to OFF. Allow accumulator to depressurize 5 minutes. Oil from accumulator will drain to the reservoir. See Accumulator Stored Energy Drain Procedure. 4. Allow accumulator temperature to stabilize when checking nitrogen gas precharge. 5. Use wheel chocks to block forward and reverse movement. 6. Prior to any work on HLA Electronic Control Unit (ECU), disconnect battery power to HLA system. 7. Check that accumulator pressure has vented completely. Use ServiceRanger diagnostic tool or manual relief valve to check system pressure. See Manual Relief Valve Drain Procedure. 8. Lockout and tag vehicle under repair in accordance with your local policy. 9. Drain vehicle air system when working on pneumatic clutch valve or transfer case. Service Procedures 31

36 Accumulator Stored Energy Drain Procedure WARNING High pressure accumulator has both stored oil and nitrogen gas under pressure. Nitrogen gas remains under pressure even when stored oil has drained. 1 Turn ignition switch to OFF. OFF 2 Wait 5 minutes. Note: System allows controlled drain of accumulator through START ON 5 Min Fluid Bladder 3 Verify pressure has drained accumulator following these (3) methods: a. Turn ignition switch to ON and check state of charge bar on driver display. b. Connect ServiceRanger to check accumulator pressure bar. c. Open manual relief valve. See Manual Relief Valve Drain Procedure. OFF START ON Manual Relief Valve Protective Cap 32

37 System Overhaul The following instructions are listed for a complete system removal including all major system components. Reservoir, Cooler and Hose Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Using ServiceRanger diagnostic tool, verify system has completely drained any pressurized oil from accumulator. If necessary, use manual relief valve to drain stored oil. See Manual Relief Valve Drain Procedure. 3. Vent vehicle air system to pneumatic clutch valve. 4. Take oil sample. See Capture Oil Sample Procedure. 5. Drain oil from reservoir. See Drain and Replace HLA System Oil. 6. Use bottom port plug to drain oil from pump case. 7. Remove vehicle drivelines. 8. Disconnect wire harness from accumulator and reservoir sensors. 9. Remove hose bolts and hoses from accumulator, cooler and reservoir. 10. Remove cooler bolts and cooler from chassis. 11. Support reservoir with transmission jack. 12. Remove reservoir mounting bolts and reservoir. CAUTION Pump weighs approximately 350 pounds. Pump/Motor and Transfer Case Removal 1. Follow Service and Maintenance Shutdown Procedure. Note: Use the Eaton HLA Pump Tool (part# RR1024HY). 2. Disconnect chassis harness from HLA enclosure connector. 3. Use bottom port plug to drain oil from pump case. 4. Remove any hoses connected to pump/motor. 5. Tie HLA harness from cooler, reservoir and accumulator to top of pump/motor. Make sure sides are clear. 6. Remove vehicle driveshafts. 7. Drain vehicle air tanks. 8. Support pump/motor with transmission jack. 9. Disconnect air supply line to pneumatic clutch valve. 10. Tie off supply line away from pump sub-frame. 11. Remove 4 vibration mounting bolts from sub-frame chassis. Service Procedures CAUTION Accumulator weighs approximately 460 pounds. Accumulator Removal Note: Measure the bracket center line to fluid port face prior to removal for proper placement during installation. 1. Remove middle bracket and strap from accumulator. 2. Support accumulator with transmission jack and strap to jack. 3. Remove outer bracket and straps from accumulator. 4. Slide accumulator toward rear and out of brackets. 5. Remove accumulator from under chassis. 33

38 12. Remove bolts and disconnect right side pump subframe. 13. Remove pump/motor from top side (for removal from bottom, go to step 14): a. Thread 5/8" eyebolts into threaded holes on pump. b. Attach hoist to eyebolts and transfer case lifting lugs. c. Lift pump/motor and slide to right side. d. Lift pump/motor and transfer case up and out of chassis. 14. Remove pump/motor from bottom side (for removal from top, go to step 13): a. Use transmission jack to lift pump/motor and transfer case and slide forward. b. Lower transmission jack. Note: Make sure all HLA components are free from chassis. c. Lift front of vehicle. d. Remove pump/motor from under chassis. Pre-install Checklist 1. Install one-inch 90º swivel fitting on pump cooler port. 2. Orient fitting straight down and torque to ± 2.5 ft-lb. See appendix Torque Specifications. 3. Install one-inch 90º nut-washer O-ring seal fitting on return manifold cooler port: Thread fitting to O-ring. Orient fitting down. Note: Do not tighten fitting. 4. Attach Warning, Caution and Important stickers to pump and components. 5. Fill transfer case with oil. See Check Transfer Case Oil Level and Fill. 6. Disconnect connector to transfer case proximity sensor and tie out of way of installation. 34

39 Pump/Motor and Transfer Case Installation 1. Install pump/motor from top side (for installation from bottom, go to step 2) after installing accumulator. Note: Use the Eaton HLA Pump Tool (part# RR1024HY). 2. Install pump/motor from bottom side (for installation from top, go to step 1): a. Position pump/motor on transmission and strap down. b. Remove right side sub-frame from pump/motor. c. Make sure vehicle front is lifted and position pump/motor under chassis. d. Lower chassis onto pump/motor. Make sure no wires or frames are caught between. e. Use transmission jack to lift pump/motor and push forward against front cross member. f. Lift pump sub-frame above chassis frame mounts. g. Move pump/motor toward rear over chassis frame mounts. h. Lower pump/motor into place. i. Reinstall right side sub-frame and torque bolts (see appendix Torque Specifications. ): 5/8-11bolts = 188 ± 19 ft-lb 3/4-10 bolts = 336 ± 34 ft-lb j. Install vibration mounting bolts and torque to ft-lb. See appendix Torque Specifications. k. Reconnect transfer case proximity sensor connector. 3. Remove all shipping plugs and covers. 4. Remove ECU shipping plug. 5. Install vehicle drivelines. 6. Lube U-joints. Accumulator Installation 1. Install accumulator into outer brackets straps and secure with bolts. 2. Adjust accumulator into for/aft position. 3. Rotate accumulator until proximity sensor port is horizontal and outwards of chassis. 4. Install middle bracket and strap and secure with bolts. 5. Torque all bracket strap bolts to 26 ft-lb. See appendix Torque Specifications. Accumulator Shield Service Procedures 35

40 Reservoir, Cooler and Hoses Installation 1. Install return manifold onto reservoir. Note: Use 7/16 open end return manifold studs with O-ring on reservoir. 2. Mount reservoir onto chassis. 3. Install hoses: Note: Lubricate suction, HP and return hose O-rings with petroleum jelly or Eaton silicon lube (part #71203). a. Suction hose b. Cooler hose on pump side c. High pressure hose d. Return hose: Install left side flange onto pump, return hose and right side flange. Pull return hose end into return manifold studs. Secure flanges with bolts. e. Cooler outlet hose 4. Install cooler to return manifold hose. 5. Install foot valve proximity sensor to accumulator and torque to 95 ft-lb. See appendix Torque Specifications. 6. Install pressor sensor to accumulator and torque to 56 ft-lb. See appendix Torque Specifications. 7. Connect wire harness to accumulator, cooler and reservoir sensors. 8. Securely tie down wire harness to hose and frame. 9. Fill transfer case with oil. See Check Transfer Case Oil Level and Fill. 10. Add oil to reservoir and fill to top of sight level gauge. See Add Oil to Reservoir. Note: Refer to Pump Fill Procedure in Roadranger lubricant section at Open air bleed plug. Note: Oil level will drop approximately 1" after start-up. 12. Reinstall plug on pump case port. 13. Make sure all wire and hose connections are secure. 14. Turn ignition key to ON and check for fault codes/ lights. 36

41 Swash Carrier Assembly Installation 1. Install the magnet carrier (170) and tighten to 26.5 ±1.5 in-lb. CAUTION Make sure the swash sensor plug (153) is orientated properly during installation. If the swash sensor plug (153) will not fully install, remove and verify proper orientation. 2. Install the swash sensor plug (153) with lubricated Nitrile o-ring into the housing subassembly using 4 UNF hex socket cap screws (55). Torque screws to 11 ±1.1 ft-lb. 3. Install feedback sensor (54), sticker or other identification away from the pump, with 2 Metric washers (150) and 2 hex socket head cap screws (87) as shown. Before tightening screws, adjust feedback the sensor so the screws are located at the center of the slot in the feedback sensor (54). Torque the screws to 26.5 ±1.5 in.lb. Service Procedures Removal 1. Remove 2 hex socket head cap screws (87), 2 Metric washers (150) and the feedback sensor (54). 2. Remove 4 UNF hex socket cap screws (55) and the swash sensor plug (153) from the housing subassembly. Remove the Nitrile o-ring from the swash sensor plug (153). 3. Loosen the hex socket cap screw and remove the magnet carrier (170). 4. Swash sensor calibration will be required after installation is complete. 37

42 Charge Pump Replacement Removal 1. Remove fasteners and cover assembly from pump assembly. 2. Remove dowel pins from pump assembly. 3. Remove O-ring from groove in cover assembly. 4. Remove fasteners and impeller subassembly from pump assembly. 5. Remove zero-leak plug from mating port. 6. Remove internal retaining ring from cover machining. 7. Remove seal sleeve from impeller. 8. Remove zero-leak plugs, fasteners from centrifugal pump housing subassembly. 9. Remove centrifugal pump housing subassembly. 10. Remove O-rings in end cover subassembly. 11. Remove transfer tube. Installation Note: Check ports for any blockage prior to installation. A blocked port will cause severe pump damage. Maintain clean environment to eliminate contaminants or debris in components during assembly. 1. Install O-ring onto transfer tube and lubricate. 2. Install transfer tube. 3. Install two O-rings in end cover subassembly. 4. Install centrifugal pump housing subassembly onto end cover subassembly. 5. Secure with fasteners and torque to 97 ± 9.7 ft-lb. See appendix Torque Specifications. 6. Install zero-leak plugs and torque to 63 ± 6.3 ft-lb. See appendix Torque Specifications. 7. Use installation tool provided to install seal sleeve onto impeller. Note: Make sure seal sleeve is pressed to shoulder on impeller. 38

43 8. Lubricate and install seal into cover machining. Note: Make sure orientation is correct. 9. Install internal retaining ring into cover machining. Note: Make sure retaining ring is fully seated into groove. 10. Install zero-leak plug into mating port and torque to 9.0 ± 1.0 ft-lb. See appendix Torque Specifications. 11. Install impeller subassembly onto pump assembly. Note: Make sure impeller is engaged over splines. Service Procedures IMPORTANT Important: Do not reuse fastener when securing impeller subassembly. Replace old fastener with new. 12. Secure impeller subassembly with washer and fastener. Torque fasteners to 39 ± 3.9 ft-lb. See appendix Torque Specifications. Note: Pump shaft will rotate if not secured prior to final tightening of fastener. A nylon strap wrench may be used to hold impeller subassembly while torquing fastener. 13. Install O-ring into groove in cover subassembly. Note: Lubricate with petroleum jelly if necessary. 14. Install dowel pins into pump assembly. 15. Install cover subassembly onto pump assembly. Note: Make sure O-ring has not fallen out of groove. 16. Install washers and fasteners and torque fasteners to 16 ± 1.6 ft-lb. See appendix Torque Specifications. 39

44 Transfer Case Replacement If pump/motor removal is also required, see Pump/Motor and Transfer Case Removal for correct procedure. CAUTION Transfer case weighs approximately 500 pounds. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain oil from transfer case. 3. Remove front and rear driveshafts connected to transfer case. 4. Disconnect harness connectors from transfer case. 5. Vent vehicle air system. 6. Disconnect airlines from pneumatic clutch valve to shift piston fittings. 7. Support transfer case with transmission jack. 8. Use 1-1/8" wrench to remove transfer case bolts from pump/motor. 9. Remove transfer case bolts from sub-frame. 10. Place oil pan under pump and transfer case. 11. Slide transfer case forward away from pump to free shaft. 12. Lower transfer case and remove from vehicle. 13. Check O-ring between transfer case and pump face for wear, cuts or damage. Replace as needed. Installation 1. Lift new transfer case and install in vehicle. 2. Slide transfer case back toward pump. Note: Make sure transfer case O-ring is in place. 3. Install transfer case to pump and secure with bolts. 4. Torque bolts to 336 ± 34 ft-lb. See appendix Torque Specifications. 5. Install transfer case onto sub-frame and secure with bolts. 6. Support transfer case with transmission jack. 7. Connect airlines from pneumatic clutch valve to shift piston. 8. Connect harness connectors to transfer case. 9. Reinstall front and rear driveshafts connected to transfer case. 10. Fill transfer case with Roadranger FE 75W-90 lubricant. 11. Reinstall air lines to transfer case shift piston fittings. 40

45 Transfer Case Warnings and Cautions Important Information - Please Read Carefully Upon receipt of product, immediately inspect for any indication of rough handling or damage in transit. This includes but is not limited to: scuffed paint, broken or damaged containers, broken or cracked housings, bent shafts, metal deformation, or shift in alignment of components. TORSIONAL VIBRATIONS, emanating from many modern diesel engines, can cause severe damage to power train components, resulting in premature failure. To insure the integrity of the power transmission system, a torsional vibration analysis should be performed and suitable vibration dampening components utilized, when indicated by the analysis. We are not responsible for damage or failure resulting from diesel engine generated torsional vibrations. Service Procedures Any evidence of damage or missing parts should be reported immediately to the carrier and a claim entered. CAUTION All units are shipped without oil! DO NOT OPERATE until unit has been filled to the proper level with the specified oil grade. Failure will occur if bearings and gears are not properly lubricated. Refer to Lubrication and Oil Filling Instructions. The following WARNING and CAUTION information is supplied to the Buyer for their protection and to provide the Buyer with years of trouble free and safe operation of your product. Read ALL instructions prior to operating transfer case. Injury to personnel or transfer case failure may be caused by improper installation, maintenance or operation. WARNING Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the product. The application by Buyer shall not be subject to any implied warranty of fitness for particular purpose. For safety, Buyer or user should provide protective guards over all shaft extensions and any moving apparatus mounted thereon. The user is responsible for checking all applicable safety codes in their area and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment. Hot oil can cause severe burns. Use extreme care when removing lubrication plugs and vents. Make certain that the power supply is disconnected before attempting to service or remove any components. Lockout the power supply and tag it to prevent unexpected application of power. Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors. If the transfer case cannot be located in a clear and dry area with access to adequate cooling air supply, precautions must be taken to avoid the ingestion of contaminates such as water, and the reduction in cooling ability due to exterior contaminates. CAUTION Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation. Refer to torque chart in the Appendix for proper torque specifications when tightening bolts. In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale: The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise, as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential damages. Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product. This information should be read together with all other printed information. 41

46 Model Identification 42

47 A name plate is mounted on every transfer case that is assembled at the factory. This nameplate provides the part number, the ratio and basic description, unit serial number, and date unit was assembled, and recommended oil type. Do not paint over, remove, or tamper with the name-plate, as this is the only type of identification for warranty repairs or replacement parts. Service Procedures Figure 1. Transfer Case, Front View 43

48 General Information The transfer case incorporates AGMA class 10 helical gears that run on taper roller bearings. Splines The transfer case has a 13T-8/16 internal spline on the input (motor/pump) gear. There are (2) 2-3/4-10 external splines (1) on each end of the input shaft supporting 1810, 1760, or 1710 series End Yokes. Oil Circulation Extensive testing was done on this transfer case gearbox to optimize the quantity of oil. The transfer case has special oil port locations that cause the oil to flow thru the bearings without the need for external pumps. Oil volume is critical to make this feature work and the oil level should be checked frequently. Motor/Pump Pad The motor/pump pad is integral to the transfer case unit. Input/Output Shaft The Input shaft of the transfer case is mounted on taper roller bearings which support the output gear via ball bearings. An intermediate shaft is located between the input and output shafts. A shift fork mounted on a parallel shaft engages and disengages the output gear thus driving the output shaft. Motor/Pump Shaft The motor/pump shaft of the transfer case is integral with the input gear mounted on taper roller bearings. Installation Instructions This unit is designed to be driven with a short coupled drive line connection to the input shaft. The input WILL NOT accept any overhung loads (i.e. belt sheaves, sprockets, or severely angled drive lines). For over hung load applications, contact Engineering. Mounting Procedures for Transfer Case The transfer case is to be supported on a rigid foundation using the mounting holes (4) each side (3/4-10 taps) provided in the transfer case housing. Inadequate mounting foundation may result in misalignment or excessive stress on the transfer case housing. This can cause undue noise, overheating, and possible failure. Note: To prevent loosening and misalignment, bolts must be tightened to recommended torque specification shown in Table 1 on page 53. CAUTION Failure to mount the transfer case in the specified orientation will cause premature failure! Alignment and Installation of U-Joints To realize the longest possible life of the transfer case, care in obtaining the best possible alignment must be maintained between the center line of the transfer case and the center line of drive/driven units. 1. It is extremely important that the forks of drive shafts between the transfer case and drive/driven units lie in the same plane. This will prevent severe vibrations from occurring. 2. The center lines of the transfer case and the drive/ driven units must be within the acceptable offset limits as determined by the U-Joint manufacturer to prolong the life of the universal joint needle bearings. 3. It is extremely important that the center lines of the transfer case and drive/driven units are parallel. This will further prevent vibrations which cause premature transfer case bearing failure. Installation of Hydraulic Motor/Pump to Transfer Case The motor/pump pad on the transfer case is a four-bolt mounting, with 3/4-10 UNC threads. Tighten to the recommended torque specification shown in Table 1 on page 53. Align the spline of the hydraulic motor/pump to the internal spline. DO NOT use the mounting holes to seat the hydraulic pump onto to the pump pad. Figure 2. Showing Mounting Pads Note: O-rings must be replaced anytime the hydraulic pump is removed from the transfer case. 44

49 Repair and Rebuilding Instructions Disassembly Instruction WARNING Make certain that the power supply is disconnected before attempting to service or remove any components. 1. Lockout the power supply and tag it to prevent unexpected application of power. 2. Drain oil while unit is still warm. 6. Evenly lift the front housing half, being careful not to lift any of the gears. Inspect the gears and bearings for any defects, wear, or contamination before removal. To remove the gears and bearings, swiftly and evenly lift from the housing. This can be done by hand as the bearings are taper roller. Service Procedures WARNING HOT oil can cause severe burns. Use extreme care when removing lubrication plugs and vents. 3. Properly support the transfer case and remove all retaining bolts from the frame mounting bolts. Note: Hydraulic motor/pump may remain connected however it is not recommended, for ease of disassembly and cleaning parts, that the motor/pump be removed. 4. Remove the hex nuts retaining the end yokes and remove from shafts on both sides. CAUTION To avoid oil leaks, all o-rings are to be replaced any time the motor/pump is removed. 5. Referring to Figure 3, place the transfer case on a flat surface with the pump pad facing down. Remove the two (2) dowel pins and all the cap screws before attempting to separate the housing halves. Use the cap screws in the threaded separating holes to split the housing halves. Slightly tap the front housing with a wooden mallet (or equal) to release the bearings and gears from the bearing cups. Figure 3. Lifting the Front Housing WARNING When rotating gears, keep hand and fingers clear from the gear mesh. 7. With all of the gears removed, drive the seals out of the covers and discard them. It is required to change the thru shaft seals any time the thru shaft has been removed from the housing. 8. To remove the bearings from the gears, use a gear puller or Arbor press. 9. To remove the bearing cups from the housings, use a driver or Arbor press. 45

50 Figure 4. Housing Half with Internal Assemblies Identified. Cleaning and Inspection Instructions 1. Replace all oil seals, o-rings, washers, snap rings etc. as a part of any maintenance or overhaul procedure. Replace shims that are damaged or destroyed in disassembly. 2. Clean all parts using EPA/OSHA approved solvents or by steam cleaning. Parts must be dried and oiled immediately. 3. Examine all parts carefully for grit, dirt and abrasives and reclean them if necessary. 4. For faces that have been joined with a sealant, scrape off old sealant material. Clean these faces with a solvent. 5. De-burr with a stone or file the vicinity of pusher screw locations. 5. Handle new replacement bearings with care. Do not remove them from their packaging until immediately Bearing Inspection We strongly recommends replacing all used bearings as a normal practice during repair or rebuild of the transfer case. However, if the bearings will be reused, the following provides pertinent information prior to reuse. 1. Thoroughly wash and soak the bearings as necessary in clean solvent. CAUTION Never dry bearings with compressed air. Do not spin bearings without lubrication. 2. Oil bearings with approved oil immediately after cleaning and protect them from contamination. 3. Inspect bearings for roughness of rotation. Replace the bearing if roughness is found. 4. Inspect bearing for corrosion, scored, scratched, cracked, pitted or chipped races, and for indication of excessive wear. Replace the bearing if any of these defects are found. before they are to be installed. 46

51 Housings and Cast Parts Inspection 1. Replace cast parts or housings that are cracked. 2. Inspect bearing bores for grooved, burred or galled conditions that would indicate that the bearing has been turning in its housing. If the damage cannot be repaired to like-new condition with a fine crocus cloth, replace the part. Bore diameters must not exceed the maximum dimension shown in the wear limits Table 2 on page Inspect machined surfaces for burrs, nicks or scratches that have material that extends above the surface. Remove material with crocus cloth or soft stone. Replace part if necessary. 4. Inspect all threads for damage. Chase damaged threads with a tap. Shaft, Gear, Sliding Collar, and Piston Inspection 1. Inspect bearing journals for grooved, burred or galled conditions that would indicate that the bearing inner race has been turning on the journal. Use crocus cloth to repair the damage, or replace the part. Bearing journals must not be less than the minimum diameters shown for the wear limits of Table Inspect seal ring grooves and ring grooves for wear or damage. 3. Inspect splines for stripped, twisted, chipped or burred conditions. Remove burrs with a soft stone. If wear or other defects exists on the sides of the tooth, replace the part. 4. Inspect gears for scuffed, nicked, burred or broken teeth. Inspect gear teeth for wear that may have changed the original profile. Replace the gears if defects are found. Reassembly Instructions Before reassembling the transfer case, make sure that cleaning and inspection instructions have been followed. 1. Install the bearing cups into the rear housing half (item #2) Figure 5. Figure 5. Rear Housing Half 2. Install the bearing cups into front housing half (item #1). Cups should be installed from the outside and be tapped into the housing until flush with the outermachined surface for now. 3. Install o-ring (item #38) and bushing (item #21) into dia. hole. Note: Later in the assembly procedure when the housing halves are brought together and ready to set the bearing endplay will the bearing cups be driven further into the housing. Service Procedures Figure 6. Picture showing cups installed in front housing half (item #1). 47

52 Input Gear Assembly Instructions 1. Heat tapered bearing cones (item #23) to 250 F in an oven or induction coil. CAUTION Do not exceed 250 F. 2. Install the cones onto the pinion shaft (item #16) as shown in Figure 7. Apply a continuous force on the inner race until cooled to room temperature. This is necessary to ensure that it remains properly seated. 2. Install the key (item #61), gear, and bearings onto the pinion/shaft (item #15) as shown in Figure 8. Apply a continuous force on the inner race until cooled to room temperature. This is necessary to ensure that the gear and cones remain properly seated Figure 8. Intermediate Assembly Figure 7. Input gear assembly Intermediate Shaft/Gear Assembly Instructions 1. Heat intermediate gear (item #10) and bearings (item #22) to 250 F in an oven or use an induction coil. Do not exceed 250 F. CAUTION Output Gear/Thru Shaft Assembly 1. Place bearing (item #66) into gear (item #9). Install snap ring (item #46) into gear groove above bearing. 2. Place new slinger (item #39) onto the side of the shaft (item #13) that has one land. 3. Heat bearing cone (item #44) to 250 F in an oven or use an induction coil. CAUTION Do not exceed 250 F. 4. Install heated bearing onto shaft (item #13) holding the slinger in place. Apply a continuous force on the inner race until cooled to room temperature. This is necessary to ensure that the gear and cones remain properly seated. 5. Place shift collar (item #11) onto shaft pre-assembly with spline end as shown in Figure Press gear/bearing pre-assembly onto the second land using a bearing driver. Only apply force to the inside of the bearing race to insure there is no damage to bearing cage or bearing balls. 7. Place spacer (item #18) as shown in Figure 9. 48

53 8. Press second ball bearing (item #66) onto shaft using a bearing driver into position shown in Figure 9. Only apply force to the inside of the bearing race. 9. Heat remaining bearing cone (item #44) to 250 F in an oven or use an induction coil. CAUTION Do not exceed 250 F. 10. Install heated bearing onto shaft (item #13). Apply continuous force on the inner race until cooled to room temperature. Service Procedures Figure 9. Output Assembly 49

54 Assembly of Shift Mechanism Cap and Piston Assembly (Figure 10) 1. Place the shifting shaft (item #14) into a clamp in an upright position with the female thread pointing up. 2. Insert the bushing (item #21) and o-ring (item #38) into the cap (item #5). Slide cap assembly onto the shaft as shown. 3. Nest both springs (items #32 and 33) into the opening of the cap. 4. Place piston (item #19) on top of the springs and cap assembly w/ 1" counter bore, face down and aligned with the shaft. 5. Secure the piston to the shaft using lock washer and bolt (items #24 and #28). Torque the bolt to ftlb. Installation into Housing 1. Place o-ring (item #37) into the bottom o-ring grove in housing (item #2). 2. Slide the sleeve (item #3) into housing bore, chamfer first. Ensure sleeve bottoms out in the housing without displacing o-ring. 3. Place 2nd o-ring (item #37) into the top o-ring groove in the housing (item #2) just above the sleeve (item #3) and below the snap ring groove. 4. Place o-ring (item #36) on piston (item #19). 5. Slide piston assembly into piston housing (item #3). 6. Secure assembly with retaining ring (item #26). 7. Apply air pressure to check for air leaks. 8. Assemble lower shaft into position (see Figure 9) and place the fork (item #17) on to the air cylinder threaded shaft (item #14). Make sure the fork legs rest in the collar (item #11) groove. 9. Apply air pressure to the air engage port in order to move the cylinder to shift the fork and engage the collar with the gear. 10. Measure fork clearance with gear and add shims (items #47-49) to bring fork face in shifted gear position away from gear face (Figure 11 is shown in the disengaged position, however, the gap is actually for the engaged position). 11. After shim pack is determined, apply loctite #243 to female threads of shift shaft (item #12). Thread to air cylinder shaft (item #14) and torque to ftlbs. Figure 10. Cap and Piston Assembly Figure 11. Shift/Collar Assembly 50

55 Housing Assembly 1. Install the input shaft/gear assembly (Figure 7) and intermediate shaft/gear assembly (Figure 8) into the rear housing half with the input side of the gear facing down, or towards the pump/motor pad. Tip: Apply a small coat of oil to the outside of the bearing cone and inside of cup to insure bearing lubrication at startup. 2. Place approximately a 1/8 bead of Loctite #587 or equivalent sealant, along the sealing surface of the housing half. CAUTION Applying too much sealant to sealing surfaces may cause excessive sealant to break loose inside gear box and damage gears, bearings, or splines. 3. Place the housing halves together. Housings must be oriented in the same direction for the dowel pins holes to line up properly. 4. Press in the two dowel pins (item #34) to insure proper alignment. 5. Install the cap screws (item #30) using Loctite #243 on threads, and torque to ft-lb. 6. Shim covers to provide end play on all bearings. 7. Apply Loctite ultra blue #587 to bearing retainers and covers. 8. Install cover bolts (item #31), using Loctite #243 on the threads, and torque to ft-lb. 9. Turn over the assembled transfer case to install the input seal. Apply a small amount of oil to seal lips to allow the seal to properly seat. Apply a thin coat of Loctite #609 to the seal O.D. and press into place. CAUTION Do not use sharp objects for pressing in seals. Press only the outer edges of the seal to keep from bending the seal casing. 10. Apply Silver Streak-200s" to thru shaft splines that mate with end yokes. 11. Both end yokes (ears or forks) must be in time with each other during assembly. 12. Apply Loctite #587 under nut washers. 13. Tighten yoke nuts to 200 ft-lb. Preventative Maintenance Oil flow and circulation in a transfer case is one of the most important features to give all internal parts the maximum life. The transfer case design incorporates several key features from previous designs. When filled to the proper level, oil will be circulated within the box to each set of bearings for smooth operation. Because the pump splines and the input shaft are exposed to the oil within the transfer case do not apply grease or any type of corrosion prevention materials to the internal spline, as these will contaminate the transfer case oil. Note: All transfer cases are shipped without oil. Verify that the drain plug is tightened to 50 ft-lb. 1. Fill the transfer case to MAX oil level of the oil level plug. CAUTION Do not over fill, as this will result in overheating and possible failure of the transfer case. 2. It is recommended to maintain clean oil and make oil changes part of the preventative maintenance procedure. Refer to the appendix and Maintenance and Inspection Intervals table for oil change frequency. 3. Stop engine before attempting to check or add oil. 4. Clean around the oil fill hole before checking or adding oil. 5. Drain oil while the unit is still warm. WARNING Hot oil can cause severe burns. Use extreme care when removing lubrication plugs and vents. 6. Inspect and clean magnetic drain plug for contamination or metal particles before replacing. Service Procedures 51

56 Oil Capacity When changing the oil some residual is left in the box, this will require less oil to fill the box. Only fill to the MAX oil level, to the oil level plug otherwise overheating may occur. Maximum Operating oil temperature for all standard oils: 210 F (99ºC). Maximum Operating oil temperature for all synthetic oils: 250ºF (121ºC). Recommended Oil Type RoadRanger FE 75W90 or synthetic equivalent. General Information Definitions Tip: Provides information that can help properly complete a specific procedure. SAE: Society of Automotive Engineers. This group defines standards in the automotive industry to allow for interchangeability between engine and component manufacturers. TIR: Total Indicator Reading. This is a measurement to determine endplay on a rotating element. Increaser Ratio: When the output gears/shafts are turning faster than the input shaft. Decreaser Ratio: When the output gears/shafts are turning slower than the input shaft. Tools Needed Sockets: 1/2", 9/16", 24MM Deep, 2-3/4" Allen Wrench: 3/8" Eye Bolts: 3/4" Gear Pullers (5.625" diameter min.) Scraper Blade Loctite 243, 587, 609 or equivalent Wooden Mallet Snap Ring Pliers Expansion Plug Remover Torque Wrench Large Flat Head Punch Adjustable Open-end Wrench Large Screw Driver Crocus Cloth Seal Driver Bearing Driver Oven or Induction Coil Hot Gloves (300 F) 52

57 Table 1: Bolt Tightening Torques SIZE GRADE 5 GRADE 8 5/ ft-lb 29 ft-lb 3/ ft-lb 54 ft-lb 1/ ft-lb 105 ft-lb Table 2: Wear Tolerances* Location Min Max Input Bore Intermed. Bore Output Bore Service Procedures 5/ ft-lb 210 ft-lb 3/ ft-lb 375 ft-lb Plug Tightening Torques Gear Bore Input Shaft Dia Intermed. Shaft Dia Breather 3/8-18 NPT Drain Plug NPT Fill Plug NPT 15 ft-lb 50 ft-lb 35 ft-lb Output Shaft Dia Gear Land Dia *Replace components if not to tolerance. 53

58 Input Shaft Seal Replacement Seal Half Round Yoke (1760) Full Round Yoke (1810) - OR - Removal Note: Transfer case shaft seals are located behind the driveline end yokes on the input and output shafts. 1. Follow Service and Maintenance Shutdown Procedure. 2. Place clean recycle pan under drain plug to capture oil drained from unit. Note: Drain plug is located on front side (opposite hydraulic pump) at bottom of unit. 3. Remove drain plug, 1/2 NPT using a 9/16" open end wrench and drain oil from unit. 4. If removing one seal: a. Disconnect/remove driveline shaft of seal being replaced. Note: Joint at transfer case end yoke must be disconnected to access end yoke securing nut. b. Remove securing nut using either 1/2" or 3/4" air impact wrench with 2-3/4 socket and 2-1/2 extension. Note: If air wrench is unavailable, use breaker bar with 2-1/2 extension to access recessed nut. Note: If removing both seals, leave one driveline connected for easier removal of end yoke securing nut. 5. If removing both seals: a. Loosen nut but do not remove totally. b. Remove second driveline connected to end yoke. 6. Secure other end yoke to keep from rotating and remove second end yoke securing nut. 7. Remove securing nut from end yoke/yokes and slide yoke/yokes from shaft exposing seals on bearing retainer cover. 8. Use seal puller (cycle/crescent style) to remove input shaft seals from cover. 9. Clean seal cavity as necessary. 54

59 Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Using spray parts cleaner, clean splines of input shaft from any rust or contamination that may have accumulated. 3. Remove seal from packaging. Included within package is cadmium plated Seal Driver. Using this seal driver, insert seal into bore of cover and seat seal by tapping perimeter of driver with hammer, using alternating strikes from side to side, top to bottom, then in a circular motion until seal is properly seated. Note: Seal should be seated equally around its perimeter. 4. Apply thin coat of anti-seize to spline of input shaft. 5. Reinstall end yoke onto splined shaft. Note: Make sure front and end rear yokes on transfer case are in-time with each other. 6. Thread securing nut onto shaft and tighten. Torque to 200 ft-lb. See appendix Torque Specifications. 7. Reinstall driveline shafts. 8. Refill unit with oil and check for leaks. Accumulator Replacement CAUTION Accumulator weighs approximately 430 pounds. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Vent accumulator nitrogen gas precharge. See Vent Nitrogen Gas from Accumulator. 3. Disconnect wire harness from accumulator sensors. 4. Remove high pressure hose from accumulator. Note: Approximately 1 gallon will drain from accumulator port and hose. 5. Measure and mark accumulator position from fluid port to mounting bracket. 6. Remove middle accumulator bracket. 7. Support accumulator with transmission jack and strap to jack. 8. Remove bolts and outer bracket straps. 9. Slide accumulator toward rear and out of brackets. 10. Remove accumulator from under chassis. Installation 1. Install accumulator into outer brackets and straps and secure with bolts. 2. Adjust accumulator using measurement and marks into for/aft position. 3. Rotate accumulator until proximity port is horizontal and outwards of chassis. 4. Install middle bracket and secure with bolts. 5. Torque all bracket bolts to 26 ft-lb. See appendix Torque Specifications. 6. Install O-ring (new recommended) on high pressure hose with petroleum jelly or Eaton silicon lube (part #71203). 7. Reinstall high pressure hose. 8. Reconnect wire harness to accumulator sensors. 9. Install accumulator shield. 10. Check and stamp installation date tag. Service Procedures 55

60 Accumulator Bladder Repair WARNING Vent the accumulator nitrogen gas pre-charge prior to servicing using the petcock on the nitrogen gage assembly. 5. Securely attach nitrogen charge kit gauge assembly to gas valve port. Avoid suffocation. Nitrogen asphyxiates and causes oxygen to dissipate in the room. It is recommended that the service is completed in a well ventilated area. CAUTION Escaping nitrogen gas is extremely cold and may freeze skin. Avoid skin contact with the nitrogen gas to prevent freezing damage to skin tissues. IMPORTANT Be sure to allow time to complete the bladder replacement so that the interior of the accumulator is not open to the atmosphere for longer than one hour. Time exceeding one hour may allow corrosions to form on the interior surface, resulting in bladder failure during operation. Tools Bladder service kit HLA Service Manual TRSM1200 Lock nut Spanner wrenches Valve core torque wrench Torque wrench with 325 foot pounds Bladder pull rod kit Thermal indicator Degreaser and rags 1/16th adjustable wrench 2 ¾ inch wrench Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Clean any dirt and debris from the gas valve protective cap area of the accumulator. 3. Remove gas valve protective cap to expose gas valve port. 4. Remove O-ring and bladder service date tag. 6. Open the pressure gauge valve per the kit manufacturer's instructions. Follow the nitrogen gas venting procedure. Open the petcock slowly to control the venting of the nitrogen gas. 7. Vent until pressure is zero. 8. Close the pressure gauge valve and remove the nitrogen charge kit gauge assembly from the gas valve port. 9. Remove gas valve core using gas valve tool. Do not reuse valve core. 10. Remove the accumulator from the vehicle, thoroughly clean it to remove any dirt and debris, and secure it in a clean location to prevent movement and contamination. 56

61 11. Using a spanner wrench, remove the fluid port lock nut. 16. Remove fluid port from shell. Service Procedures 12. Remove spacer ring. If necessary, tap spacer ring with plastic hammer to loosen. 13. Loosen and push the fluid port into accumulator shell. 14. Reach into shell opening and remove O-ring, flat ring and backup ring from fluid port. 15. Reach into shell and remove anti-extrusion ring: a. Pull ring off fluid port. b. Fold in half. c. Pull ring out of port through fluid side opening of shell. 17. Remove bladder stem lock nut from gas side of the accumulator. 18. Push gas valve stem into accumulator shell. 19. Using a shop rag or towel, firmly grab and pull and remove the bladder from the fluid port end. Discard the old bladder. A used bladder cannot be reinstalled. 20. Clean any debris and contamination from the accumulator shell interior. Visual Inspection Shell: Make sure the inside is free of any debris, rough spots or chafe marks. If any interior or exterior damage is found, contact Eaton for proper repair or replacement instructions. Fluid port: Make sure the poppet moves freely. Press the poppet and rotate it 90 degrees. If any damage is found, replace the fluid port. Anti-extrusion ring: Look on the rubber ring for any cracks, embrittlement, aging, or damage. If any defects or damage is found, replace the Anti-extrusion ring. All other parts: Inspect for damage and replace as necessary. 57

62 IMPORTANT Always use new seals and a new bladder when reassembling the accumulator. Note: Do not use water. a. Apply fluid evenly by hand to entire bladder surface. Use only dry industrial grade nitrogen to charge the accumulator. Tools Bladder service kit Spanner wrenches HLA Service Manual TRSM1200 Valve core torque wrench Torque wrench with 325 foot pounds Bladder pull rod kit Thermal indicator Degreaser and rags 1/16th adjustable wrench 2 ¾ wrench Installation 1. Open up the bag from the bladder and use as a clean work surface on a clean work bench area. 2. Prepare the bladder by first removing the shipping protection caps from the gas valve. 3. Lubricate new bladder exterior and shell interior with filtered operating HLA fluid. Note: Fluid volume should be approximately 10% of total accumulator volume. b. Spray inside and roll shell to evenly lubricate the entire interior. 4. Place bladder stem lock nut over pull rod with male threads facing pull rod handle. 5. Insert pull rod into shell with threaded connection facing fluid side opening. 6. Press any residual air out of the bladder. 7. Thread pull rod onto gas valve. 58

63 8. Fold bladder in half lengthwise, twice if necessary, as you push the bladder into the shell. 14. Fold anti-extrusion ring in half and insert into shell with steel seat facing fluid side opening: a. Push fluid port further into shell. b. Pull fluid port back through middle of anti-extrusion ring. Note: Do not allow fluid port to slip back into shell. Service Procedures 9. Pull the pull rod until gas valve emerges through gas port opening. Make sure bladder is not twisted as it enters shell. 10. Loosely attach bladder stem lock nut to gas valve. Note: This prevents bladder from slipping back into shell. 11. Remove pull rod from gas valve. 12. Insert fluid port into shell. 15. Slightly pull on fluid port and install flat ring into space between fluid port and shell. Note: If flat ring does not slide on properly, re-center fluid port in opening. Retainer Ring Collar 13. Make sure bladder is fully extended in shell. Backup Ring O-Ring Backup Ring 16. Install O-ring: a. Use your fingers or a plastic seal tool. b. Press at 90º intervals. c. Carefully level O-ring onto seat. 17. Install backup ring with grooved surface facing O- ring. 18. Install spacer ring with lip inside shell. 19. Install fluid port lock nut and torque as specified in the service manual. 20. Remove bladder stem lock nut on gas side. 21. Install name plate. 59

64 22. Reinstall bladder stem lock nut and torque based on recommendations specification in the service manual. 23. Lubricate the gas valve core seal with a light coating of hydraulic fluid. 24. Insert the gas valve core and torque using the gas valve torque tool, which will torque it to 2.7 to 4.5 inch pounds. Note: Make sure you are using a new valve core. A valve core cannot be re-used. 25. Securely attach pressure gauge hose to nitrogen port. 26. Install the hose to the pressure gauge and supply bottle. 27. Open pressure gauge valve per gauge manufacturer s instructions. 28. Add nitrogen until pressure reaches level prescribed in chart and temperature measurement ± 4 bar (58 psi). See Nitrogen Gas Precharge Pressure Chart. 29. Allow nitrogen to reach ambient temperature and adjust pressure as necessary. Note: Nitrogen gas can take up to one hour to reach ambient temperature. 30. Indent bladder service date tag with correct month and year and install over gas valve. 31. Install O-ring over tag. 32. Securely attach the gas valve protective cap and torque to 15 ft-lb. Note: The gas valve protection cap functions as a primary gas seal. Without proper assembly and torque, gas can leak out. Nitrogen Gas Precharge Pressure Chart Note: Nitrogen gas pressure is affected by temperature and volume. After HLA system has been used, some oil will remain trapped inside accumulator. Precharge Gas Pressure PSI [bar = PSI* ] Fahrenheit ( F) Temperature Celsius ( C) lb/in 2 (PSI) Pressure Bar 60

65 Electrical Enclosure ECU J04 Service Procedures ECU Connector J04 J02 ECU Connector J02 Ground and Splice Pack GNDSPB (Gray) Electronic Control Unit Replacement WARNING Always disconnect battery power before servicing ECU. See Service and Maintenance Shutdown Procedure. Removal 1. Use ServiceRanger to retrieve and record calibration settings. 2. Follow Service and Maintenance Shutdown Procedure. 3. Disconnect battery power. 4. Disconnect vehicle OEM connector J Disconnect ECU ground wire from sub-frame. 6. Remove bolts and ECU harness enclosure from subframe. 7. Disconnect ground wire from ECU case. 8. Disconnect harness connectors J02 and J04 from ECU. 9. Remove bolts and ECU from enclosure. Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Install new ECU to enclosure and secure with bolts. 3. Connect ground wire to ECU case. 4. Reconnect harness connectors J02 and J04 to ECU. 5. Install ECU harness enclosure to sub-frame and secure with bolts. 6. Reconnect ECU ground wire to sub-frame. 7. Reconnect vehicle connector J Reconnect battery power. 9. Use ServiceRanger to verify/flash latest software and update calibrations. Note: If calibration retrieval was not available, perform swash calibration procedure. 61

66 Splice Packs ECU Connector J04 12 Volt Splice Pack 12SPB1 (Red) 12 Volt Splice Pack 12SPB2 (Red) 5 Volt Splice Pack 5SPB (Pink) ECU Connector J02 Ground and Splice Pack GNDSPB (Gray) 62

67 Wire Harness Service Procedures 63

68 Connectors J J J29, J J31, J J J J J39A, J53, J89, J J41B J J43, J J45,J47, J J J J J J J J75, J J J J J J69, J J27, J J31, J

69 Reservoir Replacement Standard Reservoir Design Offset Reservoir Design Service Procedures Reservoir Reservoir Reservoir Removal Note: Reservoir weighs approximately 180 pounds. 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain oil from reservoir. 3. Disconnect HLA harness connector from oil level sensor and temperature sensor. 4. Disconnect suction hose. 5. Disconnect case drain and cooler hose from return manifold. 6. Disconnect return hose and remove return manifold. 7. Support reservoir with transmission jack and strap securely. 8. Unbolt reservoir from chassis frame. 9. Remove reservoir from chassis. Reservoir Installation 1. Install new reservoir. 2. Reinstall all components to reservoir. 3. Secure reservoir to chassis frame with bolts. 4. Reinstall return manifold, check O-ring, replace if damaged and reconnect return hose. 5. Reconnect cooler hose and case drain. 6. Check O-ring, replace if damaged and reconnect suction hose. 7. Reconnect HLA harness connector to oil level sensor and temperature sensor. 8. Fill reservoir with oil. See section Drain and Replace HLA System Oil (Oil Change). 65

70 Reservoir Cover Reservoir Cover Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Disconnect HLA harness connector from oil level sensor. 3. Drill out any rivets in cover. Note: Prevent metal chips from entering reservoir. 4. Unbolt and remove oil level sensor. 5. Remove breather. 6. Remove cover bolts and cover. 7. Remove gasket and clean surface. Note: Prevent debris from entering reservoir. Clean as needed. Standard Reservoir Design Reservoir Cover Installation 1. Install gasket dry. 2. Install cover on reservoir. 3. Clamp cover to reservoir to compress gasket. 4. Secure cover with bolts and torque bolts to 28 ± 2.8 ft-lb. See appendix Torque Specifications. 5. Install rivets with backup washers. 6. Bolts for cover must be double torqued for gasket compression. Retorque bolts to 28 ± 2.8 ft-lb. See appendix Torque Specifications. 7. Reinstall breather. 8. Reinstall oil level sensor. 9. Reconnect HLA harness connector to oil level sensor. Bolts Rivets Reservoir Cover Gasket Offset Reservoir Design Bolts Rivets Reservoir Cover Gasket 66

71 Main Filter Assembly Replacement Return Block Offset Reservoir Design Service Procedures Standard Reservoir Design Reservoir Filter Housing Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain oil from reservoir. 3. Disconnect HLA harness connector from filter pressure delta sensor. 4. Disconnect case drain and cooler hose from return manifold. 5. Disconnect return hose and remove return manifold. 6. Unbolt filter housing from reservoir. 7. Check O-ring seal. Installation 1. Install new O-ring seal, if necessary. 2. Secure filter housing to reservoir with bolts. 3. Reinstall return manifold and reconnect return hose. 4. Reconnect cooler hose and case drain to return manifold. 5. Reconnect HLA harness connector to filter pressure delta sensor. 67

72 Return Manifold Replacement Standard Reservoir Design Offset Reservoir Design Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain oil from reservoir. 3. Disconnect HLA harness connectors. 4. Disconnect case drain and cooler outlet hoses from return manifold. 5. Remove nuts from return hose flange and remove flange. 6. Disconnect return hose from return manifold. 7. Remove return manifold from studs. 8. Remove studs from filter housing. Installation 1. Reinstall studs onto filter housing. 2. Lubricate O-ring with petroleum jelly and install onto new return manifold. 3. Install return manifold onto studs. 4. Lubricate O-ring with petroleum jelly and install onto return hose. 5. Install return hose flange and reconnect return hose to return manifold. 6. Install nuts onto return hose flange and torque nuts to 60 ± 6 ft-lb. See appendix Torque Specifications. 68

73 7. Reconnect case drain and cooler outlet hoses. Torque fittings to 110 ± 2.5 ft-lb. See appendix Torque Specifications. 8. Fill reservoir with oil. See section Drain and Replace HLA System Oil (Oil Change). 9. Inspect assembly for leaks. 10. Reconnect HLA harness connectors. Service Procedures 69

74 Cooler Replacement Air Flow Oil Cooler 12V Fan Cooler Inlet Cooler Outlet Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain oil from reservoir. 3. Disconnect HLA harness connectors. 4. Disconnect inlet and outlet hoses. 5. Support cooler with transmission jack. 6. Unbolt cooler from chassis frame. 7. Remove fittings from cooler. Note: Fan turns on at 85ºC and off at 60ºC. Fan also operates at < 80ºC with pump at < 30 rpm. Installation 1. Reinstall fittings onto new cooler. 2. Support cooler with transmission jack and secure to chassis frame with bolts. 3. Reconnect inlet and outlet hoses. 4. Reconnect HLA harness connectors. 5. Fill cooler reservoir with oil. See section Drain and Replace HLA System Oil (Oil Change). 70

75 Hose Assemblies Replacement Standard Reservoir Design Case Hose High Pressure Hose Suction Hose Service Procedures Cooler Outlet Hose Cooler Inlet Hose Return Hose Offset Reservoir Design Suction Hose Case Hose Return Hose Cooler Inlet Hose High Pressure Hose Cooler Outlet Hose 71

76 Suction Hose Offset Reservoir Design End A End B Removal 1. Drain oil from reservoir. See Drain and Replace HLA System Oil. 2. Use 3/4" wrench to remove bolts and split flange from charge pump. 3. Lift hose end to allow oil to drain from hose into reservoir. 4. Use 3/4" wrench to remove bolts and split flange from reservoir. 5. Remove hose. Note: Protect hose ends from contamination during repairs and clean hose before reinstalling. 6. Inspect condition of O-rings and make sure they are: Soft and not deformed Free of nicks, cuts, damage Well lubricated with petroleum jelly Note: Replace damaged (cracks or cuts) O-rings. Installation 1. Install hose with O-rings. 2. Install split flange to reservoir and secure with bolts. 3. Install split flange to charge pump and secure with bolts at both the pump and reservoir ends. Torque to 85 ± 6 ft-lb. See appendix Torque Specifications. 72

77 Case/Cooler Hose Offset Reservoir Design Cooler Outlet Hose Service Procedures End A End B Cooler Inlet Hose End B End A 73

78 Cooler Drain Hose Offset Reservoir Design End B End A Removal 1. Drain oil from reservoir. See Drain and Replace HLA System Oil. 2. Use 1-1/2" wrench to remove charge pump fitting. 3. Lift hose end to allow oil to drain from hose into return manifold. 4. Use 1-1/2" wrench to remove return manifold fitting. 5. Remove hose. Note: Protect hose ends from contamination during repairs and clean hose before reinstalling. 6. Inspect condition of O-rings and make sure they are: Soft and not deformed Free of nicks, cuts, damage Well lubricated with petroleum jelly Note: Replace damaged (cracks or cuts) O-rings. Installation Install return manifold fitting. 74

79 High Pressure Hose Offset Reservoir Design Service Procedures End A End B Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove accumulator shield. 3. Use 15/16" wrench to remove bolts and split flange from accumulator. 4. Lift hose end to allow oil to drain from hose into drain pan. 5. Use 15/16" wrench to remove bolts and split flange from pump. 6. Remove hose. Note: Protect hose ends from contamination during repairs and clean hose before reinstalling. 7. Inspect condition of O-rings and make sure they are: Soft and not deformed Free of nicks, cuts, damage Well lubricated with petroleum jelly or Eaton silicone lube (part #71203) Note: Replace damaged (cracks or cuts) O-rings. Installation 1. Install O-rings on hose. 2. Install hose end flange to pump and secure with bolts. 3. Install hose end to accumulator and secure with split flange and bolts. 4. Torque bolts to 125 ft-lb. See appendix Torque Specifications. 5. Reinstall accumulator shield. 75

80 Low Pressure Return Hose Offset Reservoir Design End B End A Removal 1. Drain oil from reservoir. See Drain and Replace HLA System Oil. 2. Use 3/4" wrench to remove bolts and split flange from pump. 3. Lift hose end to allow oil to drain from hose into reservoir. 4. Use 3/4" wrench to remove nuts and split flange from return manifold. 5. Remove hose. Note: Protect hose ends from contamination during repairs and clean hose before reinstalling. 6. Inspect condition of O-rings and make sure they are: Soft and not deformed Free of nicks, cuts, damage Well lubricated with petroleum jelly or Eaton silicone lube (part #71203) Note: Replace damaged (cracks or cuts) O-rings. Installation 1. Install and lubricate O-rings. 2. Install split flange to pump and secure with bolts. 3. Install split flange to return manifold and secure with bolts. 4. Torque bolts to 60 ft-lb. See appendix Torque Specifications. 76

81 Sensors Replacement Swash Sensor Swash 1 Sensor (3mm Hex Socket Screw) Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove shield from pump. 3. Disconnect HLA harness connector from sensors. 4. Remove retaining cover (swash 2 only). Service Procedures 5. Remove socket head screws from sensors. 6. Remove sensors. Installation 1. Replace sensors and install socket head screws. Torque to 26.5 ± 1.5 in-lb. See appendix Torque Specifications. 2. Replace retaining cover (swash 2 only). Torque screws to 60 in-lb and bolt to 44 ft-lb. See appendix Torque Specifications. 3. Use service tool to calibrate swash sensor. 4. Reconnect HLA harness connector to sensor. 5. Reinstall shield to pump. Swash 2 Sensor 6. Use zip ties to connect harness back to mount. 7. Swash calibration is required after sensor removal and installation. Retaining Cover 77

82 Accumulator Foot Valve Proximity Sensor Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Place drain pan under accumulator fluid port end. 3. Disconnect HLA harness connector from sensor. 4. Use 15/16" wrench to remove sensor. Note: Oil will drain while port is open. 5. Check condition of sealing port surface and O-ring. Replace O-ring if damaged. Installation 1. Clean sensor port and sealing surface. 2. Check condition of O-ring on sensor. Replace if damaged. 3. Apply blue removable thread lock to sensor threads. 4. Screw sensor into port. 5. Torque sensor to 95 ft-lb. See appendix Torque Specifications. 6. Reconnect HLA harness connector to sensor. Accumulator Pressure Sensor Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Place drain pan under accumulator fluid port end. 3. Cut tie strap from HLA harness connector to shield. 4. Loosen worm gear clamp from shield and remove shield. 5. Disconnect HLA harness connector from sensor. 6. Use 1-1/16" wrench to remove sensor. Note: Oil will drain while port is open. 7. Check condition of sealing port surface and O-ring. Replace O-ring if damaged. Installation 1. Clean sensor port and sealing surface. 2. Check condition of O-ring on sensor. Replace if damaged. 3. Apply blue removable thread lock to sensor threads. 4. Screw sensor into port. 5. Torque sensor to 56 ft-lb. See appendix Torque Specifications. 6. Reconnect HLA harness connector to sensor. 7. Reinstall shield. Pressure Sensor Foot Valve Proximity Sensor Fluid Port 78

83 Transfer Case Engagement Proximity Sensor Removal Note: Sensor is located on front side at 10 o'clock position, above output shaft and on cast boss retaining shift shaft. 1. Follow Service and Maintenance Shutdown Procedure. 2. Disconnect HLA harness connector from sensor. 3. Use a 15/16 wrench to remove sensor from shift shaft boss. Installation 1. Insert new sensor into threaded hole and tighten. Torque to maximum 95 ft-lb. See appendix Torque Specifications. 2. Reconnect HLA harness connector to sensor. Speed Sensor Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Disconnect HLA harness connector from sensor. 3. Hold sensor in place using a 1/2 open end wrench and remove 5/16 serrated hex flange screw. 4. Pull out sensor from unit. Note: Rotate sensor back and forth to loosen O-ring seal if necessary. Installation 1. Apply light coating of petroleum jelly or anti-seize to O-ring seal. 2. Insert new sensor into hole: Protect O-ring from being cut or damaged. Push until sensor seats tight to mounting surface. 3. Insert 5/16" serrated flange screw into threaded hole and tighten. Torque to maximum 13 ft-lb. See appendix Torque Specifications. Note: Overtightening may cause damage to sensor. Service Procedures 4. Reconnect HLA harness connector to sensor. Speed Sensor Engagement Proximity Sensor 79

84 Filter Pressure Delta Sensor Level Sensor Level Sensor Filter Pressure Delta Sensor Gasket Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Place drain pan under return manifold. 3. Disconnect HLA harness connector from sensor. 4. Use 1-1/16" wrench to remove sensor. Note: Oil will drain from reservoir while port is open. 5. Check condition of sealing port surface and O-ring. Replace O-ring if damaged. Installation 1. Clean sensor port and sealing surface. 2. Check condition of O-ring on sensor. Replace if damaged. 3. Screw sensor into port. 4. Torque sensor to 56 ft-lb. See appendix Torque Specifications. 5. Reconnect HLA harness connector to sensor. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Disconnect HLA harness connector from sensor. 3. Remove 5 flange screws. 4. Pull out sensor and gasket. Note: Body may need to be raised for sensor removal. Installation 1. Slide gasket onto new sensor and align holes. 2. Insert new sensor into cover port. 3. Reinstall 5 flange screws. 4. Torque screws to in-lb. See appendix Torque Specifications. 5. Reconnect HLA harness connector to sensor. 80

85 Pump Temperature Sensor Pump Temperature Sensor Reservoir Temperature Sensor Service Procedures Reservoir Temperature Sensor Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain reservoir. 3. Disconnect HLA harness connector from sensor. 4. Use box wrench to remove sensor. Installation 1. Clean sensor port and threads on reservoir. 2. Apply modest amount of thread sealer to new sensor threads. 3. Use 7/8" wrench to install new sensor into port. 4. Torque sensor to 15 ft-lb. See appendix Torque Specifications. 5. Reconnect HLA harness connector to sensor. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Drain reservoir. 3. Disconnect HLA harness connector from sensor. 4. Use box wrench to remove sensor. Installation 1. Clean sensor port and threads on reservoir. 2. Apply modest amount of thread sealer to new sensor threads. 3. Use 7/8" wrench to install new sensor into port. 4. Torque sensor to 15 ft-lb. See appendix Torque Specifications. 5. Reconnect HLA harness connector to sensor. 81

86 Valves Replacement Mode Valve Directional Control Valve Normally Open 2-Way Fill Valve Directional Control Valve Pump Solenoid Solenoid Coils Motor Solenoid Normally Closed 2-Way Drain Valve Removal Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove solenoid coil retaining nut. 3. Remove solenoid coil. 4. Remove cartridge valve. Installation 1. Check O-ring condition on cartridge valve. Replace if damaged. 2. Install new cartridge valve and torque to 28 ± 3 ft-lb. See appendix Torque Specifications. 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove four screws and valve from pump. Installation 1. Check condition of O-ring seals. Replace if damaged. 2. Lightly lubricate O-rings with petroleum jelly or Eaton silicone lube (part #71203). 3. Install new valve on pump. 4. Reinstall screws and torque in cross pattern to 58 ± 4 in-lb. See appendix Torque Specifications. 3 START 1 3. Reinstall solenoid coil. 4. Reinstall solenoid coil retaining nut and torque with 5/8" wrench to 42 ± 6 in-lb. See appendix Torque Specifications

87 Bypass Valve (Main Stage) Bypass Valve (Main Stage) Charge Pump Bypass Valve Service Procedures Charge Pump Bypass Valve 3-Way, 2-Position N/O Valve Removal and Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove valve by unthreading from pump housing. 3. Check condition of O-ring on valve. Replace if damaged. 4. Check inside valve port for debris and thread condition. 5. Install new valve on pump housing and torque to 134 ft-lb. See appendix Torque Specifications. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Disconnect harness from valve coil. 3. Remove coil hold-down nut and pull off coil. 4. Use 5/8" wrench to remove cartridge screw. 5. Check condition of O-ring seals. Replace if damaged. Installation 1. Check and clean cartridge port. 2. Check for proper installation of O-ring on valve. 3. Install valve into port. 4. Torque valve to 28 ± 3 ft-lb. See appendix Torque Specifications. 5. Reinstall coil and hold-down nut. Torque hold-down nut to 42 in-lb. See appendix Torque Specifications. 83

88 Bypass Valve Pilot Cartridge Removal and Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove valve by unthreading from pump housing. 3. Check condition of O-ring on valve. Replace if damaged. 4. Check inside valve port for debris, thread condition. 5. Install new valve on pump housing and torque to 134 ft-lb. See appendix Torque Specifications. Isolation Valve Removal and Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove valve by unthreading from pump housing. 3. Check condition of O-ring on valve. Replace if damaged. 4. Check inside valve port for debris and thread condition. 5. Install new valve on pump housing and torque to 134 ft-lb. See appendix Torque Specifications. Normally Open 2-Way Valve Bypass Valve Pilot Cartridge Isolation Valve 84

89 Manual Relief Valve Pneumatic Clutch Valve Disengage (-) Red NC NC NO Engage (+) Black Supply (Red) Service Procedures (Green) OEM Air Supply Disengage Manual Relief Valve Engage Removal and Installation 1. Follow Service and Maintenance Shutdown Procedure. 2. Remove valve by unthreading from pump housing (1 1/4" hex). 3. Check condition of O-ring on valve. Replace if damaged. 4. Check inside valve port for debris and thread condition. 5. Install new valve on pump housing and torque to 105 ± 5 ft-lb. See appendix Torque Specifications. Note: The pneumatic clutch valve is located on right side of pump mounted to pump sub-frame. Removal 1. Follow Service and Maintenance Shutdown Procedure. 2. Vent vehicle air system. 3. Mark and disconnect tubing from valve. Note: Verify HLA system power is off before disconnecting coil connector. 4. Remove mounting screws and valve. Installation 1. Install new valve. 2. Reinstall mounting screws and torque to 22 ft-lb. See appendix Torque Specifications. 3. Reconnect tubing to valve. 4. Reconnect harness connectors. 85

90 Wiring Repair Instructions 1. Disconnect battery ground. 2. Disconnect connector from affected component. Remove and discard the tape and peal back the convolute wire covering. 3. Cut the first wire approximately 3 inches from the connector. Leave enough wire to allow repairs to be staggered to minimize harness diameter and to maintain harness length. Excess wire from the harness can be folded back on itself to maintain harness length. Wire colors on the harness and the repair connectors should match. 4. Strip the insulation back.3"/7.6mm. Insert wire into barrel of splice. Make sure the insulation does not enter the splice. 5. Crimp with a tool designed to crimp insulated splices. Inspect the repair for an acceptable splice. 6. Repeat steps 4 and 5 for the matching color wire on the replacement connector. 7. Using a heat gun apply heat directly to the splice, working from the center out to the edges, until the tubing shrinks and the adhesive appears on the end of the splice. DO NOT use an open flame to heat the splice. 8. Repeat steps 4, 5, 6, and 7 for the remaining wires, staggering the repairs so the harness does not become too large. 9. Reapply convolute and tape. 10. Connect to affected component. 11. Reconnect battery ground. Vehicle Harness Routing This routing procedure applies to all connections including: Speed Sensor Temperature Sensors Pressure Sensors Valve Coils Oil Level Proximity Sensor 86

91 Proper Routing Techniques Make sure wires exit base and allows for strain relief. Service Procedures Verify clips are attached to harness convoluted tubing only. Verify clip is within 6" of connector Verify no more than 12" of space exists between clips

92 Improper Routing Techniques Do not attach clips to bare wires. Avoid bending wires at the connection. This strain may cause leakage at the seal. 88