johndeere tm4541 technical manual

4400 and 4500Telescopic Handlers

DCEO-Mannheim

TM4541 (23JAN01)Printed in Germany

ENGLISH

FOREWORD

This manual is written for an experienced technician.

Essential tools required in performing certain service

work are identified in this manual and are

recommended for use.

Live with safety: Read the safety messages in the

introduction of this manual and the cautions

presented throughout the text of the manual.

N This is the safety-alert symbol. When you see

this symbol on the machine or in this manual,

be alert to the potential for personal injury.

Information is organized in groups for the various

components requiring service instruction.

Technical Manuals are concise guides for specific

machines. They are on-the-job guides containing only

the vital information needed for diagnosis, analysis,

testing, and repair.

Fundamental service information is available from

other sources covering basic theory of operation,

fundamentals of troubleshooting, general

maintenance, and basic type of failures and their

causes.

GS,TMIFC -19-10SEP97

Introduction

TM4541 (23JAN01) 4400 and 4500 Telescopic Handlers230101

PN=3

SECTION 05ÐSafety

Group 05ÐSafety Information

SECTION 50ÐTransmission

Group 00ÐGeneral Information

Group 05ÐRemoval and Replacement

Group 10ÐDisassembly and Assembly of the

Torque Converter Housing


Gearbox


Reverser Unit


Hydraulic 2/4 Wheel Drive Unit

SECTION 60ÐREMOVAL AND REPAIR OF

AXLES AND BRAKES

Group 05ÐFront Axle Removal

Group 10ÐRear Axle Removal

Group 15ÐHydraulic Steering

Group 20ÐCab - Steering Column

Group 25ÐAxles and Brakes - Brake Circuit

Group 30ÐBrakes

SECTION 70ÐHYDRAULIC SYSTEM


Group 10ÐHydraulic Pump

Group 20ÐHydraulics - Priority Valve

Group 30ÐHydraulics - Fault Finding

SECTION 80ÐCHASSIS AND BOOM

Group 05ÐRemoval and Repair

SECTION 90ÐOPERATOR'S CAB

Group 00ÐCab - Disassembly and Reassembly

Group 05ÐCab Heater/Cab Seat - Removal

SECTION 240ÐELECTRICAL SYSTEM

Group 05ÐSystem Information

Group 10ÐSystem Diagrams

Index

COPYRIGHTÞ 1997

DEERE & COMPANY

European Office Mannheim

All rights reserved

A John Deere ILLUSTRUCTIONÝ Manual

TM4541-19-23JAN01

Contents

TM4541 (23JAN01) i 4400 and 4500 Telescopic Handlers230101

PN=248

TM4541 (23JAN01) ii 4400 and 4500 Telescopic Handlers230101

PN=249

Section 05

SafetyContents

Page

Group 05ÐSafety Information . . . . . . . 05-05-1

TM4541 (23JAN01) 05-1 4400 and 4500 Telescopic Handlers230101

PN=234


PN=235

RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this

symbol on your machine or in this manual, be alert to

the potential for personal injury.

Follow recommended precautions and safe operating

practices.

PREVENT MACHINE RUNAWAY

Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Start

engine only from operator's seat, with transmission in

neutral.

HANDLE FLUIDS SAFELYÐAVOID FIRES

When you work around fuel, do not smoke or work near

heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

spontaneously.

DX,ALERT -19-03MAR93

GS,BYPAS1 -19-15JUL95

DX,FLAME -19-04JUN90

Group 05Safety Information

TM4541 (23JAN01) 05-05-1 4400 and 4500 Telescopic Handlers230101

PN=4

PREPARE FOR EMERGENCIES

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

service, hospital, and fire department near your

telephone.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and

cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15Ð30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).

3. Get medical attention immediately.

DX,FIRE2 -19-03MAR93

DX,POISON -19-21APR93


PN=5

AVOID HIGH-PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin

causing serious injury.

Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all

connections before applying pressure.

Search for leaks with a piece of cardboard. Protect

hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any

fluid injected into the skin must be surgically removed

within a few hours or gangrene may result. Doctors

unfamiliar with this type of injury should reference a

knowledgeable medical source. Such information is

available from Deere & Company Medical Department in

Moline, Illinois, U.S.A.

PARKING AND LEAVING THE MACHINE

Lower attachment or carriage to the ground before

leaving the machine.

Shut off engine, select neutral with both the gear lever

and the forward/reverse control.

Apply handbrake, remove main switch key and lock the

operator's cab. Position chock blocks.

Never leave machine unattended as long as engine is

still running.

Never leave the cab when driving.

DX,FLUID -19-03MAR93

GS,PARK -19-01SEP95


PN=6

SUPPORT MACHINE PROPERLY

A raised boom can drop suddenly and cause serious

injury. Before working under a raised boom, install a

boom safety strut.

Do not support the machine on cinder blocks, hollow

tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by

a jack. Follow recommended procedures in this manual.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment

appropriate to the job.

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or

uncomfortable loud noises.

Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones

while operating machine.

WORK IN CLEAN AREA

Before starting a job:

· Clean work area and machine.

· Make sure you have all necessary tools to do your job.

· Have the right parts on hand.

· Read all instructions thoroughly; do not attempt

shortcuts.

GS,LOWER -19-01JUL95

DX,WEAR -19-10SEP90

DX,CLEAN -19-04JUN90


PN=7

SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near

machine tools or moving parts. If these items were to get

caught, severe injury could result.

Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.

WORK IN VENTILATED AREA

Engine exhaust fumes can cause sickness or death. If it

is necessary to run an engine in an enclosed area,

remove the exhaust fumes from the area with an

exhaust pipe extension.

If you do not have an exhaust pipe extension, open the

doors and get outside air into the area.

ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the

machine. Make sure the bulb is enclosed by a wire

cage. The hot filament of an accidentally broken bulb

can ignite spilled fuel or oil.

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the

machine operator's manual for correct safety sign

placement.

DX,LOOSE -19-04JUN90

DX,AIR -19-04JUN90

DX,LIGHT -19-04JUN90

DX,SIGNS1 -19-04JUN90


PN=8

USE PROPER LIFTING EQUIPMENT

Lifting heavy components incorrectly can cause severe

injury or machine damage.

Follow recommended procedure for removal and

installation of components in the manual.

AVOID HEATING NEAR PRESSURIZEDFLUID LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to

yourself and bystanders. Do not heat by welding,

soldering, or using a torch near pressurized fluid lines or

other flammable materials. Pressurized lines can be

accidentally cut when heat goes beyond the immediate

flame area.

REMOVE PAINT BEFORE WELDING ORHEATING

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area. Dispose

of paint and solvent properly.

Remove paint before welding or heating:

· If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

· If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove solvent or

paint stripper containers and other flammable material

from area. Allow fumes to disperse at least 15 minutes

before welding or heating.

DX,LIFT -19-04JUN90

DX,TORCH -19-03MAR93

DX,PAINT -19-03MAR93


PN=9

KEEP ROPS INSTALLED PROPERLY

Make certain all parts are reinstalled correctly if the

roll-over protective structure (ROPS) is loosened or

removed for any reason. Tighten mounting bolts to

proper torque.

The protection offered by ROPS will be impaired if

ROPS is subjected to structural damage, is involved in

an overturn incident, or is in any way altered by welding,

bending, drilling, or cutting. A damaged ROPS should be

replaced, not reused.

SERVICE TIRES SAFELY

Explosive separation of a tire and rim parts can cause

serious injury or death.

Do not attempt to mount a tire unless you have the

proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld

or heat a wheel and tire assembly. The heat can cause

an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and

NOT in front of or over the tire assembly. Use a safety

cage if available.

Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.

DX,ROPS3 -19-03MAR93

DX,RIM -19-24AUG90


PN=10

PRACTICE SAFE MAINTENANCE

Understand service procedure before doing work. Keep

area clean and dry.

Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from

power-driven parts. Disengage all power and operate

controls to relieve pressure. Lower equipment to the

ground. Stop the engine. Remove the key. Allow

machine to cool.

Securely support any machine elements that must be

raised for service work.

Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before making

adjustments on electrical systems or welding on

machine.

USE PROPER TOOLS

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.

Use power tools only to loosen threaded parts and

fasteners.

For loosening and tightening hardware, use the correct

size tools. DO NOT use U.S. measurement tools on

metric fasteners. Avoid bodily injury caused by slipping

wrenches.

Use only service parts meeting John Deere

specifications.

DX,SERV -19-03MAR93

DX,REPAIR -19-04JUN90


PN=11

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used

with John Deere equipment include such items as oil,

fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead

someone into drinking from them.

Do not pour waste onto the ground, down a drain, or

into any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth's atmosphere. Government regulations

may require a certified air conditioning service center to

recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from

your John Deere dealer.

LIVE WITH SAFETY

Before returning machine to customer, make sure

machine is functioning properly, especially the safety

systems. Install all guards and shields.

DX,DRAIN -19-03MAR93

DX,LIVE -19-25SEP92


PN=12


PN=13

Section 50

TransmissionContents

Page


Basic information . . . . . . . . . . . . . . . . . 50-00-1

Specifications . . . . . . . . . . . . . . . . . . . 50-00-2

Towing procedure . . . . . . . . . . . . . . . . 50-00-4

Descriptions . . . . . . . . . . . . . . . . . . . . 50-00-5

Synchronizer description . . . . . . . . . . . . 50-00-8

Synchronizer operation . . . . . . . . . . . . . 50-00-10

Reverser clutch operation . . . . . . . . . . . 50-00-11

Clutch operation four-wheel drive . . . . . . 50-00-12

Clutch operation front wheel drive . . . . . . 50-00-13

Group 05ÐRemoval and Replacement

Removal and replacement of torque

converter housing . . . . . . . . . . . . . . . 50-05-1

Removal and replacement of the gearbox . 50-05-4

Fitting procedure . . . . . . . . . . . . . . . . . 50-05-5


Torque Converter Housing

Disassembly of the torque converter

housing . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembly of the torque converter housing . 50-10-2

Torque converter housing with PTO . . . . 50-10-3

Torque converter stall test . . . . . . . . . . . 50-10-5

Pressure and flow test . . . . . . . . . . . . . 50-10-8


Gearbox

Disassembly of the gearbox . . . . . . . . . . 50-15-1

Assembly of the gearbox . . . . . . . . . . . . 50-15-14

Fault finding - gearbox . . . . . . . . . . . . . 50-15-30


Reverser Unit

Disassembly and assembly of the

solenoid valve . . . . . . . . . . . . . . . . . 50-20-1

Disassembly of the reverser unit . . . . . . . 50-20-2

Assembly of the reverser unit . . . . . . . . . 50-20-4


Hydraulic 2/4 Wheel Drive Unit

Disassembly of the hydraulic 2/4 wheel

drive unit . . . . . . . . . . . . . . . . . . . . . 50-25-2

Page

Assembly of the hydraulic 2/4 wheel drive

unit . . . . . . . . . . . . . . . . . . . . . . . . . 50-25-3

Transmission testing . . . . . . . . . . . . . . . 50-25-4

Pressure and flow testing . . . . . . . . . . . 50-25-5

Pressure testing the 2/4 WD clutch . . . . . 50-25-7

Fault finding in the 2/4 wheel clutch . . . . 50-25-8

Fault finding in the drive train . . . . . . . . . 50-25-10


PN=236


PN=237

BASIC INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . Combined reverser and gearbox unit with integral

parking brake and remote torque converter.

Designation . . . . . . . . . . . . . . . . . . . . . . . . SS660 (4 wheel drive)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kg (441 lb.)

Torque Converter Diameter . . . . . . . . . . . . . 279 mm (11 in.)

Torque Multiplication at Stall . . . . . . . . . . . . 2.2:1

No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . Std. Ratio

Countershaft, 1st and 2nd speed . . . . 19

Countershaft, 3rd and 4th speed . . . . . 36

Gear Ratios

1st . . . . . . . . . . . . . . . 4.29:1

2nd. . . . . . . . . . . . . . . 2.66:1

3rd . . . . . . . . . . . . . . . 1.41:1

4th . . . . . . . . . . . . . . . 0.77:1

Torque Converter Colour Code 2.2:1 Ratio

Identification

Colour Coded Dots . . . . . . . . . . . . . . . . . . . 2 purple

1 white

Minimum Engine Speed at Converter Stall:

2050 rpm

GS4400,2 -19-01FEB97

Group 00General Information


PN=14

SPECIFICATIONS

Item Measurement Specification

Converter

Converter In at 50 ÊC;122 ÊF, Pressure (in Neutral) 240 to 340 kPa;2.4 to 3.4 bar;34.8 to

1000 rpm 49.3 psi

Converter In at 50 ÊC;122 ÊF, Pessure (in Neutral) 70 to 620 kPa;0.7 to 6.2 bar;10.1 to

2000 rpm 89.9 psi


1000 rpm 29 psi


2000 rpm 85.5 psi

Converter Out at 50 ÊC;122 ÊF, Pressure (in Neutral) 100 to 170 kPa;1.0 to 1.7 bar;14.5 to

1000 rpm 26.6 psi

Converter Out at 50 ÊC;122 ÊF, Pressure (in Neutral) 0 to 210 kPa;0 to 2.1 bar;0 to 30.4 psi

2000 rpm

Converter Out at 100 ÊC;212 ÊF, Pressure (in Neutral) 30 to 60 kPa;0.3 to 0.6 bar;4.3 to 8.7

1000 rpm psi

Converter Out at 100 ÊC;212 ÊF, Pressure (in Neutral) 100 to 170 kPa;1.0 to 1.7 bar;14.5 to

2000 rpm 24.5 psi

Converter inlet relief valve Pressure (max) 650 kPa;6.5 bar;94.2 psi

Lubrication Pressure

At 50 ÊC;122 ÊF, 1000 rpm Pressure (in Neutral) 20 to 30 kPa;0.2 to 0.3 bar;2.9 to 4.3

psi


psi


psi


psi

Main Line Pressure

At 50 ÊC;122 ÊF, 1000 rpm Pressure (in Neutral) 930 to 1030 kPa;9.3 to 10.3 bar;134.8

to 149.4 psi

Continued on next page


PN=15


At 50 ÊC;122 ÊF, 2000 rpm Pressure (in Neutral) 1070 to 1170 kPa;10.7 to 11.7

bar;155.2 to 169.7 psi

Full engine revs Pressure (in Neutral) 1100 to 1240 kPa;11.0 to 12.4

bar;159.5 to 179.8 psi


to 149.4 psi


to 149.4 psi

Clutch Pressure

At 50 ÊC;122 ÊF, 1000 rpm Pressure (forward and reverse) 550 to 620 kPa;5.5 to 6.2 bar;79.7 to

89.9 psi


139.2 psi


91.4 psi


100.0 psi

Clutch Pressure

At 50 ÊC;122 ÊF, 1000 rpm Pressure (to disconnect 4 wheel 860 to 930 kPa;8.6 to 9.3 bar;124.7 to

drive) 134.8 psi

At 50 ÊC;122 ÊF, 2000 rpm Pressure (to disconnect 4 wheel 860 to 930 kPa;8.6 to 9.3 bar;124.7 to

drive) 134.8 psi

Flow Rates Torque Converter

Housing-with Hydraulic Pump

Drive

Cooler at 50 ÊC;122 ÊF, 1000 rpm Flow rate 12.38 to 16.19 L/min;3.33 to 4.28 US

gal/min


gal/min


gal/min


gal/min

Continued on next page


PN=16


Pump at 50 ÊC;122 ÊF, 1000 rpm Flow rate 13.09 to 17.85 L/min;3.45 to 4.76 US

gal/min

Pump at 50 ÊC;122 ÊF, 2000 rpm Flow rate 26.78 to 35.12 L/min;7.14 to 9.28 US

gal/min

NOTE: The forward/reverse clutch

pressures should be same as mainline

pressure to within 70 kPa;0.7 bar;10.1

psi.

TOWING PROCEDURE

If there is no damage, the machine may be towed for

a distance of approximately 1.5 kilometers (1 mile).

Always use a rigid tow bar, ensure that the gear lever

is in neutral. Restrict towing speed to 25 km/h

(15 mph).

If it is necessary to tow the machine for a distance in

excess of 1.5 kilometers (1 mile), the axle drive

shafts should be disconnected to prevent damage to

the transmission system.

IMPORTANT: Removal or disconnection of the

axle drive shaft(s) will disable the

parking brake. It is essential that the

following procedure be adopted.

Position the maschine on firm level ground and block

the wheels securely to prevent any movement. Select

neutral and release the parking brake.

Disconnect the rear drive shaft(s) from the axle(s),

and tie up the shaft securely well clear of the rotating

axle yoke. Alternatively remove the shaft(s)

completely.

Connect the towing vehicle via the tow bar before

removing the blocks from the wheels. Restrict the

towing speed to 25 km/h (15 mph).

When towing is complete, block the wheels securely

before removing the tow bar and reconnecting the

drive shafts.

IMPORTANT: In some countries neither of the

procedures described above may be

legally acceptable for towing on

public highways.

GS4400,3 -19-01FEB97

GS4400,4 -19-01FEB97


PN=17

GS4400,5 -19-01FEB97


PN=18

GENERAL DESCRIPTION AND OPERATION

AÐReverser unit EÐSolenoid valve HÐCountershaft LÐClutch

BÐCrescent-type pump FÐMain shaft JÐ1st/2nd synchromesh unit MÐHydraulic pump drive

CÐTorque converter GÐ3rd/4th synchromesh unit KÐOutput gear NÐRemote oil filter

DÐPressure maintenance

valve

The transmission consists of a torque converter,

mounted on the engine, and a separately mounted

drop gearbox. The gearbox comprises a hydraulic

reverser unit, 4-speed synchromesh gear system and

a four-wheel drive clutch assembly.

The reverser unit (A) consists of a pair of

hydraulically operated drive clutches giving

forward-neutral-reverse drive. Oil pressure is provided

by a crescent-type pump (B) which is driven at

engine speed by the drive lugs of the torque

converter (C). The oil pressure is controlled by

maintenance valve (D) and clutch selection is

achieved by means of solenoid valve (E). See

ªReverser Clutch Operationº in this Group for further

information on the reverser unit.

Drive is transferred from the reverser unit by helical

gears to the mainshaft (F), which carries the 3rd/4th

synchromesh unit (G), and to the countershaft (H),

which carries the 1st/2nd synchromesh unit (J). The

synchromesh units are of the blocking pin type.

Drive is finally transmitted from the countershaft (H)

via the output gear (K) to both axles. In two-wheel

drive a hydraulically operated clutch (L) disconnects

the drive from the rear axle.

GS4400,6 -19-01FEB97


PN=19

GS4400,7 -19-01FEB97


PN=20

SCHEMATIC HYDRAULIC FLOW DIAGRAM (4WD CLUTCH, SPRING ON/PRESSURE OFF)

AÐReverser unit EÐSolenoid valve JÐ4WD clutch (spring ON/ 1ÐLubrication circuit

BÐCrescent type pump FÐOil filter pressure OFF) 2ÐPressurised circuit

CÐTorque converter GÐRelief valve KÐSolenoid valve 3ÐReturn circuit

DÐPressure maintaining HÐOil cooler (water type) LÐSump with suction

valve strainer

SYNCHRONIZER DESCRIPTION

The gearbox is fitted with blocking pin synchromesh,

comprising the following parts:

Synchro Hub (A) controls the operation of the

synchromesh unit and gear selection, the selector fork

fitting into the outer groove. Internal dog teeth link the

selected gear to the drive shaft. Through the synchro

hub center are two sets of holes for the blocker pins (C)

and the split energiser pin (D), spaced alternately.

Synchro rings (B) are rigidly joined by the blocker pins,

with the split energiser pins held, in counterbores,

between the two synchro rings.

Blocker pins (C) have a narrow neck in the center,

against which the synchro hub transmits radial drive

during gear changes. The edges of the blocker pin neck

and their mating synchro hub holes are designed so that,

as the radial loads are reduced, the synchro hub can

slide over the shoulder of the blocker pin.

Split energiser pins (D) take the initial axial load of the

synchro hub on the shoulder of the split energiser pin

neck. As the axial load reaches approximately 400 N

(40.8 kg; 90Ib) the internal springs allow the split

energiser pin to collapse and the synchro hub to move

axially.

Synchro cups (E) take the frictional drive from the

synchro ring on their inner faces. The synchro cups are

splined to drive their respective gears while

synchronisation is taking place.

GS4400,8 -19-01FEB97

GS4400,9 -19-01FEB97


PN=21

AÐSynchro hub CÐBlocker pins DÐSplit energiser pins EÐSynchro cup

BÐSynchro ring

GS4400,10 -19-01FEB97


PN=22

SYNCHRONIZER OPERATION

Diagram (F) shows the gearbox with first gear

engaged. Synchro ring (B) is in contact with synchro

cup (E) and the synchro hub dog teeth are linking

first gear to the shaft gear. In this position the split

energiser pins (D) are collapsed.

When selecting second gear the synchro hub (A)

slides along the split energiser pins until the pin

recess and the synchro hub flange are in line. At this

point the split energiser pins open and the synchro

rings are moved by the synchro hub pushing on the

split energiser pin shoulder.

Initial contact between the synchro ring and the

synchro cup starts to synchronise the speed of the

shaft and second gear. The rotational force of the

synchro ring is taken by the block pin against the

egde of the synchro hub hole, as at (G).

As the axial load on the synchro hub increases, the

split energiser pin collapses and the conical faces of

the blocking pin and synchro hub hole come into

contact, as at (H).

Further increases in the axial loads increase the

frictional grip of the synchro ring and the synchro

cup, causing the shaft and gear speeds to

synchronise.

As the speeds are synchronised, the radial load on

the blocker pin and the synchro hub is reduced. This

allows the synchro hub to slide freely along the

blocker pin and engage its dog teeth with second

gear, see diagram (J).

GS4400,325A -19-01FEB97


PN=23

FORWARD/REVERSE DRIVE CLUTCH OPERATION

In neutral, the flow of pressurised oil to the clutches

is blocked by the solenoid valve. When either forward

or reverse is selected, the solenoid valve diverts

pressurised oil via the reverser shaft to the

appropriate clutch in the reverser unit. Pressure from

the other clutch is vented to the sump via the

solenoid valve spool.

GS4400,11 -19-01FEB97


PN=24

CLUTCH OPERATION FOUR-WHEEL DRIVE

AÐSolenoid valve CÐPiston DÐDisk springs EÐDrive output flange

BÐClutch friction/counter

plates

Four-wheel drive switched ON

The clutch is engaged and disengaged by introducing

or dumping pressurised oil behind piston (C) via a

solenoid valve (A). The solenoid valve is controlled by

a toggle switch inside the cab.

When the toggle switch is in the 4 wheel drive

position, solenoid valve (A) is de-energised, the oil

supply to the piston (C) is blocked (shown at port 3).

The solenoid valve in the de-energised position also

vents oil from the back of piston (C) to the sump via

ports 1 and 2.

Because there is no pressure behind piston (C),

clutch friction/counter plates (B) are forced togther by

disk springs (D), thus driving 4 wheel drive output

flange (E).

GS4400,12 -19-01FEB97


PN=25

CLUTCH OPERATION FOUR WHEEL DRIVE

AÐSolenoid valve CÐPiston FÐActuating sleeve HÐSpool

BÐClutch friction/counter DÐSprings GÐPressure plate

plates

Front wheel drive switched OFF

When the toggle switch is in the 2 wheel drive

position, solenoid valve (A) is energised. The

energised valve causes spool (H) to move to the right

and forms a connection between ports 3 and 2.

Pressurised oil is directed to piston (C) via ports 3

and 2. The piston moves actuating sleeve (F) and

then pressure plate (G) against the force of springs

(D), thus releasing spring force on the clutch

friction/counter plates (B).

The clutch plates now freely rotate on the output

shaft thus disengaging drive to the front axle.

When the brake pedal(s) are pressed, the machine

will go automatically into 4 wheel drive and the

indicator light will go out. When the brake pedal(s) is

released the machine will revert to 2 wheel drive and

the indicator light will be illuminated.

GS4400,13 -19-01FEB97


PN=26


PN=27

TORQUE CONVERTER HOUSING

Park the machine on firm level ground.

N CAUTION: A raised and badly supported

machine can fall on you. Position the machine

on a firm level surface. Before raising one end

ensure the other end is securely chocked. Do

not rely solely on the machine hydraulics or

jacks to support the machine when working

under it. Disconnect the battery, to prevent the

engine being started while you are beneath the

machine.

Removal

1. Stabilise the machine. Lift and secure boom to allow

room for the torque converter housing to be pulled clear.

Block/support the machine.

2. Disconnect hoses (A) from the valve/pump assemblyAÐDisconnect hoses DÐYokes(B). Plug ports to prevent ingress of dirt.BÐValve/pump EÐTransmission shaft

assembly FÐScrews3. Remove transmission shaft drive bolts (C) and CÐDrive bolts

separate the yokes (D)

4. Swing transmission shaft (E) to one side and secure

safely.

5. Support the weight of the housing/pump unit (B) and

remove hexagon head mounting screws (F) from the

housing/engine casing.

6. Withdraw and lower the housing/pump unit (B) and lift

the unit off.

7. Remove the torque converter (see torque converter,

removal and replacement).

Replacement is reverse of the Removal procedure.

Torque Settings

Housing to engine mounting screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N´m; 72 lb-ft

GS4400,14 -19-01FEB97

Group 05Removal and Replacement


PN=28

TORQUE CONVERTER

Item N´m lb-ft

3 40 30

5 19 14

AÐAlignment tool

BÐConverter runout

1ÐDrive plate

2ÐDrive plate annulus

3ÐRetaining bolts

4ÐMount washer

5ÐBolt

GS4400,15 -19-01FEB97


PN=29

Removal

1. Slacken and remove retaining bolts (3) from drive

plate (1).

2. Withdraw torque converter and drive plate from

splined flywheel mounting.

Before replacing

Ensure that flywheel face, drive plate, and hardware

are clean and free from burrs or other surface

imperfections.

When replacing

1. Install drive plate (1) and drive plate annulus (2) to

torque converter.

2. Place an alignment tool (A) over the torque

converter spigot, make sure that the tool locates in

two of the converter bolt holes as shown. It is

important to note that the converter drive tube must

be protected against damage or contamination at all

times.

3. Fit four of the drive plate retaining bolts (3) and

tighten to 40 N´m (30 lb-ft.). Remove the alignment

tool and fit the remaining two retaining bolts (3).

4. Install the torque converter and drive/annulus

assembly on the flywheel, bolt the drive plate annulus

to the flywheel (use only 3 bolts). Check the

converter runout as shown at (B), which should not

exceed 0.38 mm (0.015 in).

5. Remove the torque converter and drive

plate/annulus assembly from the flywheel.

6. Install the converter assembly to the

transmission/engine:

6.1 Install the torque converter with its drive

plate/annulus sub-assembly onto the transmission

input shaft.

6.2 Rotate the engine flywheel so that one bolt hole

is in a six o' clock position.

6.3 Rotate the torque converter and drive plate

assembly so that one bolt hole is in a six o'clock

position.

6.4 Install the pump housing/torque converter

assembly to the engine (see Torque Converter

Housing, Removal and Replacement).

6.5 Remove the access plate from the bottom of the

engine flywheel housing and through access hole fit

and hand tighten one bolt (5) in the six o' clock

position.

6.6 Rotate the flywheel until the next bolt hole is

accessible, fit and hand tighten the next bolt (5).

Repeat the operation until all bolts are fitted. Finally

tighten bolts (5) to 19 N´m (14 lb-ft), rotating the

flywheel each time to align bolts (5) with access hole.

Refit access plate.

GS4400,16 -19-01FEB97


PN=30

REMOVAL AND REPLACEMENT OF THE GEARBOX

Park the machine on firm level ground.

N CAUTION: A raised and badly supported

machine can fall on you. Position the

machine on firm, level surface. Before

raising one end ensure the other end is

securely chocked. Do not rely solely on the

machine hydraulics or jacks to support the

machine when working under it. Disconnect

the battery, to prevent the engine being

started while you are beneath the machine.

Removal

1. Stabilise machine and raise the boom to allow

room for the gearbox to be pulled clear. Block/support

the machine.

2. Drain the gear box.

3. Disconnect the gearshift lever from the top of the

gearbox.

4. Remove transmission shaft and axle drive shaft

bolts and separate the yokes.

5. Remove 4 WD and transmission solenoid

connectors and pressure sender. Label the

connectors for identification when refitting.

6.1 Disengage the parking brake clevis at the parking

brake caliper and remove outer cable retaining snap

ring (Clydesdale type).

6.2 Disengage the parking brake clevis at the parking

brake caliper and remove cable (Hayes type).

7. Remove the gearbox dipstick tube and filter.

8. Support the gearbox with a trolley jack fitted with a

cradle to partially embrace the gearbox.

9. Make sure the weight of the gearbox is supported

by the trolley jack and remove the bolts from the

mounting brackets on both sides of the unit.

10. Disconnect the transmission oil cooler.

11. Remove the breather pipe from the pressure

maintenance valve block to the top of the dipstick

tube.

12. Using the trolley jack, lower and move the

gearbox clear of the mountings and the machine.

Reinstallation

Reinstallation is the reverse of the Removal

procedure.

Set the parking brake cable as described in Parking

Brake.

If the parking brake caliper has been removed, reset

central to the parking brake disk.

Fill the gearbox with the specified amount of John

Deere HYSTAT-GARD transmission oil.

Leave oil cooler hose off the gearbox mounting until

the filling operation is complete, then refit.

TORQUE SETTINGS

Axle drive shaft bolts . . . . . . . . . . . . . . . . . . . . 118 N´m;87 lb-ft

Transmission shaft bolts . . . . . . . . . . . . . . . . . . 79 N´m;58 lb-ft

Gearbox mounting screws . . . . . . . . . . . . . . . . . 98 N´m;72 lb-ft

GS4400,17 -19-01FEB97


PN=31

FITTING PROCEDURE

1. Wind the PTFE piston ring seal around your finger as

shown, so that the seal forms a coil.

2. Use grease to install the seal on the shaft. Make sure

that the seal sits below or flush with the outer diameter

of the shaft. If necessary, use finger pressure as shown

to make the seal flush with the shaft.

N CAUTION: If the seal is not set below or flush

with the outer diameter of the shaft, then the

seal will cut when the shaft is fitted to its

mating component.

GS4400,18 -19-01FEB97

GS4400,19 -19-01FEB97


PN=32


PN=33

DISASSEMBLY OF THE TORQUE CONVERTER HOUSING

1. Using a suitable tool to prevent the drive shaft

yoke from turning, unscrew retaining stake nut (1).

Remove the nut, washer (2) and yoke (3) from the

splined shaft. Discard the stake nut. Repeat for stake

nut (4), washer (5) and yoke (6).

2. Remove and discard seal (7).

3. Loosen and remove the six retaining screws (8).

Lift the valve/pump assembly (9) away from cover

(10). Put the valve/pump to one side unless the

reason for disassembly is a fault in these

components. In such a situation proceed to step (9).

4. Lift out gear (11), located against the bell housing,

from inside the cover (10). Check for damage to the

drive dogs. Damage indicates misalignment during

assembly and, if excessive, necessitates replacement

of the gear.

5. Inspect the thrust washers (12) for damage and if

necessary discard and renew. Damaged thrust

washers are a sign of damage to the surfaces

against which they run. Check the relevant surfaces

of the gear and the bell housing for scoring, dress if

necessary and clean thoroughly. If the surfaces are

badly scored, renew the components. Remove and

discard PTFE washer (13) and O-ring (14).

6. Unscrew bolts (15) and separate cover (10) from

bell housing (16). See NOTE at step 3.

7. If necessary, remove drive shaft yoke oil seal (17).

8. Lift out the assembly comprising drive shaft and

gear (18), bearing (19) from the bell housing. Check

the bearings for wear and if necessary remove and

renew.

9. Return to the valve/pump assembly (9) removed at

step 3. Remove banjo bolt (20) and adapter (21).

Discard the two O-rings (22) and (23) from the banjo

bolt and the O-ring (24) from the face of the adapter.

10. Remove snap ring (25) and withdraw the

assembly comprising drive shaft (26), bearing (27),

seal (28), snap ring (29) and PTFE ring (30).

11. Remove the four retaining bolts (31) and lift the

transmission oil pump clear of the valve.

12. Remove and discard rubber pump sealing ring

(32).

13. Separate the cover plate (33) and shaft (34) of

the pump. Check that gear (35) rotates freely but

without discernible play on its white metal bearing.

Also look for debris and/or signs of scoring.

Check pump gear (36) for free movement in cover

plate (33). Also check for debris and/or signs of

scoring. Examine the gear drive dogs, damage to

which indicates misalignment during assembly.

14. Remove plug (37) and take out the pressure

maintaining valve components (38, 39, 40). Check

that spool (40) moves freely in its bore and that it

does not stick against its seat (using a magnetic

probe should move it in and out). If necessary dress

the seat and fit a new spool. Severe damage will

necessitate renewal of the valve block.

Remove plug (41) and take out the torque converter

relief valve components (42, 43, 44). Check the ball

(44) and seat for signs of damage. If necessary dress

the seat and renew the ball. Severe damage will

necessitate renewal of the valve block.

GS4400,20 -19-01FEB97

Group 10Disassembly and Assembly of the Torque Converter Housing


PN=34

ASSEMBLY

Assembly is the reverse of the disassembly procedure.

Note the following points:

1. Renew all O-rings and PTFE seals.

2. Oil the bearing races to avoid dry running at start up.

3. Check that all oil galleries are clear.

4. Check that the cross drilling (X) behind the pressure

maintenance valve is clear.

5. Graese thrust rings (12) to avoid dry running at start

up.

6. When fitting yokes (3) and (6), take care not to

damage seals (16) and (7) respectively. Damage will

cause the unit to suck in air instead of oil during priming.

7. Position yokes (3) and (6) on their splines so that

access to the staking point is not impeded. Stake using

a square ended staking tool.

SPECIFICATIONS


Torque Settings

1, 4 Torque 300 N´m; 221 lb-ft

8, 15 Torque 56 N´m; 41.3 lb-ft

20 Torque 102 N´m; 75 lb-ft

31 Torque 28 N´m; 20.6 lb-ft

GS4400,21 -19-01FEB97


PN=35

TORQUE CONVERTER HOUSING WITH HYDRAULIC PUMP DRIVE

GS4400,22 -19-01FEB97


PN=36

TORQUE CONVERTER HOUSING WITH HYDRAULIC PUMP DRIVE

1ÐStake nut 12ÐWasher 23ÐO-ring 34ÐShaft

2ÐWasher 13ÐPTFE washer 24ÐO-ring 35ÐGear

3ÐYoke 14ÐO-ring 25ÐSnap ring 36ÐPump gear

4ÐStake nut 15ÐBolts 26ÐPTO drive shaft 37ÐPlug

5ÐWasher 16ÐCover 27ÐBearing 38ÐValve component

6ÐYoke 17ÐOil seal 28ÐSeal 39ÐValve component

7ÐSeal 18ÐGear 29ÐSnap ring 40ÐSpool

8ÐScrew 19ÐBearing 30ÐPTFE ring 41ÐPlug

9ÐValve/pump assembly 20ÐBanjo bolt 31ÐRetaining bolts 42ÐRelief valve component

10ÐCover 21ÐAdapter 32ÐSealing ring 43ÐRelief valve component

11ÐGear 22ÐO-ring 33ÐCover plate 44ÐRelief valve component

GS4400,380 -19-01FEB97


PN=37

TORQUE CONVERTER STALL TEST (REMOTE FILTER)

GS4400,23 -19-01FEB97


PN=38

TORQUE CONVERTER STALL TEST

DÐFlow meter assembly GÐPort JÐPort LÐValve

FÐOil cooler inlet line HÐPort KÐPressure gauge/flow

meter

Ensure that the engine and transmission are at

normal working temperature. Run engine at maximum

speed and check the No load speed. See Engine

technical data for correct figure; adjust if necessary.

Apply parking brake and footbrake firmly. Select 4th

speed forward or 3rd speed forward (Germany only)

and open throttle fully. Engine speed should be as

specified at Torque converter stall in transmission

technical data. Select reverse and repeat test.

If engine speeds are higher than the stated figures

check the transmission for clutch slippage or internal

leakage.

If engine speeds are below the stated figures either

the engine is losing power and should be

serviced/overhauled or the torque converter reaction

member clutch is slipping. To check the engine ,

select neutral, open throttle fully and operate a

function to blow off the main relief valve. Engine

speed should fall to slightly above the maximum

governed speed (see engine technical data). If engine

speed is correct the torque converter is faulty.

GS4400,24 -19-01FEB97


PN=39

TORQUE CONVERTER STALL TEST (ATTACHED FILTER)

GS4400,024 -19-01FEB97


PN=40

PRESSURE AND FLOW TEST

N CAUTION: Take care when disconnecting

hydraulic hoses and fittings as the oil will

be hot.

1. Stop engine, disconnect filter flow/return hoses

from the converter valve block and connect flow

meter assembly (D), and connect a 0-2000 kPa (0-20

bar; 290 psi) pressure gauge to screwed connector

(E).

2. Start engine and run at 1000 rpm. The flowmeter

will show the pump flow which should be as shown in

Specifications. A low reading indicates a worn pump

or blocked suction strainer. The pressure gauge will

show the main line pressure (see Specifications). A

low reading can be caused by either a faulty pressure

maintenance valve or a worn pump. A high reading

indicates a faulty pressure maintenance valve or, if

the pump flow is low, the oil cooler may be blocked.

3. Stop engine, remove flow test adapters and refit

filter. Connect pressure gauge and flowmeter into

converter out line as shown at (F). Run engine at

1000 rpm with transmission in neutral. Note converter

out pressure and oil cooler flow, which should be as

shown in Specifications. A high pressure together with

low flow could be caused by a blocked oil cooler.

(See also check 7.)

4. With parking brake and footbrake firmly applied,

select forward and check flow reading, which should

not fall by more than 4.5 liters (1.2 US gal) per

minute. A low reading indicates a high leakage rate in

that particular clutch, which could be caused by worn

or broken piston seals or shaft sealing rings. Select

reverse and repeat the test.

5. If the clutch leakage rate is high, the clutch

pressures may be checked by connecting the

pressure gauge into ports (G) and (H) and repeating

test (4). A low reading would confirm a high leakage

rate in the particular clutch selected.

6. Stop engine, connect the pressure gauge into port

(J) in the converter valve block, and fit a load valve

(L) into the converter out line (see note).

Start engine, run at 1000 rpm and slowly screw down

the load valve while observing the gauge reading,

which should rise to setting of the converter relief

(safety) valve .

If the reading is higher than specified, the relief

(safety) valve must be faulty. A low reading indicates

a faulty relief (safety) valve, leaking converter piston

ring type seal or leaking pump seal.

7. Stop engine and connect pressure gauge and

flowmeter into return line from oil cooler to converter

valve block as shown at (K). Start engine, and with

transmission in neutral check flowmeter reading,

which will show the cooler flow rate (see

Specifications). The pressure gauge will show the

lubrication pressure (see Specifications). Low flow

and pressure readings could indicate a blocked oil

cooler.

GS4400,25 -19-01FEB97


PN=41

DISASSEMBLY OF THE GEARBOX

1. Mount the gearbox on a suitable stand as shown.

2. Drain the oil (if not already done) by removing the

magnetic drain plug (A). Clean the plug. Remove the

suction strainer (B). Discard the strainer gasket.

3. If fitted, disconnect and remove the 4 WD clutch

hydraulic pipe (C) and non-return valve (D). Remove the

4 WD clutch solenoid securing nut and lift off the

solenoid (E). Retain the solenoid nut and washer.

4. Remove the 4 WD clutch valve. Unstake and slacken

off the front drive shaft retaining nut using a suitable

tool, in preparation for removing the coupling.

GS4400,26 -19-01FEB97

GS4400,27 -19-01FEB97

GS4400,28 -19-01FEB97

GS4400,29 -19-01FEB97

Group 15Disassembly and Assembly of the Gearbox


PN=42

5. Remove the 4 WD clutch housing bolts. Note that

there are four bolts on the rear face of the flange (not

shown).

6. Pull off the 4 WD clutch and housing. Discard the

gasket.

7. Using a suitable tool to hold the coupling, remove the

front drive shaft retaining nut and its washer. Pull off the

coupling yoke.

8. Remove the 4 WD clutch from the housing (snap ring

X and sleeve Y not used on 4400 and 4500).

GS4400,30 -19-01FEB97

GS4400,31 -19-01FEB97

GS4400,32 -19-01FEB97

GS4400,33 -19-01FEB97


PN=43

9. Remove the seal, snap ring and bearing.

10. Using a suitable tool to hold the coupling, unstake

and remove the input shaft retaining nut and its washer.

Pull off the coupling yoke.

11. Unscrew the bolts and remove the bearing cap.

12. Remove the seal.

GS4400,34 -19-01FEB97

GS4400,35 -19-01FEB97

GS4400,36 -19-01FEB97

GS4400,37 -19-01FEB97


PN=44

13. Remove spacer (A) and shims (B).

14. Remove the screws and lift off the gear lever turret.

Discard the gasket.

15. Components of the gear lever turrets.

Slacken clamps and remove rubber boot.

16. For large turret assembly, remove spring retaining

snap ring (X). For small turret assembly release spring

from the locating lugs inside the housing.

N CAUTION: Beware of spring pressure acting on

nylon seat when snap ring is removed.

GS4400,38 -19-01FEB97

GS4400,39 -19-01FEB97

GS4400,39A -19-01FEB97


PN=45

17. Unscrew cap screws (E) and remove solenoid

selector valve.

18. Unscrew four bolts and remove the adapter block

(F).

19. Remove the gasket and discard.

20. Using a suitable tool to hold the coupling, unstake

and remove the rear output shaft retaining nut and

washer. Pull off the coupling yoke. Withdraw the

shaft/gear.

GS4400,39B -19-01FEB97

GS4400,40 -19-01FEB97

GS4400,41 -19-01FEB97

GS4400,42 -19-01FEB97


PN=46

21. Remove the seal (F) and outer bearing cone (G).

22. If the bearing is to be renewed, remove the outer

bearing cup.

23. Remove the collapsible spacer (H) (and the inner

bearing cone (J) if the bearing is to be renewed).

Discard the spacer. If damaged or worn, remove the

taper roller cage from the shoulder of the splined hub.

24. If the inner bearing is to be renewed, remove the

bearing cup.

GS4400,43 -19-01FEB97

GS4400,44 -19-01FEB97

GS4400,45 -19-01FEB97

GS4400,46 -19-01FEB97


PN=47

25. Position the gearbox as shown. Then remove the

bolts and lift off the rear housing.

26. If the reverser shaft solenoid end bearing is to be

renewed, remove the cup.

27. Unscrew and remove the selector detent plugs.

28. Remove the selector detent balls and springs.

Remove the 4 WD output switch (if fitted).

GS4400,47 -19-01FEB97

GS4400,48 -19-01FEB97

GS4400,49 -19-01FEB97

GS4400,50 -19-01FEB97


PN=48

29. Unscrew selector fork retaining screws (H) and lift

out selector rods.

30. Remove selector forks.

31. Using a wire support as shown, remove interlock

plunger situated between selector rod bores.

32. Lift off 3rd/4th synchro-hub (J). Note the position for

refitting the mating cups.

GS4400,51 -19-01FEB97

GS4400,52 -19-01FEB97

GS4400,53 -19-01FEB97

GS4400,54 -19-01FEB97


PN=49

33. Lift out countershaft assembly (K).

34. Remove idler gear upper thrust washers and thrust

bearing.

35. Tilt mainshaft (L) to one side and lift off idler gear.

36. Remove idler gear lower thrust washers and thrust

bearing.

GS4400,55 -19-01FEB97

GS4400,56 -19-01FEB97

GS4400,57 -19-01FEB97

GS4400,58 -19-01FEB97


PN=50

37. Lift off idler gear spacer.

38. Tilt mainshaft (L) to one side and lift out reverser

assembly (M) taking care not to damage piston ring

seals.

39. Remove mainshaft (L).

40. The idler gear spindle is a press fit in the casing.

Use a suitable puller screwed into the 1/2 in. hole in the

end of the spindle for extraction.

GS4400,59 -19-01FEB97

GS4400,60 -19-01FEB97

GS4400,61 -19-01FEB97

GS4400,62 -19-01FEB97


PN=51

41. While holding brake disk with tool 992/04800,

unscrew output shaft nut. Support output shaft from

beneath and lift off brake disk.

42. Pry out oil seal and discard.

43. Withdraw output shaft assembly and lift out outer

bearing. Remove and discard collapsible spacer (N).

44. Using a suitable puller, withdraw output shaft inner

bearing.

GS4400,63 -19-01FEB97

GS4400,64 -19-01FEB97

GS4400,65 -19-01FEB97

GS4400,66 -19-01FEB97


PN=52

45. Pull off 3rd gear, synchro-hub and bearing from

mainshaft using press 892/00179 with adapter

992/06300.

46. Mainshaft with 3rd gear, synchro-hub and spacer

washer withdrawn.

47. Remove bearing from converter end of mainshaft

using press 892/00179.

48. Remove the output gear and bearing from the

countershaft.

GS4400,67 -19-01FEB97

GS4400,68 -19-01FEB97

GS4400,69 -19-01FEB97

GS4400,70 -19-01FEB97


PN=53

49. Lift off 1st gear.

50. Remove 1st gear needle roller bearings.

51. Lift off 1st/2nd synchro-unit. Keep synchro cups and

cones in the correct relationship, i.e. cup and cones as a

pair.

52. Pull off 2nd gear, synchro-hub, synchro cup and

needle roller bearing from countershaft.

See hydraulic 4-wheel drive unit - Disassembly, for the

disassembly and assembly procedures.

Finally, after repair and renewal of parts, make sure

casings and parts have been thoroughly cleaned using

suitable solvents before starting the assembly

procedures.

GS4400,71 -19-01FEB97

GS4400,72 -19-01FEB97

GS4400,73 -19-01FEB97

GS4400,74 -19-01FEB97


PN=54

ASSEMBLY OF THE GEARBOX

1. Lubricate bearing surface of shaft with grease and fit

2nd gear and synchro cup onto shaft.

2. Press 2nd gear synchro-hub and 1st gear needle

roller bearing sleeve onto countershaft.

3. Fit 1st/2nd synchro unit the correct way round to

match cups.

GS4400,75 -19-01FEB97

GS4400,76 -19-01FEB97

GS4400,77 -19-01FEB97


PN=55

4. Slide 1st gear needle roller bearing over sleeve.

Lubricate bearings with oil.

5. Fit 1st gear over needle roller bearings.

6. Assemble 4 WD transfer gear over splines.

7. Press bearing onto assembled countershaft and

lubricate bearing with grease.

GS4400,78 -19-01FEB97

GS4400,79 -19-01FEB97

GS4400,80 -19-01FEB97

GS4400,81 -19-01FEB97


PN=56

8. Lubricate bearing surface of mainshaft with grease

and assemble 3rd gear and synchro-hub. Fit spacer

washer (S) with bevel towards bearing. Press bearing

onto shaft and lubricate with grease.

9. Liberally coat output shaft inner bearing with grease

before fitting. Fit a new collapsible spacer (N) over

output shaft; assemble into output end casing.

10. After lubricating with grease, fit outer bearing

followed by a new oil seal. Pack the space between the

lips of the seal with grease before fitting. Assemble

brake disk (or spacer if applicable) and retaining nut.

11. Tighten retaining nut to achieve a rolling torque of

0.7 to 2.0 N´m (0.5 to 1.5 lb-ft).

GS4400,82 -19-01FEB97

GS4400,83 -19-01FEB97

GS4400,84 -19-01FEB97

GS4400,85 -19-01FEB97


PN=57

12. Finally stake the nut into its slot in the shaft.

13. Press the inner bearing cone (J) onto the output

gear shaft and coat with grease. Fit a new collapsible

spacer (H). Also, if the original was removed, press a

new taper roller cage into the shaft shoulder.

14. Fit new inner and outer bearing cups for the rear

output shaft, if the original ones were removed.

15. Insert the rear output gear into the front casing.

GS4400,86 -19-01FEB97

GS4400,87 -19-01FEB97

GS4400,88 -19-01FEB97

GS4400,89 -19-01FEB97


PN=58

16. Coat the rear output gear outer bearing with grease,

then fit it fully onto the shaft.

17. Pack the space between the lips of the seal with

grease, then press the seal into the housing.

18. Fit the coupling yoke, washer and retaining nut.

Measure seal drag. Using service tool 892/00812, tighten

nut to achieve a rolling torque of 1 to 3 N´m (0.7 to 2.2

lb-ft) plus seal drag.

19. Press the idler gear spindle into the front casing.

Ensure that the oil drain hole (V) faces towards the

bottom of the casing. Fit new bearing cups where the

original ones were removed. Temporarily fit the input

shaft bearing cap, to hold the cup in place.

GS4400,90 -19-01FEB97

GS4400,91 -19-01FEB97

GS4400,92 -19-01FEB97

GS4400,93 -19-01FEB97


PN=59

20. Pack the mainshaft input end bearing with grease

and place the shaft in position.

21. Pack the reverser input bearing with grease and

place it in position.

22. Install the idler gear spacer on the spindle.

23. Oil the idler gear lower thrust bearing backing

washer, thrust race and needle roller cage. Install them

on the spindle, with the needle rollers and cage

uppermost and the thrust race at the bottom.

GS4400,94 -19-01FEB97

GS4400,95 -19-01FEB97

GS4400,96 -19-01FEB97

GS4400,97 -19-01FEB97


PN=60

24. Tilt the mainshaft to one side and install the idler

gear (L).

25. Oil the upper thrust bearing and install the needle

rollers towards the gear, followed by the thrust race. Fit

the thick spacer washer last with its spigot towards the

gear.

26. Pack the countershaft output end bearing with

grease and carefully lower the countershaft into position.

27. Install the 3rd/4th synchro assembly and the cup. It

may be preferable to locate the cup on the splines of the

transfer gear (see Step 33).

GS4400,98 -19-01FEB97

GS4400,99 -19-01FEB97

GS4400,100 -19-01FEB97

GS4400,101 -19-01FEB97


PN=61

28. Using a suitable wire support as shown, locate the

interlock plunger into its bore. Grease will hold the

plunger in position.

29. Locate the selector forks.

30. Slide the selector rods into position, taking care not

to dislodge the interlock plunger. Apply Loctite 242 to the

selector rod retaining screws (H) and tighten to 35 N´m

(26 lb-ft).

31. Fit the 4 WD cut-out switch. Insert the selector

detent springs and balls into their bores.

GS4400,102 -19-01FEB97

GS4400,103 -19-01FEB97

GS4400,104 -19-01FEB97

GS4400,105 -19-01FEB97


PN=62

32. Apply Loctite 242 to the selector detent plug threads.

Screw the plugs into position. Check that each gear

engages fully and that the interlock prevents

simultaneous engagement of two ratios. Check that the

4 WD cut-out switch is closed only in 4th gear.

33. If reverser shaft bearing cup was removed from rear

casing, press in a new bearing cup. If not fitted in step

27, position the 4th gear synchro cup on the transfer

gear splines, using grease to hold it in place while the

casings are mated (Steps 34,35).

34. Pack the mainshaft and countershaft upper bearings

with grease. Apply grease to the reverser shaft piston

ring seals. Grease the reverser rear bearing. Apply a

bead of liquid sealant to the mating face of the casing.

35. Carefully lower the rear casing into position. Apply

Loctite 242 to the casing bolts and tighten to 56 N´m (42

lb-ft). Turn the gearbox upright.

GS4400,106 -19-01FEB97

GS4400,107 -19-01FEB97

GS4400,108 -19-01FEB97

GS4400,109 -19-01FEB97


PN=63

36. Remove the input shaft bearing cap (temporarily

fitted in Step 18). Fit shims (B) and spacer (A).

37. Fit a new seal, packing the space between the lips

with grease.

38. Refit the bearing cap and a new gasket. Tighten the

bolts to 56 N´m (42 lb-ft).

39. While rotating the shaft, measure the end play, which

should be 0.03 to 0.08 mm (0.001 to 0.003 in.). Add or

subtract shims (Step 36) to achieve the correct end play.

Apply Loctite 242 to the bearing cap bolt threads before

final tightening.

GS4400,110 -19-01FEB97

GS4400,111 -19-01FEB97

GS4400,112 -19-01FEB97

GS4400,113 -19-01FEB97


PN=64

40. Fit the coupling, positioning it to give best access for

a staking tool. Then fit the washer and a new retaining

nut. Using a suitable tool to restrain the coupling, tighten

the nut to 350 N´m (263 lb-ft). Stake the nut into the

groove in the shaft.

41. Remove the mainshaft bearing cap and fit service

tool 990/0083, using a new gasket. Tighten the securing


42. While rotating the shaft, measure the end play - 0.03

to 0.08 mm (0.001 to 0.003 in). Add/subtract shims

between bearing spacer and bearing as necessary. Refit

bearing cap and same gasket. Apply Loctite 242 to bolt

threads before tightening. Re-torque bolts.

43. Remove the plug (X). Screw a 1/2ª bolt into the

tapped end of the countershaft.

GS4400,114 -19-01FEB97

GS4400,115 -19-01FEB97

GS4400,116 -19-01FEB97

GS4400,117 -19-01FEB97


PN=65

44. Using a suitably shaped lever, applied to the

underside of the bolt head, measure the end play - 0.03

to 0.08 mm (0.001 to 0.003 in.). Add/subtract shims

between bearing spacer and bearing as necessary. Refit

bearing cap and same gasket. Apply Loctite 242 to the

bolt threads before final tightening. Re-torque bolts.

45. Using a new gasket, mount the valve block onto the

rear casing. Apply Loctite 242 to the bolt threads.

Tighten to 7 N´m (5 lb-ft).

46. Mount the solenoid valve, aligning port P with small

metering port in the valve block. (It will not fit correctly

the other way round.) Ensure spacers (E) are installed.

Apply Loctite 242 to the threads of cap screw and

tighten to 5 N´m (3.7 lb-ft).

GS4400,118 -19-01FEB97

GS4400,119 -19-01FEB97

GS4400,120 -19-01FEB97


PN=66

47. Assemble gear lever components, applying grease

liberally to the working surfaces.

48. Refit components into gear lever housing, secure in

position with spring retaining snap ring (X) in large turret

assembly.

Secure the spring onto the locating lugs in the small

turret assembly.

49. Refit the rubber boot and tighten the clamps.

50. Using a new gasket, fit the gear lever turret to the

gearbox. Apply Loctite 242 to the mounting bolts and

tighten to 56 N´m (42 lb-ft). Check the gear selection.

GS4400,121 -19-01FEB97

GS4400,122 -19-01FEB97

GS4400,123 -19-01FEB97


PN=67

51. Fit the front drive shaft bearing (after packing with

Lithium based, No. 2 consistency grease) and secure

with snap ring.

52. Fit a new seal. Pack space between the lips of the

seal with grease.

53. Locate the 4 WD clutch. Take care not to damage

the shaft piston ring seals.

54. Install the front drive coupling onto the clutch shaft,

positioning it to give best access for staking tool. Then fit

the washer and a new retaining nut. Tighten to 400 N´m

(300 lb-ft) using a suitable tool to restrain the coupling.

Stake the nut into the groove in the shaft.

GS4400,124 -19-01FEB97

GS4400,125 -19-01FEB97

GS4400,126 -19-01FEB97

GS4400,127 -19-01FEB97


PN=68

55. Fit the 4 WD housing, using a new gasket. Apply

Loctite 242 to the bolt threads. Note that there are four

bolts on the rear face of the flange (not shown). Tighten


56. Renew the 4 WD clutch valve seals and back-up

ring.

57. Screw the 4 WD clutch valve into place.

58. Place the 4 WD valve solenoid into position and

secure with its retaining nut, seal and washer.

GS4400,128 -19-01FEB97

GS4400,129 -19-01FEB97

GS4400,130 -19-01FEB97

GS4400,131 -19-01FEB97


PN=69

59. Connect the 4 WD clutch hydraulic pipe (C) and

non-return valve (D).

60. Fit the suction strainer (B), using a new gasket.

Apply Loctite 242 to the securing bolts before fitting.

Tighten to 10 N´m (7 lb-ft). Fit the magnetic drain plug

(A), using a new bonded washer.

GS4400,132 -19-01FEB97

GS4400,133 -19-01FEB97


PN=70

GEARBOX

Before carrying out the checks listed, the machine

should, if possible, be operated to determine the fault

area(s), and to bring the systems to their normal working

temperatures. Ensure that the correct quantity and grade

of oil is used and that there are no obvious leaks.

A If the transmission is noisy, start check 1.

B If the transmission is overheating , start at check 4.

C If the transmission will not pull, start at check 12.

D If there is no drive in one or both directions, start at check 17.

E If the transmission is jumping out of gear, start at check 29.

F If the transmission is sticking in gear, start at check 39.

G If ratios are crash changing, start at check 41.

CHECK ACTION

1 Is there a noise when selecting direction ? Yes: Check 3

No: Check 2

2 Is there noise when running with direction Yes: Check 9

selector in neutral and ratio selector in 1st ? No: Check 19

3 Is there air in the hydraulic system ? Yes: Continue running to expel air.

No: Check 4

4 Is the fluid level correct ? Yes: Check 5

No: Check level only when machine is cold and

top-up as required.

5 Are the oil passages restricted ? Yes: Clear the restriction.

No: Check 6

6 Is the suction strainer restricted ? Yes: Remove and clean the strainer.

No: Check 7

7 Is pump pressure as specified ? Yes: Check 9

No: Check if clutch pressure maintenance valve is

free to operate.

8 When flow testing pump, is output low ? Yes: Renew pump.

No: Check converter sprag clutch for wear or slip

9 Does the noise continue when direction selector Yes: Check 10

is in forward or reverse ? No: Check 11

10 Is transmission misaligned ? Yes: Renew mountings and check position.

No: Check converter out pressure and flow.

11 Are the pump bushings worn? Yes: Renew

No: Check converter for wear or cooler for

restriction to flow.

GS4400,134 -19-01FEB97


PN=71

CHECK ACTION

12 Is transmission not pulling in one direction Yes: Check 16

only ? No: Check 13

13 Is the transmission not pulling in both Yes: Stall test machine, Check 14.

forward and reverse ? No: Check 16

14 Is converter in pressure as specified ? Yes: Check 15

No: Inspect converter relief valve for damage.

Check cooler bypass valve pressure settings.

15 Is pump being driven by converter ? Yes: Check pump pressure.

No: Renew damaged parts.

16 Are clutch sealing rings damaged ? Yes: Tap pressure gauge into clutch feed lines

to monitor pressure.

No: Check clutch plates for damage.

17 Is there drive in one direction only ? Yes: Check 19

No: Check 18

18 Is the start switch in the run position and Yes: Check 19

supplying current to the neutral start relay ? No: Rectify.

19 Is the fault only when the transmission is hot ? Yes: Disassemble solenoid and check components.

No: Check microswitches, relay and wiring harness.

20 Is the noise a growl, hum or grinding ? Yes: Check gears for damage or wear.

No: Check 21

21 Is the noise a hiss, thump or bumping ? Yes: Check bearings for damage or wear.

No: Check 22

22 Is the noise a squeal ? Yes: Check free running gears for seizure.

No: Check 23

23 Is the noise present when in neutral or when Neutral: Check 24

in gear ? In gear: Check 27

24 Is the countershaft or its bearings worn Yes: Renew damaged parts.

or damaged ? No: Check 25

25 Is there excessive backlash in the gears ? Yes: Adjust by checking shaft end play.

No: Check 26

26 Is the mainshaft pilot bearing worn ? Yes: Renew.

No: Check gear teeth for scuffing.

27 Is the mainshaft rear bearing worn ? Yes: Renew.

No: Check 28

28 Are the sliding gear teeth worn or damaged ? Yes: Renew gears.

No: Check 29

GS4400,370 -19-01FEB97


PN=72

CHECK ACTION

29 Are the selector forks loose ? Yes: Tighten screws.

No: Check 30

30 Are the selector fork pads or grooves in gears Yes: Renew worn parts.

worn ? No: Check 31

31 Are the dog gear teeth worn ? Yes: Renew.

No: Check 32

32 Are the selector rod detent springs broken ? Yes: Renew.

No: Check 33

33 Are the selector rods worn or damaged ? Yes: Renew.

No: Check 34

34 Are the selector forkpads out of position ? Yes: Reposition or renew (check interlock).

No: Check 35

35 Is there excessive end play in gears or shafts? Yes: Adjust.

No: Check thrust washers and mating faces.

36 Is the synchroniser bronze worn ? Yes: Renew synchro pack.

No: Check 37

37 Are steel chips embedded in the bronze ? Yes: Continue using, chips will either embed

below bronze or be rejected.

No: Check 38

38 Are the synchroniser components damaged ? Yes: Renew.

No: Check free running gears for seizure or

damage.

39 Are the sliding gears tight on the splines ? Yes: Free or renew.

No: Check 40

40 Are chips wedged between splines of shaft or Yes: Renew chips.

gear ? No: Ensure that clutch is disengaged when dump

pedal is pressed.

41 Are steel chips embedded in the bronze ? Yes: Continue using, chips will either embed

below bronze or be rejected.

No: Check 42

42 Are the synchroniser spring pins damaged ? Yes: Renew synchro.

No: Check 43

43 In the synchroniser bronze worn ? Yes: Renew synchro.

No: Check blocker pins.

GS4400,371 -19-01FEB97


PN=73

DISASSEMBLY AND ASSEMBLY

The numerical sequence shown on the illustration is

intended as a guide to disassembly.

For clarity, only one solenoid has been numbered in the

disassembly sequence.

When Disassembling

Unscrew the knurled nut (2) and remove O-ring (3),

withdraw the solenoid (4) and O-ring (5).

Hold the solenoid valve body (6) in a vice, using the

spanner flats (A), remove spindle (7) and O-ring (8).

Pull out actuating pin (9), spring (10), spring retainer (11)

and spool (12).

Disassemble the opposite solenoid in the same

sequence as described above.

Inspect the spool and spool bore for signs of wear,

nicks, scratches etc..

When Assembling

Renew all O-rings.

Lightly lubricate all parts with clean transmission oil

before assembling.

Check that the leads are secure and that the connectors

are intact.

AÐSpanner flats

1ÐO-rings

2ÐKnurled nut

3ÐO-ring

4ÐSolenoid

5ÐO-ring

6ÐSolenoid valve body

7ÐSpindle

8ÐO-ring

9ÐActuating pin

10ÐSpring

11ÐSpring retainer

12ÐSpool

GS4400,135 -19-01FEB97

Group 20Disassembly and Assembly of the Reverser Unit


PN=74

DISASSEMBLY

1. Carefully remove piston ring seals.

2. Loosen the clutch end bearing by tapping the

assembly on a piece of wood as shown. Remove the

bearing using pullers.

3. Remove the bearing, thrust washer and plastic type

washer.

4. Withdraw the gear and splined hub assembly with the

needle roller bearing.

5. Remove plastic type washer and thrust washer.

6. Remove the clutch friction/counter plates retaining

snap ring.

7. Remove pressure (end) plate.

GS4400,136 -19-01FEB97

GS4400,137 -19-01FEB97

GS4400,138 -19-01FEB97

GS4400,139 -19-01FEB97


PN=75

8. Remove the clutch friction/counter plates. Keep them

together in sets, Do not mix the plates with those from

other clutches.

9. Remove pressure (end) plate.

10. Remove disk spring assembly.

11. Position clutch assembly in press to compress piston

spring, then remove snap ring.

12. Lift off spring retaining plate.

13. Remove spring.

14. Knock the clutch shaft on a piece of aluminium (or

wood) to remove the piston.

15. Remove and discard piston and shaft O-rings. Make

sure the piston liner is secure. The liner must be a tight

fit on the piston.

16. Repeat steps (2) to (15) to disassemble the opposite

clutch.

GS4400,140 -19-01FEB97

GS4400,141 -19-01FEB97

GS4400,142 -19-01FEB97

GS4400,143 -19-01FEB97


PN=76

ASSEMBLY

1. Fit new O-rings onto the piston and shaft, lubricate

with oil then press piston fully into bore of clutch

housing.

2. Install the piston spring, make sure the spring seats in

the piston.

3. Fit the spring retaining plate.

4. Compress spring and secure with snap ring.

5. Fit the disk spring assembly. Fit the assembly so that

the outer diameter curves away from the clutch piston.

6. Fit pressure (end) plate. Make sure that the prongs on

the pressure plate Do not locate in the large grooves in

the hub (the ones with drilled holes).

7. Firstly, fit one friction plate followed by one steel

counter plate.

8. Continue fitting alternate friction and plain steel plates,

finishing with a friction plate.

GS4400,144 -19-01FEB97

GS4400,145 -19-01FEB97

GS4400,146 -19-01FEB97


PN=77

9. Fit the pressure (end) plate. Make sure that the

prongs on the pressure plate Do not locate in the large

grooves in the hub (the ones with drilled holes).

10. Fit the clutch friction/counter plates retaining snap

ring.

11. Using a dial indicator as shown, measure the end

play of the pressure (end) plate, which should be 3.2 to

4.4 mm (0.126 to 0.173 in.). If necessary, fit shim

between the retaining snap ring and pressure (end) plate

to correct end play inaccuracies.

12. Fit thrust washer and plastic type washer.

GS4400,147 -19-01FEB97

GS4400,148 -19-01FEB97

GS4400,149 -19-01FEB97


PN=78

13. Fit gear and splined hub assembly.

14. Fit needle roller bearing.

15. Fit plastic type washer and thrust washer.

16. Lubricate the clutch end bearing with grease and

press the bearing onto shaft.

17. Fit piston ring seals.

18. Repeat steps 1 to 16 for the opposite clutch. Make

sure that the opposite clutch end taper roller bearing is

packed with grease.

GS4400,150 -19-01FEB97

GS4400,151 -19-01FEB97


PN=79

GS4400,152 -19-01FEB97

Group 25Disassembly and Assembly of the Hydraulic 2/4 Wheel Drive Unit


PN=80

DISASSEMBLY

1. Remove the 2/4 WD unit from the transmission -

loosen the output yoke retaining nut before removal.

2. Remove bearing (1), only if to be renewed.

3. Remove seal ring (2).

4. Pull off the 4 WD output gear (5), together with its

bearing (3), needle roller bearing (6) and thrust washer

(4).

5. Using a suitable press, compress disk springs (8A),

(8B) and remove the snap ring (7).

N CAUTION: There is approximately 26700 N

(6000 lb) clamping force acting on the springs.

6. Remove disk springs (8A), (8B), pressure plate (9),

shim (s) (10) (keep the shims separate from the counter

plates), and clutch pack friction plates and counter plates

(11).

7. Remove the clutch drum retaining snap ring (12) and

support washer (13).

8. Remove clutch drum (14) and actuating sleeve (15).

9. Remove disk spring (16).

10. Remove the piston (17) and its spring steel ring (18).

11. Remove and discard piston O-rings (19) and (20).

12. Remove the piston housing (21) only if necessary,

the housing is a press fit on shaft (22).

GS4400,153 -19-01FEB97


PN=81

ASSEMBLY

1. Grease the shaft (22) then fit the piston housing

(21) by pressing the shaft squarely into the housing

(make sure the housing is securely supported).

2. Fit new O-rings (19) and (20) to piston (17), locate

the piston into housing (21). Fit spring steel ring (18)

ensuring that it seats firmly in its groove.

3. Place the disk spring (16) into the housing (21).

4. Position the actuating sleeve (15) onto the disk

spring (16).

5. Install the clutch drum (14) in the housing. Fit

support washer (13) and drum securing snap ring

(12).

6. Build up the clutch pack (11), installing friction

plates and counter plates alternately, starting with a

counterplate and finishing with a friction plate.

7. Install shim (s) (10) and pressure plate (9).

8. Use the output gear (5) to align the clutch plate

splines. Ensure that all the plates are engaged with

the gear shaft splines. Rotate the output gear back

and forth to create maximum backlash then withdraw

the gear taking care not to disturb the pack.

9. Place the first two disk springs (8B) with their

convex sides uppermost, onto the clutch pack. (There

are four disk springs, which are identical). Place the

other two disk springs (8A), with their convex sides

down, onto the first two - refer to inset (A).

10. Using a suitable press, compress the disk springs

(8A) and (8B), fit snap ring (7).

11. Use levers to remove free play, as shown at (B).

Measure the gap between pressure plate (9) and

actuating sleeve (15). The gap should be 0.75 - 1.5

mm; 0.030 - 0.059 in. If necessary fit new shim (10)

to achieve the correct gap. (Shim (10) can be a

combination of a single counter plate, shim (thinner

than the counter plate) or both counter plate and

shim). Check that the clutch pack splines are still

aligned - see step 8.

12. Install the 4 WD output gear (5) and its needle

roller bearings (6).

13. Install thrust washer (4) and bearing (3).

14. Fit sealing ring (2) and bearing (1).

15. Fit the 2/4 WD unit to the transmission using a

new gasket. Apply Loctite 242 to the mounting bolts,

tighten the bolts to 56 N´m; 42 lb-ft.

16. Fit the output yoke (E), retaining nut (F) and

washer (G). Tighten the nut to 400 N´m (295 lb-ft).

Check shaft end play which should not exceed 0.03

mm; 0.001 in.

17. If the end play is incorrect, remove the output

yoke (E) and bearing retaining snap ring (H).

18. Add or subtract shims (J) to obtain correct

settings. Shims should be fitted between bearing

outer race (K) and spacer (L). Replace the snap ring

and yoke and re-check the shaft end play.

19. When the shaft end play is correct, remove the

yoke and fit a new oil seal (M).

20. Refit the output yoke (E) and tighten the new

retaining nut (F) to 400 N´m (295 lb-ft). Stake the nut

to the shaft using a square ended staking tool, as

shown at (N).

21. Refit the hydraulic pipework and electrical

connections.

GS4400,154 -19-01FEB97


PN=82

TRANSMISSION TESTING

Ensure that the engine and transmission are at normal

working temperature. Run the engine at maximum speed

and check the No load speed (2410 rpm ). If the engine

does not reach the maximum no load speed, then check

the engine condition, i.e fuel filters, throttle cable

adjustment, air cleaner condition, fuel injection equipment

etc. Apply the footbrakes firmly and select 3rd gear and

four wheel drive. Open the throttle fully and select

forward drive. Note the engine speed which is now also

the Torque Converter Stall Speed. Do not stall the

torque converter for more than 20 seconds or the

transmission oil will overheat. If the engine speeds are

higher than those stated, check the transmission for

clutch slippage or internal leakage. If the engine speeds

are below those stated, the fault is with the engine and

should be repaired accordingly.

GS4400,155 -19-01FEB97


PN=83

GS4400,156 -19-01FEB97


PN=84

PRESSURE AND FLOW TESTING

The following tests must only be carried out in order

and step by step.

Take care when disconnecting hydraulic hoses and

fittings as the oil will be hot.

1. Stop engine, disconnect filter flow/return hoses

from the converter valve block or transmission filter

and connect the flow meter assembly (D). Connect a

0-2000 kPa; 0-20 bar (0 - 290 psi) pressure gauge to

screwed connector (E).

2. Start the engine and run at 1000 rpm. The flow

meter will show pump flow. A low reading indicates a

worn pump or blocked suction strainer. The pressure

gauge will show the main line pressure. A low

reading can be caused by either a faulty pressure

maintenance valve or, if pump flow is low, a blocked

oil cooler.

3. Stop the engine, remove the flow test adapters

and refit the filter. Connect pressure gauge and flow

meter into converter out line as shown at (F). Run

engine at 1000 rpm with transmission in neutral and

note converter out pressure and oil cooler flow which

should be as specified. A high pressure together with

a low flow could be caused by a blocked oil cooler.

4. With the footbrake firmly applied, select forward

and check the flow reading which should not drop by

more than 4.5 l/min (1.2 gal/min). A low reading

indicates a high leakage rate in the forward clutch,

which could be caused by worn or broken piston

seals or shaft sealing rings. Select reverse and

repeat the test.

5. If the clutch leakage rates are high, the clutch

pressures may be tested by connecting the pressure

gauge into ports (G) and (H) and repeating test (4). A

low reading (see Specifications) would confirm a high

leakage rate in the particular clutch selected.

6. Stop the engine, connect the pressure gauge into

port (J) in the converter valve block, and fit a load

valve (L) into the converter out line (see NOTE).

Start the engine and run at 1000 rpm and slowly

screw down the load valve while observing the gauge

reading, which should rise to the setting of the

converter relief valve. Do not allow the pressure to

exceed 1030 kPa; 10.3 bar (150 psi) or damage to

the converter seals will occur. If the reading is higher

than specified, the relief valve must be faulty. A low

reading indicates a faulty relief valve, leaking

converter piston ring type seal or leaking pump seal.

7. Stop engine and connect pressure gauge and flow

meter in the return line from oil cooler to converter

valve block as shown at (K). Start the engine, and

with the transmission in neutral, check flow meter

rate, which will show the cooler flow rate. The

pressure gauge will show the lubrication pressure.

Low flow and pressure readings could indicate a

blocked oil cooler.

GS4400,157 -19-01FEB97


PN=85

PRESSURE TESTING THE 2/4 WD CLUTCH

1. Assemble the 2/4 wheel drive clutch, as described

in Assembly.

2. Check the clutch pack end play and adjust as

required (see Assembly, step 11).

3. Insert the adapter (A) (see NOTE) into the oil

gallery in the end of the 2/4 wheel drive clutch shaft

as shown (via sleeve). Hold the adapter in position

with clamp (B).

4. Use a hand pump to pressurise the clutch

assembly until gear, item (5) can be turned by hand.

5. If the pressure gauge reading is between 860 -

930 kPa (8.6 - 9.3 bar; 124.7 to 134.8 psi), then the

clutch is operating correctly and can be fitted in the

transmission .

6. If, however, the pressure gauge reading is above

930 kPa (9.3 bar; 134.8 psi), then re-check the clutch

for assembly defects, especially the clutch pack end

play (incorrect shim thickness). Re-test after checking

for (and rectifying) assembly defects.

GS4400,158 -19-01FEB97


PN=86

2/4 WHEEL DRIVE CLUTCH (SPRINGON/PRESSURE OFF)

2WD cannot be engaged

In normal operation the 2/4 wheel drive clutch is spring loaded and therefore

engaged to give 4 wheel drive. Before starting the more detailed fault finding

procedures - eliminate the obvious:

1 Check that the transmission oil level is correct.

2 Check that the fuse for the 2/4 WD circuit is intact.

3 Check that the 4-wheel drive external pipework is not damaged.

4 Check that all the electrical connections are clean and secure.

5 Check that the mainline pressure is correct (see low Mainline Pressure).

6 Check that the pump flow rate is correct.

If the fault is not rectified after eliminating the obvious, check the following:

Possible cause Remedy

7 Low mainline pressure _7 Identify if the fault is related to the 2/4 WD

disconnect:

Minimum pressure required to disengage 7.1 Disconnect the external pipework to the 2/4 WD

2/4 WD clutch is 860 kPa; 8.6 bar clutch. Cap and plug open orifices.

(124.7 psi)

7.2 Check the mainline pressure - if the pressure is

correct, the fault must be within the 2/4 WD (see

step 8). If the reading is still low check the

transmission in the normal manner.

8 Low mainline pressure _8 Rectify fault:

(due to 2/4 WD clutch)

8.1 2/4 WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve, renew

valve if required.

8.2 2/4 WD solenoid permanently 8.2 Check the 2/4 WD relay and select switch. Replace

energised. as necessary.

8.3 2/4 WD solenoid spool O-rings failed. 8.3 Renew O-ring.

8.4 Clutch shaft sealing rings leaking. 8.4 Renew clutch shaft sealing rings.

8.5 Excessive clutch shaft end play. 8.5 Rectify fault, renew parts as required, reset end

play (should not exceed 0.03 mm; 0.001 in)

8.6 Wrong type clutch piston fitted. 8.6 Fit correct type clutch piston (i.e., without

bleed hole).

8.7 Clutch piston O-ring failed. 8.7 Replace clutch piston O-ring.

GS4400,159 -19-01FEB97


PN=87

Possible cause Remedy

9 Defective 2/4 WD clutch: _9 Rectify fault:

9.1 Worn pressure plate. 9.1 Inspect pressure plate, renew as required.

9.2 Worn actuating sleeve. 9.2Measure length of actuating sleeve and renew as

required, sleeve length should be:

Old type clutch = 48.5 mm; 1.909 in

New type clutch = 60.7 mm; 2.390 in

9.3 Incorrect clutch pack end play. 9.3Measure clutch pack end play (should be 0.75 -

1.5 mm; 0.03 - 0.059 in). Correct as required.

10 4 WD cannot be engaged: _10 Rectify fault:

10.1 No pressure required to engage 10.1 Faulty springs, replace springs as required.

4 WD (spring loaded).

10.2 Check that front axle drive train 10.2 Refit, replace shaft as required.

is intact (i.e. drive shaft and

axle connected).

10.3 Check that solenoid spool is not 10.3 Inspect solenoid valve, clean, replace as

sticking in the 2 WD position. required.

10.4 Check the 2/4 WD switch and relays. 10.4 Replace as required.

GS4400,160 -19-01FEB97


PN=88

FAULT FINDING IN THE DRIVE TRAIN

_

ITEM FAULT TEST REPAIR

1 No drive Is there 12 V at the forward/reverse

solenoid when the forward/reverse

lever is in either forward or

reverse? Yes: See item 2

No: See item 8. Is the handbrake applied. The

handbrake warning light switch is stuck on.

2 No drive - electrical Check the transmission pressure

power at the forward/ gauge in the instrument panel or

reverse solenoid pressure test transmission at the

pressure test port in the front of

the transmission. Is the pressure

correct (9.9-11.6 bar;990 - 1160 kPa; Yes: See item 3

143.5 - 168.2 psi)? No: Zero pressure - see item 6

Low pressure - see item 7

3 No drive - electrical Fit the pressure test gauge into the

power at the forward/ clutch test port at the front of the

reverse solenoid and transmission and select forward or

correct pressure at the reverse. Is the pressure correct

pressure test port (9.9-11.6 bar;990 - 1160 kPa; Yes: When in gear does the drive shaft rotate

143.5 - 168.2 psi)? (remote transmission only). If yes, check

torque converter pressure. If no, has the

transmission drive shaft become disconnected. Has

the axle drive shaft become disconnected, if so

repair and replace. Possible failure in a

drive shaft internally of transmission on the

gearbox side. Clutch shaft sheared (the

welding of the housing to the shaft).

No: If no or low pressure in either test port, check

aluminium block supplying oil to the solenoids:

Possible oil way blockage, faulty solenoids,

clutch shaft piston seals.

4 No drive in one Is there 12 V at the directional

direction only solenoid which is not providing

drive? Yes: See item 5

No: Check 12 V supply coming out of the forward/

reverser lever, if zero replace lever. Faulty

forward/reverse relay.

Faulty connection between the forward/reverse

lever and solenoids.

5 No drive in one Pressure test the directional Yes: Clutch plates worn and slipping.

direction only. clutch at the test port. Is the No: Faulty electrical solenoid.

12 V at the directional pressure correct (9.9 - 11.6 bar; Faulty clutch piston seal.

solenoid which is not 990 - 1160 kPa;143.5 - 168.2 psi)? Faulty clutch shaft sealing rings.

providing drive. Clutch drive plates faulty. O-rings between

the two transmission casings faulty.

Clutch plate retaining clip slipped out of

the clutch pack.

GS4400,506 -19-01FEB97


PN=89

FAULT FINDING IN THE DRIVE TRAIN(CONTINUED)

_


6 No drive - electrical Fit a flow meter in the line where the

power at the forward/ filter is.

reverse solenoid, but

zero pressure at the Is the flow correct (22 - 29 ltr/min;

test port. 5.81 - 7.66 gal/min at 1000 rpm)?

Yes: Check pressure maintenance valve

in the torque converter housing.

Check the converter pressure

safety relief valve in the

torque converter housing.

No: Check the transmission oil

level. Check the suction line

filter in the bottom of the

transmission casing. Check

suction line hoses and

connections for air being drawn

in. Check the torque converter

drive lugs. Faulty transmission

oil pump.

7 No drive - electrical Fit a flow meter in the line where the

power at the forward/ filter is.

reverse solenoid but

low pressure at the Is the flow correct (22 - 29 ltr/min;

test port. 5.81 - 7.66 gal/min at 1000 rpm)? Yes: Check pressure maintenance valve

in the torque converter housing.

Check the converter pressure

safety relief valve in the

torque converter housing.

No: Low transmission oil level,

check suction line for air being

drawn in, possibly through the

suction line filter gasket.

Check suction filter for

blockage.

Worn or faulty transmission

pump.

8 No drive - no Is there 12 V entering the forward/

electrical power at the reverse lever ? Yes: Fault in the forward/reverse

forward/reverse lever, if no electrical power

solenoid. coming out of the lever when it

is in either forward or reverse.

Fault in the wiring connections

between the forward/reverse

lever and the directional

solenoids.

No: See item 9.

GS4400,300 -19-01FEB97


PN=90

FAULT FINDING IN THE DRIVE TRAIN(CONTINUED)

_


9 No drive - no Is there power entering the gear lever

electrical power switch (the switch in top of the gear

entering the forward/ lever) ? Yes: Check that there is power

reverse lever. through the switch without it

being depressed, if not replace

the switch, if O.K. see item 10.

No: Check the fuse that operates the

transmission disconnect system.

Faulty wiring connection between

ignition load relay and gear

lever switch.

10 No drive - no When depressing the gear lever switch

electrical power is it possible to hear a relay

entering the forward/ operating ? Yes: Fault in the wiring between the

reverse lever - transmission dump relay (the one

electrical power that clicks when depressing the

through the gear lever gear lever switch) and the

switch foreward/reverse lever.

No: Faulty relay.

Faulty ground from relay

(terminal 85) or faulty seat pad

switch, faulty feed from gear

switch to relay.

11 No drive - no Is there electrical power entering the

electrical power brake dump relay ? Yes: See item 12.

entering the forward/ No: Fuse failure.

reverse lever - Wiring fault between battery

electrical power feed and brake dump relay.

through the gear lever

switch.

12 No drive - no Is electrical power coming out of

electrical power terminal 87a on the brake dump relay ?

entering the forward/ Yes: Fault in wiring harness between

reverse lever - the brake dump relay and the

electrical power transmission dump relay.

through the gear lever No: Relay being energised by a power

switch and also feed in terminal 86 of the brake

entering the brake dump dump relay:

relay. This power feed comes from the

brake dump override switch on

the dash being either turned on

or shorting out, plus the brake

dump switch being operated by

the brake pedal being depressed

or it being shorted out.

GS4400,507 -19-01FEB97


PN=91

Section 60

REMOVAL AND REPAIR OF AXLES ANDBRAKES

Contents

Page

Group 05ÐFront Axle Removal

Front axle removal . . . . . . . . . . . . . . . . 60-05-1

Group 10ÐRear Axle Removal

Special tools (self-manufactured) . . . . . . 60-10-1

Rear axle removal . . . . . . . . . . . . . . . . 60-10-3

Torque settings . . . . . . . . . . . . . . . . . . 60-10-22

Group 15ÐHydraulic Steering

Steering system layout . . . . . . . . . . . . . 60-15-1

Hydraulic steering . . . . . . . . . . . . . . . . 60-15-2

Two wheel steer to the right . . . . . . . . . 60-15-3

Four wheel steer to the right . . . . . . . . . 60-15-4

Four wheel steer to the left . . . . . . . . . . 60-15-5

Crab steer to the right . . . . . . . . . . . . . 60-15-6

Testing of the steering system . . . . . . . . 60-15-7

Steering orbitrol removal . . . . . . . . . . . . 60-15-8

Orbitrol repair . . . . . . . . . . . . . . . . . . . 60-15-8

Assembly of the pressure relief valve . . . 60-15-20

Assembly of the dual line shock valves . . 60-15-21

Pressure setting procedure for dual line

shock valves . . . . . . . . . . . . . . . . . . 60-15-22

Group 20ÐCab - Steering Column

Cab - steering column . . . . . . . . . . . . . 60-20-1

Group 25ÐAxles and Brakes - Brake Circuit

Axles and brakes - brake circuit . . . . . . . 60-25-1

Axles and brakes - brake bleeding . . . . . 60-25-2

Group 30ÐBrakes

Removal and replacement of the parking

brake caliper . . . . . . . . . . . . . . . . . . 60-30-1

Disassembly and assembly of the parking

brake caliper . . . . . . . . . . . . . . . . . . 60-30-2

Setting procedure parking brake caliper . . 60-30-5


PN=238


PN=239

FRONT AXLE REMOVAL

The axles should only be removed once all tests

have been completed to ensure removal of the axle

is absolutely necessary. To remove the front axle,

lower the boom and place a suitable stand

underneath the chassis as shown in figure 1. Release

all the pressure in the braking system by operating

the brake pedal at least thirty times, undo the brake

hose connected to the axle and place a container

underneath the disconnected hose to catch any

residual oil.

Remove the two steering hoses from the center

steering cylinder, catch any residual oil in the

container. Do not remove the wheels as it will be

easier to remove the axle with the wheels still

attached to the axle. Remove the propellor shaft

retaining bolts, lift off the propellor shaft from the axle

drive shaft and retain it away from the area of work.

Release the axle retaining bolts, once these have

been removed the axle is free to wheel out. Wheel

out the axle and place it on a suitable work surface

and undo and remove the wheels.

GS4400,161 -19-01FEB97

Group 05Front Axle Removal


PN=92


PN=93

SPECIAL TOOL (SELF-MANUFACTURED)

Tool for bevel distance measurment on differential

GS4400,O -19-01JUL97

Group 10Rear Axle Removal


PN=94

SPECIAL TOOL (SELF-MANUFACTURED)

Tool for loosening pinion shaft nut on differential

GS4400,P -19-01JUL97


PN=95

REAR AXLE REMOVAL

Place a suitable stand underneath the rear of the

chassis as shown in figure 2, remove the rear wheels

from the axle. Release all pressure within the braking

system by operating the brake pedal at least thirty times

and remove the brake hose.

Disconnect the overload transducer from the main wiring

harness and remove the propellor shaft from the axle

drive flange. Place suitable lifting equipment underneath

the center of the axle and remove the retaining bolts at

the front (fig 3) and rear of the axle. The axle can now

be removed.

Drain the oil from the reduction hub. Lock two wheel

nuts onto the collared studs and remove (fig. 4), undo

the two hex. socket bolts and pry off the outer cover

complete with the planetary gears.

Remove the planetary gears by knocking out the

retaining pins from the center outwards (fig. 5).

GS4400,162 -19-01FEB97

GS4400,163 -19-01FEB97

GS4400,164 -19-01FEB97


PN=96

Gently knock out the planetary pin from the inner side of

the reduction hub and carefully slide out the gear and

shims (fig. 6).

Remove the inner spacer and carefully remove the

needle roller bearings (fig. 7).

Remove the snap ring on the hub drive gear (fig. 8) and

remove the drive gear.

Remove the outer retaining snap ring (fig. 9).

GS4400,165 -19-01FEB97

GS4400,166 -19-01FEB97

GS4400,167 -19-01FEB97

GS4400,168 -19-01FEB97


PN=97

Lift out both the outer retaining plate and the brake disk

(fig. 10).

Undo the ring of the retaining bolts at the center of the

hub (fig. 11).

Using the four threaded holes in the hub, screw in four

M10 threaded studs (fig. 12). Screw the studs in equally

so that the sun gear is pulled off complete with the

brake piston.

Place the ring gear and piston face down on a work

surface and remove the brake piston retaining bolts (fig

13). The brake actuating plate will fall out from the ring

gear. Remove the outer snap ring from the rear of the

piston.

GS4400,169 -19-01FEB97

GS4400,170 -19-01FEB97

GS4400,171 -19-01FEB97

GS4400,172 -19-01FEB97


PN=98

Turn the hub ring over and remove the inner retaining

snap ring from next to the brake piston (fig. 14).

Remove the brake bleed nipple and also the brake drain

plug from the brake piston housing and lift off the sun

gear (fig. 15) leaving the brake piston in housing.

Screw two M4 screws into the brake piston to pull out

the brake piston (fig. 16).

Remove the wheel hub outer bearing (fig. 17) and lift off

the hub.

GS4400,173 -19-01FEB97

GS4400,174 -19-01FEB97

GS4400,175 -19-01FEB97

GS4400,176 -19-01FEB97


PN=99

Turn the hub onto a wooden sheet so that the wheel

studs are facing down, pry out the seal (fig. 18). Turn

the hub over and drive out the inner bearing race.

Undo the steering ball joint retaining nut and using a ball

joint splitter drift apart the ball joint, lift out the ball joint

from the swivel housing. Remove the three lower king

pin retaining bolts and remove the king pin, repeat for

the upper king pin (fig. 19).

Remove the upper (fig 20) and lower belleville washers.

Lift off the swivel housing.

Remove the king pin bushings from the axle housing (fig

21).

GS4400,177 -19-01FEB97

GS4400,178 -19-01FEB97

GS4400,179 -19-01FEB97

GS4400,180 -19-01FEB97


PN=100

Place the swivel housing face down on a suitable work

surface and remove the inner seal (fig 22).

Lift out the drive shaft (fig 23).

Remove the inner axle oil seal (fig 24).

Unscrew the tie rod end ball joint from the swivel hub

and lift it out (fig. 25), if it has not already been removed

previously.

GS4400,181 -19-01FEB97

GS4400,182 -19-01FEB97

GS4400,183 -19-01FEB97

GS4400,184 -19-01FEB97


PN=101

Unscrew the swivel joint from the same end of the

steering cylinder (fig. 26) as the end screw held on by

the four retaining screws.

Remove the four bolts retaining the end cap onto the

steering cylinder (fig. 27).

Extract the end cap from the steering cylinder (fig. 28).

Remove the end cap and pry out the seals (fig. 29)

housed in the end cap and discard them.

GS4400,185 -19-01FEB97

GS4400,186 -19-01FEB97

GS4400,187 -19-01FEB97

GS4400,188 -19-01FEB97


PN=102

Remove the steering cylinder and rod from the axle by

sliding out the cylinder from the retaining eyes. Slide out

the steering cylinder rod (fig. 30) taking care to note

which side the spacer is fitted. Remove the seals and

discard. To reassemble the steering cylinder reverse the

disassembly procedure and fit new seals.

Unscrew the differential housing retaining bolts (fig. 31),

remove the housing and place it on a suitable work

surface.

Unscrew the differential nut locking clips (fig. 32).

Unscrew the differential nut retaining bolts and lift off the

half caps (fig. 33). Lift out the differential unit.

GS4400,189 -19-01FEB97

GS4400,190 -19-01FEB97

GS4400,191 -19-01FEB97

GS4400,192 -19-01FEB97


PN=103

Unscrew the crown wheel retaining bolts (fig. 34).

Lift the crown wheel away from the differential unit (fig.

35). Take care that the differential unit does not come

apart.

Mark the two halves of the differential prior to splitting to

ensure correct reassembly. Lift off one half of the

differential housing (fig. 36).

Lift off the differential lock pack (fig. 37).

GS4400,193 -19-01FEB97

GS4400,194 -19-01FEB97

GS4400,195 -19-01FEB97

GS4400,196 -19-01FEB97


PN=104

Lift off the sun gears (fig. 38). Take note of the position

of the thrust washers. Remove the cross shaft and the

planetary gears.

Inspect all parts prior to reassembly and replace any

faulty items. Replace the lower sun gear with the

differential lock pack, refit the cross shaft planetary gears

with the thrust washers (fig. 39).

Replace the upper differential lock pack (fig. 40).

Refit the upper differential housing, replace the crown

wheel. Fit new crown wheel retaining bolts (bolts should

be renewed once they have been removed). Use Loctite

270 and torque to 78 N´m; 57.5 lb-ft (fig. 41).

GS4400,197 -19-01FEB97

GS4400,198 -19-01FEB97

GS4400,199 -19-01FEB97

GS4400,200 -19-01FEB97


PN=105

Lock the pinion shaft and undo the pinion shaft retaining

nut using self-manufactured special tool (fig. 42).

Lift out the pinion shaft retaining nut (fig. 43) and using a

soft hammer knock out the pinion shaft.

Remove the pinion shaft bearings (fig. 44), from the

pinion and also the outer races from the differential

support housing.

The illustration (fig. 45) shows the pinion shaft assembly.

Note the position of the washers and shims. A new

collapsible washer must be fitted every time the pinion

shaft is disassembled.

GS4400,201 -19-01FEB97

GS4400,202 -19-01FEB97

GS4400,203 -19-01FEB97

GS4400,204 -19-01FEB97


PN=106

1ÐN=Position of gear protrusion 2ÐPosition of spiral gear/pinion

dimension mating number

To set the depth of mesh of the pinion shaft (using

self-manufactured special tool) install the pinion shaft

bearings into the differential support housing and

clamp using the tool. Lightly clamp the bearings so

that the cones can be turned by hand. Do not

overtighten. Install the differential half collars and

tighten using the clamp bolts. Using an internal

micrometer measure the side bore (D) see fig. 46.

Locate the circular bar (2) across the differential

bearing bores in the support casing and using a

depth gauge measure the dimension Y. Determine

the shim thickness by using the following calculation

(fig. 46). N (etched on the face of the pinion shaft) -

B (B = Y -25 (shaft diameter) + 1/2 D). Select the

calculated shim thickness from the range available

and install on the pinion shaft.

Fit the bearings, a new collapsible washer and the shims

as determined in the previous instruction to the pinion

shaft. Tighten the pinion shaft nut until the bearing end

play has been removed. Using a rolling torque meter,

check the rolling torque of the bearings. Tighten the

pinion shaft nut until a rolling torque (fig. 47) of 92 - 138

N´m (67.8 - 101.7 lb-ft) has been obtained.

GS4400,205 -19-01FEB97

GS4400,206 -19-01FEB97


PN=107

Refit the differential assembly into the differential support

housing, fit the outer bearing races and the bearing caps

(fig. 48). Tighten the bearing caps so that they can be

adjusted easily, gently tap each bearing housing with a

soft mallet to ensure that the bearings are seated

properly. Screw in the bearing cap on the spiral gear

side of the differential in a clockwise direction until all

movement in the bearing has been removed, i.e. the

bearing cap becomes tight. Repeat this for the other

bearing cap.

Place a dial indicator against the teeth of the crown

wheel and measure the amount of backlash (0.19 - 0.24

mm; 0.007 - 0.009 in.). Measure the backlash at least

twice around the crown wheel and fit the dial indicator

onto the tooth that shows the least amount of backlash.

To adjust the backlash, turn the ring nuts on the sides of

the differential an equal amount. This will move the

crown wheel either closer to or further away from the

pinion gear. Repeat this until the correct setting has

been reached.

To set the differential bearing pre-load, tighten the

bearing ring nuts retaining the differential equally,

ensuring that the backlash is not adjusted and using a

rolling torque meter measure the pre-load of the crown

wheel and pinion, so that the total pre-load is: T where

T=(P + 25 N´m) to (P + 37.6 N´m) where P is the

preload of the pinion shaft prior to fitting the differential

(see fig. 47).

Torque the differential cap nuts to 266 N´m (196 lb-ft).

Install the adjuster ring lock tabs (fig. 51) and torque to

13 N´m (9.6 lb-ft). Re-check the backlash.

GS4400,207 -19-01FEB97

GS4400,208 -19-01FEB97

GS4400,209 -19-01FEB97

GS4400,210 -19-01FEB97


PN=108

Install a new pinion shaft oil seal assembly (fig. 52).

Install the differential support housing into the axle (fig.

53) and torque the retaining nuts to 169 N´m; 124.5 lb-ft.

Install new inner axle oil seals, lightly lubricate the seal

with clean oil prior to refitting the drive shaft (fig. 54). Fit

the king pin bushings.

Install new oil seals in the swivel hub, lubricate the seal

with clean oil prior to refitting over the drive shaft. Fit the

belleville washers between the swivel housing and the

axle casing (fig. 55). Ensure that the belleville washers

are fitted with the dish up.

GS4400,211 -19-01FEB97

GS4400,212 -19-01FEB97

GS4400,213 -19-01FEB97

GS4400,214 -19-01FEB97


PN=109

Fit new piston ring seals, lubricate the seals with clean

hydraulic oil prior to refitting into the piston hub (fig. 56).

Place the sun gear over the piston hub (fig. 57) and fit

the outer retaining ring. Refit the brakes bleed nipple and

also the drain plug.

Place the brake actuation plate into the ring gear (fig.

58).

Refit the inner retaining ring.

Refit the actuating plate retaining bolts with a spacer on

every bolt and a spring on every other i.e. 6 spacers and

3 springs and tighten (fig. 59). Refit the outer snap ring.

GS4400,215 -19-01FEB97

GS4400,216 -19-01FEB97

GS4400,217 -19-01FEB97

GS4400,218 -19-01FEB97


PN=110

Fit a new brake oil feed O-ring to the rear of the piston

and retain with vasaline prior to refitting the sun gear

assembly into the reduction hub.

Refit the brake disk and the reaction plate (fig. 61). Refit

the retaining ring.

Slide the sun gear onto the drive shaft and fit the

retaining snap ring (fig. 62).

Replace the planetary gears into the reduction unit (fig.

63), retain the needle roller bearings in the gears by

using a light coating of vasaline, slide in the thrust

washers, fit a new seal to the center pin and slide into

place.

GS4400,219 -19-01FEB97

GS4400,220 -19-01FEB97

GS4400,221 -19-01FEB97

GS4400,222 -19-01FEB97


PN=111

Fit a new spiral pin to retain the center pin in place.

Clean the mating surfaces between the reduction hub

and the planetary carrier. Apply silicone sealant around

the mating surfaces. Screw in the two planetary carrier

retaining screws and torque to 80 N´m; 58.9 lb-ft. Refit

the two collared studs (fig. 64) and torque to 70 N´m;

51.6 lb-ft.

Fit new seals to the steering cylinder and piston head,

slide the cylinder rod into the cylinder (fig. 65) and fit the

spacer.

Fit new seals into the cylinder end cap (fig. 66).

Refit the steering cylinder and rod into the axle retaining

eyes. Fit the cylinder end cap to the steering cylinder,

refit the retaining bolts (fig. 67) and torque to 120 N´m;

88.4 lb-ft.

GS4400,223 -19-01FEB97

GS4400,224 -19-01FEB97

GS4400,225 -19-01FEB97

GS4400,226 -19-01FEB97


PN=112

Screw in the steering rod ball joint and torque to 300

N´m; 221 lb-ft, screw on the tie rod ball joint and fit into

the reduction hub (fig. 68).

Fit the tie rod ball joint retaining nut and torque to 220

N´m; 162 lb-ft.

DRIVE SHAFT REPAIR

Remove the reduction hub as explained earlier in this

chapter, lift out the drive shaft and remove the four cup

retaining snap rings (fig. 69).

Place the jaw of the drive shaft over a vice (fig. 70) and

using a soft hammer drive the swivel unit downwards

thus raising the cup out of the drive shaft jaw.

Clamp the cup in the vice and lift the swivel unit away

from the cup, repeat this procedure for the remaining

cup on the other cap and lift the cross away from the

drive shaft jaw (fig. 71). Repeat previous instruction so

that the cross is completely removed from the drive

shaft.

GS4400,227 -19-01FEB97

GS4400,228 -19-01FEB97

GS4400,229 -19-01FEB97

GS4400,230 -19-01FEB97


PN=113

Prior to fitting a new cross, apply grease to the cups to

prevent the needle rollers from falling out upon

replacement. Press one cup into the drive shaft hub until

it is flush with the outside edge. Fit the cross into the

cup, press the other cup into the drive shaft hub, swivel

the cross to ensure that the cross has entered the hub

correctly. Press the cup further into the hub (fig. 72) until

the snap ring groove is showing.

Repeat the procedure described above for the remaining

cups, once reassembled hold up and using a small

hammer gently hit the drive hub (fig. 73). This will

release any slight misalignment that may cause the

swivel to be tight.

GS4400,231 -19-01FEB97

GS4400,232 -19-01FEB97


PN=114

TORQUE SETTINGS

Thread Torque

Bevel Drive - Differential

Pinion shaft retaining nut M40 x 1.5 As pre-load

Bolts - Differential support to axle casing M12 x 1.75 169 N´m (124.5 lb-ft)

Bolts - Crown wheel bearing locking plate M6 13 N´m (9.6 lb-ft)

Bolts - Crown wheel to diffrential housing M10 x 1.5 78 N´m (57.5 lb-ft

(use Loctite 270)

Breather M10 x 1 10 N´m (7.5 lb-ft)

Nuts - Input flange. M10 x 1.25 56 N´m (40 lb-ft)

Plug - Oil drain and level M22 x 1.5 60 N´m (45 lb-ft)

Bolts - Crown wheel bearing half collar to M14 x 2

differential housing

King Pin - Steering Cylinder

Bolts - King pin to swivel housing M14 190 N´m (136 lb-ft)

Nuts - Steering stop lock nut M14 100 N´m (70 lb-ft)

Bolts - Steering cylinder to differential support M12 120 N´m (88.4 lb-ft)

Ball joint - to steering cylinder rod 300 N´m (221 lb-ft)

Nuts - Tie rod clamp lock nuts 250 N´m (186 lb-ft)

Nuts - Ball joint to swivel housing M20 x 1.5 220 N´m (162 lb-ft)

Final Drives

Bolts - Wheel hub bearing M14 220 N´m (162 lb-ft)

Stud - Planetary gear carrier (wheel stud) M18 x 2.5 70 N´m (51.6 lb-ft)

Screw - Planetary carrier to wheel hub M12 x 30 80 N´m (58.9 lb-ft)

Screw - Brake oil drain M10 8 to 12 N´m (6 - 8.5 lb-ft)

Wheel hub drain plug M30 80 N´m (58.9 lb-ft)

Brake bleed screw M10 8 to 12 N´m (6 -8.5 lb-ft)

Nuts - Wheel rim to final drive 300 N´m (221 lb-ft)

(re-tighten after 50 hours)

GS4400,233 -19-01FEB97


PN=115

GS4400,233A -19-01FEB97

Group 15Hydraulic Steering


PN=116

HYDRAULIC STEERING

The steering system has three different modes to allow

the machine to be more manouverable. The modes are:

1. Front wheel steer. This mode should always be used

for any roadwork carried out by the machine. In this

mode the mode valve receives no electrical current from

the switch in the cab. If an operator can only select front

wheel steer, then the fault may be one of no electrical

supply to the mode valve.

2. Four wheel steer. In this mode all four wheels steer at

once allowing a smaller turning circle and thus greater

manouverability. Electrical current is required by the

mode valve to allow it to divert the oil to the rear

steering cylinder. The wheels need to stay in line (front

to rear). Should they go out of alignment, turn the

steering wheel until the rear wheels are straight ahead.

Turn the steer mode switch to select front wheel steer,

align the front wheels and then reselect four wheel steer.

It is normal to have to do this three or four times a day

if the machine is being operated all day in four wheel

steer. Should the wheels become misaligned more

frequently, then the fault could be faulty steering

cylinders or excessive leakage past the mode valve. Test

the steering cylinders first (as explained on the following

pages). If they are not faulty, then change the mode

valve.

3. Crab steer. With this mode the wheels turn in the

same direction causing the machine to move

side/forwards like a crab. Electrical current is required by

the mode valve to divert oil to the steering cylinders. The

wheels should stay in alignment the same as in four

wheel steer.

GS4400,238 -19-01FEB97


PN=117

GS4400,234 -19-01FEB97


PN=118

GS4400,235 -19-01FEB97


PN=119

GS4400,236 -19-01FEB97


PN=120

GS4400,237 -19-01FEB97


PN=121

TESTING OF THE STEERING SYSTEM

To determine the fault within the steering system,

start the engine and very slowly turn the steering

wheel. If the steering wheel is heavy and difficult to

turn, then the problem is one of a lack of pressure, a

seized steering column or king pins. If the steering

wheel is free to turn, then turn the wheel a little faster

and a little faster until it is heavy to run. If this is the

scenario, then the problem is one of flow. Test the

priority valve and take appropriate action if the fault is

found within the priority valve. If the testing of the

priority valve shows that the fault is elsewhere, then

continue with the steering system testing.

Test 1: Turn off the engine, remove one of the hoses

that feed oil to the right hand side of the front

steering cylinder (fig 22), fit a pressure gauge into

that hose and plug the open port in the steering

cylinder. Run the machine and operate the steering to

the right so that the hose with the pressure gauge

fitted into it comes under pressure. Note the reading

on the pressure gauge. If the reading is the same as

that given at the pressure test port (175 bar; 17500

kPa; 2537.5 psi) on the steering orbitrol, then the

fault is not with the orbitrol valve.

Test 2: There is one hose that feeds pressure oil to

the front steering cylinder on right hand lock and one

that returns oil. When steering to the left, the feed

hose becomes the return hose in the other direction.

Turn the steering to full right hand lock. Remove the

return hoses from the steering cylinder (left hand side

of the front steering cylinder), try to turn the steering

further on full lock. Do not turn the steering to the

opposite lock. If oil flows out of the steering cylinder,

then there is an internal fault with the steering

cylinder. To test the rear steering cylinder, select four

wheel steer and turn to the opposite lock. Remove

the return hoses from the steering cylinder (right hand

side of the rear steering cylinder), try to turn the

steering further on full lock. Do not turn the steering

to the opposite lock.

To test this, misalign the wheels in four wheel steer

so that on right hand lock the rear wheels reach full

lock before the front. Remove the return hose from

the rear steering cylinder, turn the steering to right

hand lock and see if oil flows from the cylinder port.

If it does, then change the cylinder seals. Repeat the

test for left hand lock i.e. the front wheels reach full

lock before the rear wheels. Remove the steering

cylinders if required.

Test 3: The steering needs electrical power in four

wheel and crab steer; see electrical system for the

wiring diagrams.

Removal of the front steering cylinder

Turn the steering to full lock to enable access to the

steering joints. Remove the retaining nuts on the left

hand reduction hub. Repeat for the right hand side.

Remove the steering swivel joint from the right hand

side of the steering rod. Unscrew the four cylinder

retaining bolts. Remove the two hoses that feed and

return oil to the cylinder and plug them. Remove the

hydraulic adapters in the cylinder and remove the

cylinder to the left hand side.

Removal of the rear steering cylinder

Turn the steering to full lock to enable access to the

steering joints. Remove the retaining nuts on the right

hand reduction hub. Repeat for the left hand side.

Remove the steering swivel joint from the left hand

side of the steering rod. Unscrew the four cylinder

retaining bolts. Remove the two hoses that feed and

return oil to the cylinder and plug them. Remove the

hydraulic adapters in the cylinder and remove the

cylinder to the right hand side.

Steering Cylinder Repair

See section in the axle and brakes chapter for the

repair of the steering cylinders.

GS4400,239 -19-01FEB97


PN=122

STEERING ORBITROL REMOVAL

Place the machine on firm level ground. Apply the

handbrake and shut off the engine. Remove the lower

steering column cover plate (fig. 27). Undo the two hex.

socket set screws that retain the distribution block to the

steering orbitrol. Remove the steering column to cab

retaining bolts (4 used). Remove the two nuts at the

front right hand side of the cab underneath the switch

panel that retain the switch panel to the cab. Pull the

steering column away from the cab frame. Remove the

two studs and nuts that retain the steering orbitrol in the

column assembly. Remove the knuckle joint clamp bolt

and the retaining studs. The orbitrol valve can be

removed.

AÐPriority valve

BÐSteer mode valve

CÐPressure test port

DÐOrbitrol valve

EÐRear axle

FÐFront axle

Disassemble the steering column from the steering

orbitrol unit and place the steering unit in a suitable

holding tool. Screw out the screws in the end cover (fig.

28). There are six screws plus one special screw.

GS4400,240 -19-01FEB97

GS4400,241 -19-01FEB97


PN=123

Remove the end cover sideways. Lift the gearwheel set

(with spacer if fitted) off the unit. Take out the two

O-rings.

Remove the cardan shaft (fig. 30) and the distributor

plate.

Screw out the threaded bushing over the check valve

(fig. 31). Remove the distributor plate O-ring.

Shake out the check valve ball and suction valve pins

and balls (fig. 32).

GS4400,242 -19-01FEB97

GS4400,243 -19-01FEB97

GS4400,244 -19-01FEB97

GS4400,245 -19-01FEB97


PN=124

Take care to keep the cross pin in the sleeve and spool

horizontal. The pin can be seen through the open end of

the spool. Press the spool inwards and the sleeve ring

bearing races and needle bearing will be pushed out of

the housing together.

Take the ring, bearing races and the needle bearing

from sleeve and spool (fig. 34). The outer (thin) bearing

race can sometimes stick in the housing therefore ckeck

that it has come out.

Press out the cross pin, using the special pin.

Carefully press the spool out of the sleeve (fig. 36).

GS4400,246 -19-01FEB97

GS4400,247 -19-01FEB97

GS4400,248 -19-01FEB97

GS4400,249 -19-01FEB97


PN=125

Press the neutral position springs out of their slots in the

spool (fig. 37).

Remove dust seal and O-ring/kin-ring.

Remove plugs from the shock valves using a 6 mm

hexagon socket spanner (fig. 39). Remove seal washers

and the setting screws underneath the shock valves.

Shake out the two springs and two valve balls into your

hand. The valve seats are bonded into the housing and

cannot be removed.

GS4400,250 -19-01FEB97

GS4400,251 -19-01FEB97

GS4400,252 -19-01FEB97

GS4400,253 -19-01FEB97


PN=126

Screw out the plug using an 8 mm (0.31 in.) hexagon

socket spanner (fig. 41). Remove the seal washer.

Unscrew the set screw using an 8 mm (0.31 in.)

hexagon socket spanner.

Shake out the spring and piston (fig. 42). The valve seat

is bonded into the housing and cannot be removed. The

pressure relief valve is now disassembled.

Clean parts. Replace all seals and washers and lubricate

all parts with hydraulic oil.

Assembly pattern and colour code for neutral position

springs.

2-off flat, grey.

4-off curved, grey.


springs.

Weak springs (Blue).

2 - off flat, blue.

4 - off curved, blue

GS4400,254 -19-01FEB97

GS4400,255 -19-01FEB97

GS4400,256 -19-01FEB97

GS4400,257 -19-01FEB97


PN=127


springs.

Strong springs (grey and blue).

2 - off flat, grey and blue.

4 - off curved, grey and blue.


springs.

Stiff springs (yellow).

2 - off flat, yellow.

4 - off curved, yellow.

Assemble spool and sleeve. When assembling spool and

sleeve only one of two possible ways of positioning the

spring slots is correct. There are three slots in the spool

and three holes in the sleeve in the end of the

spool/sleeve opposite to the end with spring slots. Place

the slots and holes opposite to each other so that parts

of the holes in the sleeve are visible through the slots in

the spool.

Place the two flat neutral springs in the slot. Place the

curved springs between the flat ones and press them

into place (fig. 48). Line up the edges of the springs.

GS4400,258 -19-01FEB97

GS4400,259 -19-01FEB97

GS4400,260 -19-01FEB97

GS4400,261 -19-01FEB97


PN=128

Guide the spool into the sleeve. Make sure that spool

and sleeve are placed correctly to each other.

Press the springs together and push the neutral position

springs into place in the sleeve (fig. 50).

Line up the springs and center them.

Guide the ring down over the sleeve (fig. 52).

GS4400,262 -19-01FEB97

GS4400,263 -19-01FEB97

GS4400,264 -19-01FEB97

GS4400,265 -19-01FEB97


PN=129

Fit the cross pin into the spool/sleeve.

Fit the bearing races and needle bearing as shown on

following drawings.

Assembly pattern for standard bearings.

* The inside chamfer on the inner bearing race must

face the inner spool.

1ÐOuter bearing race

2ÐNeedle bearing

3ÐInner bearing race

4ÐSpool

5ÐSleeve

Assembly pattern for double bearings.

* The inside chamfer on the inner bearing race must

face the inner spool.

1ÐWasher for axial bearing

2ÐOuter needle bearing

3ÐOuter bearing race

4ÐSpool

5ÐSleeve

6ÐInner needle bearing

7ÐInner bearing race

GS4400,266 -19-01FEB97

GS4400,267 -19-01FEB97

GS4400,268 -19-01FEB97

GS4400,269 -19-01FEB97


PN=130

Turn the steering unit until the bore is horizontal. Guide

the outer part of the assembly tool (part number 501814)

into the bore for the spool/sleeve (fig. 57).

Grease the O-ring and kin-ring with hydraulic oil and

place them onto the tool.

Hold the outer part of the assembly tool in the bottom of

steering housing and guide the inner part of the tool right

to the bottom.

Press and turn the O-ring/kin-ring into position in the

housing. Draw the inner and outer parts of the assembly

tool out of steering unit bore, leaving the guide from the

inner part in the bore.

GS4400,270 -19-01FEB97

GS4400,271 -19-01FEB97

GS4400,272 -19-01FEB97

GS4400,273 -19-01FEB97


PN=131

Lubricate the lip seal and place it onto the assembly tool

- part number 501815. Lubricate it with hydraulic oil.

Guide the assembly tool into the bottom of the steering

unit. Press and turn the lip seal into place in the

housing.

With a light turning movement, guide the spool and

sleeve into the bore.

The spool set will push out the assembly tool guide. The

O-ring and kin-ring are now in position.

GS4400,274 -19-01FEB97

GS4400,275 -19-01FEB97

GS4400,276 -19-01FEB97

GS4400,277 -19-01FEB97


PN=132

Turn the steering unit until the bore is vertical again. Put

the check valve ball into its hole. Screw the threaded

bushing lightly into the check valve bore (fig. 65). The

top of the bushing must lie just below the surface of the

housing.

Place a ball into the two holes indicated by the arrows

(fig. 66).

Place a pin in the same two holes.

Grease the distributor plate O-ring with mineral oil

(approx viscosity 500 cSt, 20 ÊC;68ÊF). Place the

distributor plate so that the channel holes match the

holes in the housing.

GS4400,278 -19-01FEB97

GS4400,279 -19-01FEB97

GS4400,280 -19-01FEB97

GS4400,281 -19-01FEB97


PN=133

Guide the cardan shaft down into the bore so that the

slot is parallel with the connection flange. Place the

cardan shaft as in figure 69 so that it is held in position

by the mounting fork - part number 501816.

Grease the two O-rings with mineral oil (approx viscosity

500 cSt, 20 ÊC;68 ÊF) and place them in the two grooves

in the gear rim. Fit the gearwheel and rim on the cardan

shaft (fig. 70).

IMPORTANT: Fit the gearwheel (rotor) and cardan

shaft so that a tooth base in the rotor

is positioned in relation to the shaft

slot as shown (fig. 71). Turn the gear

rim so that seven through holes match

the holes in the housing.

Fit the spacer, if any. Place the end cover in position.

GS4400,282 -19-01FEB97

GS4400,283 -19-01FEB97

GS4400,284 -19-01FEB97

GS4400,285 -19-01FEB97


PN=134

Fit the special screw with washer and place it in the hole

shown in figure 73.

Fit the six screws with washers and insert them.

Cross-tighten all the screws and the rolled pin with a

torque of 30 N·m ± 6 N·m (22.11 lb-ft ± 4.42 lb-ft).

Place the dust seal ring in the housing. Fit the seal ring

by using service tool number 501817 (fig. 75).

ASSEMBLY OF THE PRESSURE RELIEFVALVE

Fit the piston (fig. 76).

GS4400,286 -19-01FEB97

GS4400,287 -19-01FEB97

GS4400,288 -19-01FEB97

GS4400,289 -19-01FEB97


PN=135

Fit the spring (fig. 77) and screw in the adjusting screw.

Set the pressure to 17500 kPa (175 bar; 2537.5 psi) by

fitting the unit to the machine, operating the steering

(refit the shock valves before refitting to the machine)

and adjusting the set screw to achieve the correct

setting.

Screw the cover plug into the housing and torque to 50

N´m (36.8 lb-ft).

ASSEMBLY OF THE DUAL LINE SHOCKVALVES

Place a ball into the two holes as shown in figure 79.

Place the springs (fig. 80) and valve cones over the two

balls.

GS4400,290 -19-01FEB97

GS4400,291 -19-01FEB97

GS4400,292 -19-01FEB97

GS4400,293 -19-01FEB97


PN=136

Screw in the two set screws using a 6 mm (0.23 in.)

hexagon socket spanner. Follow the pressure setting

procedure to set the shock valves. Screw the plug with a

new seal ring into the two shock valves and tighten to

30 N´m (22.11 lb-ft).

PRESSURE SETTING PROCEDURE FORDUAL LINE SHOCK VALVES

The pressure must be set before refitting the unit to the

machine because the opening pressure is higher than

the maximum pressure permitted in the steering circuit. If

there are no bench test facilities available, then No

attempt to set the pressure should be made. Use a

hand pressure pump with a gauge that will accept at

least 300 bar (30000 kPa; 4350 psi) to set the pressure.

Connect the hand pump to one of the orbitrol outlet ports

as shown in figure 82. Gradually apply pressure until the

shock valve opens (shown by oil leakage from the other

orbitrol outlet port). Note the pressure. If the pressure is

less than 22000 - 24500 kPa (220 - 245 bar; 3190 -

3552.5 psi), then increase the pressure by screwing in

the adjusting screw (figure 81.). Repeat this procedure

until the correct setting is reached.

If the pressure is too high, then unscrew the adjusting

screw until correct pressure is reached. Repeat the

procedure described above for the opposite shock valve.

GS4400,294 -19-01FEB97

GS4400,295 -19-01FEB97


PN=137

BLEEDING THE FOUR WHEEL STEERINGSYSTEM

Whenever any hydraulic steering component is

disconnected or removed the system must be bled as

follows. The procedure must be carried out in the correct

order that is laid down. You must not alter the order of

selections and operation or air will be moved from

steering cylinder to steering cylinder.

Select two wheel steer

a) Turn the steering wheel to the right until full lock is

reached.

b) Turn the steering wheel to the left until full lock is

reached.

Realign the wheels and select four wheel steer

a) Turn steering wheel to the right until full lock is

reached.

Realign the wheels and select two wheel steer

a) Turn the steering wheel to the left until full lock is

reached.

b) Turn the steering wheel to the right until full lock is

reached.

c) Turn the steering wheel to the left until full lock is

reached.


a) Turn the steering wheel to the right until the front

wheel reach full lock.

Realign the wheels and select two wheel steer

a) Turn the steering wheel to the left until full lock is

reached.

b) Turn the steering wheel to the right until full lock is

reached.

c) Turn the steering wheel to the left until full lock is

reached.


a) Turn the steering wheel to the right until the front and

rear wheels reach full lock.

GS4400,296 -19-01FEB97


PN=138


PN=139

CAB - STEERING COLUMN

The steering column is adjustable by means of a pivot

approximately half way up the column. This enables the

column to be moved closer to the operator for a more

comfortable operating position. Prior to removing the

steering column, if it is a steering fault, the steering

system should be fully tested.

Removal and repair of the steering column

Place the machine on firm level ground. Shut off the

engine. Remove the steering wheel nut cover. Remove

the steering wheel retaining nut. Using a suitable puller,

remove the steering wheel (fig. 4). Remove the four bolts

retaining the lower steering column to the front of the

cab. Remove the two nuts at the front right hand side of

the switch panel just below the top side of the switch

panel. Undo the steering column wiring harness. Pull the

steering column assembly away from the front of the

cab. Remove the two nuts retaining the steering orbitrol

to the steering column. Remove the orbitrol valve and lift

out the steering column assembly. To remove the

knuckle joint, slide out the stub shaft that was bolted to

the orbitrol valve. Remove the clamp bolt in the knuckle

joint and pry the joint off the upper steering column

shaft.

To remove the upper steering column shaft, undo and

remove the pivot bolts (fig. 4). Lift off the upper steering

column assembly. Access to the four bolts retaining the

upper steering column to the frame is possible. Remove

the four bolts which are threaded into the upper housing

and lift out the upper steering column shaft. The dash AÐSteering column

BÐUpper steering columnpanel can be removed with the steering column andCÐLower steering column cover platesteering wheel in place by removing the cover retainingDÐOrbitrol valve

screws and the dash panel screws. It is also necessaryEÐSteering column to cab retaining bolts

to remove the wiring connectors. Note where each

connector fits ready for refitting.

GS4400,297 -19-01FEB97

Group 20Cab - Steering Column


PN=140


PN=141

BRAKE CIRCUIT

AÐAccumulator CÐTank EÐAxle brake pistons FÐAxle brake pistons

BÐFlow from priority valve DÐFoot brake valve

The braking circuit receives its oil flow from the

priorty valve where the brake charge valve restricts

the pressure to 8500 kPa (85 bar; 1232.5 psi)

maximum in the hydraulic hose feeding the brake

accumulator and the brake valve. The accumulator

retains the brake charge pressure within the braking

circuit so if there is an engine or hydraulic failure the

brake system can still operate. To test the hydraulic

pressures in the braking circuit firstly, release the

pressure within the circuit by shutting off the engine

and operating the brake pedal at least thirty times.

Carefully undo the hydraulic hose feeding oil into the

brake pedal. Fit an in line pressure gauge into the

circuit, start the engine and note the pressure, which

is called the brake charge pressure. This pressure

should be between 12000 kPa (120 bar; 1740 psi)

and 15000 kPa (150 bar; 2175 psi). If not, the

problem is within the priority valve which is explained

in Section 70 of this manual. The brake charge

pressure is preset and cannot be adjusted. The flow

from the priority valve is restricted to 5 liters per

minute (1.32 gal/min).

The brake pedal when depressed feeds oil to the

brake cylinders and also to the underside of the spool

(as shown above) which gives a feeling of

progressive braking. The oil that is fed to the axle

brake pistons is restricted to 8500 kPa (85 bar;

1232.5 psi) by the brake pedal valve. To test this

pressure, release the pressure within the circuit as

previously explained and tee in a suitable pressure

gauge, start the machine, depress the brake pedal

and note the pressure. If it is significantly lower than

8500 kPa (85 bar; 1232.5 psi) when the pedal is fully

depressed, the problem is within the footbrake valve,

As this valve is preset, a replacement must be fitted

in this case.

GS4400,298 -19-01FEB97

Group 25Axles and Brakes - Brake Circuit


PN=142

BRAKE BLEEDING

AÐPlug BÐBrake bleed screw CÐOil brake drain plug

Start the brake bleeding procedure on the wheel hub

furthest away from the footbrake pedal, i.e. rear

offside wheel. Turn the reduction hub until plug (A)

(fig. 74) is at top dead center. Remove the plug to

allow access to the brake bleed screw (B). Operate

the brake pedal with the engine at low idle five times,

unscrew the bleed screw about 1.5 turns to allow air

in the oil to escape. Use a flexible tube over the

bleed screw to prevent the hub oil and brake

(hydraulic) oil from mixing. Repeat the bleeding

procedure until all air has been expelled. Tighten plug

(A) to a torque of 80 N´m (58.96 lb-ft).

GS4400,299 -19-01FEB97


PN=143

REMOVAL AND REPLACEMENT

N CAUTION: Brake pads generate dust which if

inhaled, may endanger health. Wash off the

caliper assemblies before commencing work.

Clean hands thoroughly after work.

N CAUTION: Before working on the parking

brake, park on level ground and put chocks on

each side of all four wheels. Stop the engine

and disconnect the battery so that the engine

cannot be started. If you do not take these

precautions the machine could run over you.

Removal

1 Make sure that the precautions listed above are

completed.

2 Release the handbrake lever.

3 Disconnect cable clevis (A) from operating lever (B).

4 Support the caliper and remove the two mounting bolts

(C) (including washers). Remove the reaction bracket (D)

and caliper assembly (E).

InspectionAÐCable clevis

BÐOperating leverCheck the thickness of the friction material on the two CÐMounting bolts (including washers)

brake pads. If either pad is worn below 2 mm (0,079 in.) DÐReaction bracket

EÐCaliper assemblyfit a new pair of pads. For reference, the thickness of

friction material on new pads is 3.18 mm (0.125 in.).

Check also the surface condition of the brake disk.

Replace the disk if it is badly warped, pitted or out of

tolerance:

Minimum thickness - 8.89 mm (0.350 in.). Maximum

thickness - 9.65 mm (0.380 in.).

Replacement

Reverse the removal procedure.

Tighten mounting bolts (C) to figure shown below.

If required, reset the caliper as described in setting

procedure.

Torque Settings

Bolts C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 N´m;180 lb-ft

GS4400,501 -19-01FEB97

Group 30Brakes


PN=144

GS4400,301 -19-01FEB97


PN=145

DISASSEMBLY AND ASSEMBLY

1ÐScrew 6ÐShaft seal 10ÐPlain bearing 14ÐBushings

2ÐAnti-rotation clip 7ÐFriction pad 11ÐRotor 15ÐO-ring

3ÐWasher 8ÐBrake pad 12ÐBall spacer 16ÐO-ring

4ÐLever 9ÐRotor seal 13ÐBall bearings 17ÐCaliper housing

5ÐSpring

The numerical sequence shown on the illustration is

intended as a guide to disassembling. For assembly

the sequence should be reversed.

N CAUTION: Brake pads generate dust which

if inhaled, may endanger health. Wash off

the caliper before commencing work. Clean

hands thoroughly after work.

When Disassembling

Brake pads (7) and (8) are removed through the

brake disk slot located in the caliper housing (17).

To remove brake pads (7) and (8), first lever pad (8)

towards the center of housing. Then press brake pad

(7) towards the housing and remove through the

brake disk slot.

Separate brake pad (8) from rotor seal (9). Brake pad

(8) is held in position by center snap tabs. Use care

when removing the friction pad, that is, do not break

off the center snap tabs. Remove brake pad (8), rotor

seal (9) and plain bearing (10) through the brake disk

slot.

Remove rotor (11), ball spacer (12) and ball bearings

(13) through the aperture vacated by the removal of

pad (7). Take care not to lose the ball bearings.

The shaft seal (6) need only be replaced if

excessively worn or cracked. Press out the plastic

shaft seal from inside the casting, using a suitable

spacer block and press. (Spacer block dimensions -

27.38 mm (1.078 in.) diameter x 63.5 mm (2.5 in.)

long.

After the shaft seal is pressed out, remove the sliver

of plastic that may be left in the casting groove.

Inspection

Ensure that all parts are free from excessive wear,

damage or corrosion. Light scores or stains should be

removed. Renew corroded or deeply scored parts.

Check the rotor assembly for cracks. Replace if

necessary. The rotor assembly must be replaced as a

complete unit. No individual parts are available for

service.

GS4400,502 -19-01FEB97

GS4400,302 -19-01FEB97


PN=146

When assembling

Stamped on the back of each friction pad is a code.

The first 1 or 2 characters indicate the friction

material type. Make sure that new pads have the

same type friction material.

Install a new shaft seal (6) by inserting the seal from

the outside of the housing (17) with the extended

smooth surface inserted first. Use an appropriate

press. With the spacer (see disassembly), between

the press and the seal, gently press the seal in until

it snaps into the groove in the housing.

Coat the spindle, ball pockets surface of rotor (11),

the inside face of rotor seal (9) and ball pockets of

housing (17) with silicone grease.

Locate the small diameter of spring (5) around the

outside of the four pins on lever (4), and the large

diameter of the spring outside the boss of housing

(17).

With the lever (4) set in the 12 o'clock position (see

inset), screw (1) should be tightened to the figure

shown below. When the screw has been correctly

tightened, bend back the locking tab on anti-rotation

clip (2), as shown in the inset.

Align the flat on pad (8) with the flat on rotor seal (9),

which will allow the pad to sit flat. If the center snap

tabs are gone, dab some adhesive around the back

edge of the friction pad (8) and press firmly into place

(align flat as described).

Before fitting the friction pad (7), clean out existing

pad adhesive from the pad compartment. Place a

layer of suitable adhesive along the back edge of the

friction pad and press firmly into position.

Once assembled, stroke lever (4) in its direction of

operation. The lever must rotate through 60 degrees

of rotation. Allow the lever to return to its original

position (12 o'clock) and make sure that friction pad

(8) is fully returned.

The O-rings (15) and (16) must be assembled into

grooves in housing (17) and lubricated with silicone

grease prior to insertion of bushings (14). Wipe off

any excess grease.

Set the caliper as described in setting procedure.

Torque settings

Screw 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5-15.5 N´m; 9.2-11.5 lb-ft

GS4400,303 -19-01FEB97


PN=147

GS4400,304 -19-01FEB97


PN=148

SETTING PROCEDURE

AÐHandle grip CÐLock nut EÐPark brake lever GÐAnti-rotation clip

BÐPin DÐClevis FÐScrew HÐOperation lever

If the parking brake caliper assembly has been

disassembled or the brake pads renewed, then the

caliper must be set as follows:

N CAUTION: Before adjusting the parking

brake, make sure that the machine is on

level ground. Put chocks on each side of all

four wheels. Disconnect battery so that the

engine cannot be started. If you do not take

these precautions, the machine could run

over you.

1. Disengage the parking brake (lever horizontal).

Turn handle grip (A) to bring pin (B) central to the

slot.

2. Adjust the cable's effective length so that the park

brake is fully engaged when the park brake lever is

vertical:

2.1 Release and adjust the two lock nuts (C) and/or

clevis (D).

2.2 Further adjustment, if required, is available at the

clevis and cable mounting position at the park brake

lever (E).

3. In the event that there is insufficient adjustment in

the cable, remove screw (F), anti-rotation clip (G) and

take operation lever (H) off its mounting spline.

4. Rotate the lever clockwise, one notch of the spline.

Refit anti-rotation clip (G) and screw (F). Tighten the

screw to 12.5 - 15.5 N´m; (9.2 - 11.5 lb-ft).

5. After the screw has been tightened, bend the tabs

of clip (G) to secure the screw.

6. Make sure that the parking brake switch (item X) is

correctly adjusted; refer to park brake switch

adjustment.

7. Test the parking brake.

7.1 Make sure the parking brake is fully engaged

(lever vertical - also see Note above). Select 2 wheel

drive and third gear.

7.2 Make sure the brake pedals are locked together,

push down hard on the brake pedals and select

forward drive.

N CAUTION: If the machine starts to move

during the following test, immediately apply

the foot brakes and reduce the engine

speed.

7.3 Slowly release the brake pedals, if the machine

has not moved use the accelerator to gradually

increase the engine speed to 1500 rpm - the machine

should not move. Do not test for longer then 20

seconds.

7.4 If the machine has moved, inspect the

caliper/pads, reset as described above.

GS4400,305 -19-01FEB97


PN=149

Section 70

HYDRAULIC SYSTEMContents

Page


Hydraulics - principles of operation . . . . . 70-00-1

Hydraulics - layout . . . . . . . . . . . . . . . . 70-00-2

Hydraulic pump operation . . . . . . . . . . . 70-00-3

Testing the hydraulic pump . . . . . . . . . . 70-00-3

Conclusion . . . . . . . . . . . . . . . . . . . . . 70-00-4

Group 10ÐHydraulic Pump

Pump removal . . . . . . . . . . . . . . . . . . . 70-10-1

Pump replacement . . . . . . . . . . . . . . . . 70-10-2

Hydraulic - pump . . . . . . . . . . . . . . . . . 70-10-3

Reassembly of the pump . . . . . . . . . . . . 70-10-4

Group 20ÐHydraulics - Priority Valve

Priority valve . . . . . . . . . . . . . . . . . . . . 70-20-1

No steering at all . . . . . . . . . . . . . . . . . 70-20-2

Control valve hydraulics . . . . . . . . . . . . 70-20-3

Cable . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3

Joystick . . . . . . . . . . . . . . . . . . . . . . . 70-20-4

Basic method of operation . . . . . . . . . . . 70-20-4

Joystick operation - wiring . . . . . . . . . . . 70-20-5

Control valve solenoid operation . . . . . . . 70-20-6

Removal of the control valve - cable . . . . 70-20-7

Control valve . . . . . . . . . . . . . . . . . . . . 70-20-9

Inlet section . . . . . . . . . . . . . . . . . . . . 70-20-10

Testing the inlet section . . . . . . . . . . . . 70-20-11

Repair . . . . . . . . . . . . . . . . . . . . . . . . 70-20-12

Priority valve principles of operation . . . . 70-20-13

Testing the priority valve . . . . . . . . . . . . 70-20-14

Steering circuit . . . . . . . . . . . . . . . . . . 70-20-15

Safety lock valve test procedure . . . . . . . 70-20-16

Safety lock valve removal . . . . . . . . . . . 70-20-17

Cylinder removal . . . . . . . . . . . . . . . . . 70-20-18

Cylinder repair . . . . . . . . . . . . . . . . . . . 70-20-19

Tilt/Crowd cylinder removal . . . . . . . . . . 70-20-21

Tilt cylinder repair (4400) . . . . . . . . . . . . 70-20-22

Tilt cylinder repair (4500) . . . . . . . . . . . . 70-20-23

Compensator cylinder removal . . . . . . . . 70-20-24

Compensator cylinder repair (4400) . . . . . 70-20-25

Compensator cylinder repair (4500) . . . . . 70-20-26

Extension cylinder removal . . . . . . . . . . 70-20-27

Extension cylinder repair (4400) . . . . . . . 70-20-28

Extension cylinder repair (4500) . . . . . . . 70-20-29

Plunger cylinder removal . . . . . . . . . . . . 70-20-30

Page

Plunger cylinder repair . . . . . . . . . . . . . 70-20-30

Group 30ÐHydraulics - Fault Finding

Hydraulics - fault finding . . . . . . . . . . . . 70-30-1

Hydraulics - hydraulic schematic . . . . . . . 70-30-11


PN=240


PN=241

HYDRAULICS - PRINCIPLES OF OPERATION

The basic principle of hydraulics is to use oil power

to operate a mechanical system. A liquid cannot be

compressed, so as the liquid (oil) flows it will try to

move anything in its path. The resistance to flow

created by operating a function creates an operating

pressure which can be regulated by means of a

pressure relief valve. This valve is designed to

prevent damage to the system components caused

by excessive pressure. If there is no operation of a

function, there will be no resistance to the flow of oil

so it can pass around the circuit freely. The hydraulic

pump does not create any pressure, it only creates

flow. The pump is able to supply flow to a restricted

circuit. If the restriction is too great, then the pressure

will rise above the setting of the relief valve which will

open allowing the flow to return to the tank under no

restriction. The system consists of a suction filter,

hydraulic pump, priority valve, control valves, steering

orbitrol and a return line filter (fig. 1). The first item in

the circuit is the suction filter which takes out any

large pieces of contamination that may have found

the way into the hydraulic tank.

The hydraulic pump is driven from the engine timing

case at the rear of the machine. The priority valve is

situated in the center well of the chassis at the left

hand side close to the cab. The purpose of the valve

is to supply oil flow to the two priority circuits being

the steering and braking system. The steering orbitrol

valve feeds oil to the steering cylinders. The control

valves are bolted to the top of the hydraulic tank.

Their function is to divert oil from the main circuit to

the individual functions as required by the operator.

Finally the return line filter, which is the last item in

the circuit, is bolted to the hydraulic tank. Its purpose

is to remove any contamination from the system

before the oil is returned to the tank.

GS4400,306 -19-01FEB97

Group 00General Information


PN=150

GS4400,307 -19-01FEB97


PN=151

HYDRAULIC PUMP OPERATION

AÐSteering mode valve DÐSteering orbitrol HÐBrake accumulator LÐHydraulic pump

BÐSteering cylinder rear EÐBrake pedal IÐBrake hoses rear axle MÐHydraulic tank filter

axle FÐBrake hoses front axle JÐSuction filter NÐReturn filter

CÐSteering cylinder front GÐBrake switch block KÐPriority valve OÐControl valve

axle

The hydraulic pump is of the gear type, which means

that the flow from it is constant compared to a

constant engine rpm. There are two connections on

the pump. The hoses are suction and flow to and

from the pump. The flow from the pump is variable

with engine rpm, i.e. as engine rpm rises so does the

pump flow. When a function cylinder reaches the end

of its stroke, the pressure rises in both the cylinder

and the load sense line. Once the pressure reaches

21000 kPa (210 bar), the main relief valve opens

allowing the pump to return the hydraulic oil to the

tank. (Load sense line is an internal line within the

main control valve)

TESTING THE HYDRAULIC PUMP

Before testing the hydraulic pump it is important that

the hydraulic oil is at a minimum operating

temperature of 50ÊC (122ÊF). All tests must be carried

out with the engine at high idle speed.

1. Remove the 'flow in' hose from the priority valve

and fit a flow meter and pressure gauge 25000 kPa

(250 bar; 3625 psi) with a shut off tab into the hose

and return it to tank.

2. Remove the return line filter in the top of the

hydraulic tank.

3. Check that the suction filter inside the hydraulic

tank is clean.

4. Ensure that the shut-off valve is fully open or

damage to the pump will occur.

5. Run the machine at 2200 engine rpm. Note the

flow from the pump: 66 l/min for 4400 and 93 l/min

for 4500 (17 gpm for 4400 and 25 gpm for 4500).

6. Slowly increase the pressure by turning the

shut-off valve.

7. Do not allow the pressure to rise above that of the

pressure relief valve setting, which should be either

21000 kPa (210 bar; 4400) or 24100 kPa (241 bar;

4500). Damage to the hydraulic pump will occur if

these pressures are exceeded as the pump has NO

relief valve protection with the test equipment fitted at

this point.

8. Note the rate of flow, it should not have dropped

more than 20 % of the flow rates stated in test 5. If it

has, the pump should be repaired or replaced.

GS4400,503 -19-01FEB97

GS4400,309 -19-01FEB97


PN=152

CONCLUSION

If the flow rate in test 5 is significantly lower than stated,

either the oil supply to the pump, engine speed or the

pump is faulty. If the pump is suspected, continue with

the test procedure. If the fault is in the pump, the flow

will drop further when the pressure rises. If the flows in

test 5 are correct or close to the correct figure (within 5

%), but the flow drops by more than 20 % as the

pressure is increased, then the pump is worn.

GS4400,310 -19-01FEB97


PN=153

PUMP REMOVAL

AÐHydraulic pump CÐUnion EÐPump retaining screw GÐSeal

BÐSeal DÐFlow out hose FÐUnion HÐSuction hose

Remove the hydraulic filler cap so that all pressure

within the tank is released. Undo and remove the

pump suction hose (H) and also the flow out hose

(D). Remove the pump mounting bolts.

GS4400,311 -19-01FEB97

Group 10Hydraulic Pump


PN=154

PUMP REPLACEMENT

Clean the mating surfaces of the hydraulic pump.

Replace the mounting bolts. Fit a new seal to the suction

hose where its connects to the pump and reconnect the

suction hose. Pour some clean hydraulic oil into the

outlet of the pump and allow it to drain through the

pump. Continue to do this until 1 liter (0.2642 gal) of oil

has passed through the pump. This will lubricate and

prime the pump to prevent immediate damage to the

pump components when the engine is started. Connect

the outlet hose to the pump, start the engine and run at

low idle speed for a maximum of 20 seconds. If the

steering is not operational, stop the engine and re-prime

the pump. If the steering is operational, then restart the

engine and test the system.

GS4400,312 -19-01FEB97


PN=155

PUMP REPAIR

1ÐBolts 6ÐBack up seal 10ÐGear 16ÐShaft seal

2ÐSpring washer 7ÐBushings 11ÐDrive shaft 17ÐSnap ring

3ÐEnd cover 8ÐBushings 12ÐKey 18ÐSpecial ring

4ÐO-ring 9ÐBody 15ÐMounting flange 19ÐNut

5ÐBack up seal

1. Remove the pump as explained on the previous

page.

2. Before starting work ensure that the unit, work

area and all tools are thoroughly clean to prevent

contamination from entering the unit.

3. Withdraw the drive gear from the drive shaft using

a suitable puller. Do not lever or hammer off the gear

or damage will occur to the internal components of

the pump.

4. Remove key (12, fig. 3) from the shaft.

5. Lightly mark the end cover, body and mounting

flange (3, 9 and 15) to ensure reassembly in the

correct position.

6. Remove the bolts and spring washer (1 and 2).

7. Remove the end cover (3), body O-ring (4),

bushing seal and back up seal (6 and 5).

8. Turn the unit over and lightly tap the mounting

flange (15) to disengage it from the locating dowels.

Take care not to damage any sealing surfaces.

9. Remove snap ring (17) and push the shaft seal

(16) squarely out of the mounting flange. Take care

not to damage any sealing surfaces.

10. Before removing the internal components, mark

the bushings to denote the location in the body. Mark

on a plain area away from the seal location mark.

11. With the unit lying on its side hold the drive shaft

(11) and pull it squarely out of the body with its

bushings (7 and 8).

12. Remove the driven gear (10) and the two

remaining bushings.

GS4400,313 -19-01FEB97


PN=156

INSPECTION

If any part shows signs of wear or damage, then either

replace those parts or the complete assembly. The body

should have wear not exceeding 0.08 mm (0.0031 in.) in

the gear area.

GS4400,314 -19-01FEB97


PN=157

REASSEMBLY OF THE PUMP

AÐCusp removal flat BÐPosition of drive shaft CÐFlange end DÐLocation dowels

Ensure all parts are perfectly clean. Lubricate the

bushings and gears with clean hydraulic oil (ensure

O-ring recess and end faces of body remain dry).

1. Refit end cover bushings into the undowelled end

of the body. The 'C' shape cut out in the bushings

(fig. 4) must be to the side of the body with the cusp

removal flat.

2. Place the end cover (3, fig. 3) against the

undowelled end of the body (9) and stand the

assembly on the cover so the dowels are uppermost

and to the left hand side.

3. Fit drive shaft (11) and driven gear (10) into their

original positions in the body.

4. Refit flange end bushings into their original bores

remembering the 'C' cut out must be to the side of

the body with the cusp removal flat and match the

cover end bushings.

5. Fit new body O-ring (4), bushing seal and back-up

seal (5 and 6) ensuring that the seals locate correctly

in the seal grooves.

6. Fit new shaft seals into the recess in the mounting

flange with the garter spring facing into the pump.

Refit snap ring (17) into the groove. Apply a coat of

high point melting grease to the shaft seal lips.

7. Fit the shaft seal assembly sleeve (supplied in the

seal kit) over the driveshaft and carefully refit the

mounting flange (15) ensuring that it locates squarely

onto the dowels in the body - remove assembly

sleeve.

8. Holding the unit together carefully turn it over but

ensure that it is supported on the mounting flange

and not the drive shaft.

9. Replace the end cover and refit the bolts and

spring washers. Torque the bolts to 46 - 51 N´m (34 -

38 lb-ft).

10. Pour a small amount of clean hydraulic oil into a

port and check that the shaft can be rotated without

undue force.

GS4400,504 -19-01FEB97


PN=158


PN=159

PRIORITY VALVE COMPONENTS (FIG. 10)

1-Priority valve body

2-Main spool spring

3-O-ring

4-Plug

5-Main spool

6-O-ring

7-Plug

8-Check valve assembly

9-O-ring

10-O-ring

11-Filter

12-Shuttle Assembly

13-Core plug

14-Steering relief valve adjusting

15-O-ring

16-O-ring

17-Steering relief valve poppet

18-Steering relief valve spring

19-Brake charge valve assembly

20-O-ring

21-Anti-extrusion ring

22-O-ring


24-O-ring


26-O-ring

GS4400,315 -19-01FEB97

Group 20Hydraulics - Priority Valve


PN=160

NO STEERING AT ALL

If the steering is not operational, but the control valve

hydraulics are working correctly, then the priority valve

must be supplying all the oil from the hydraulic pump to

the control valve hydraulics. In this case the main spool

(item 5) must be jammed in the open position. Remove

the valve, clean and inspect. Refit the spool. If the fault

remains, change the priority valve. If there is no steering

or main control valve hydraulics, then the pump drive

and operation should be checked.

GS4400,601 -19-01FEB97

GS4400,316 -19-01FEB97


PN=161

CONTROL VALVE HYDRAULICS

Should there be no operation of the control valve

hydraulics but the steering is O.K., the fault may not

necessarily be with the priority valve. The control valve

should be tested thoroughly before the priority valve is

suspected to be at fault (see ªFault Findingº Group to

test the control valve). If the steering and brakes are

working correctly, and there is no flow of oil to the

control valve when the steering is being operated at the

same time as a function, then the fault is within the

priority valve. If there is a flow of oil when the steering is

operated at the same time as a function, then the fault is

within the control valve (see ªFault Findingº Group within

this Section).

CABLE

The operation of the control valve for the cable machines

is done by means of a series of cables from the control

cab. There are various protection valves within the

system which will be covered in detail later in this

section of the manual. The control valve for the

operation of the hydraulic functions is situated

underneath the front cover and is bolted onto the front

chassis. The control valve is operated by means of a

cable from the cab. Once the cable is operated then a

spool within the control valve is moved allowing oil to be

diverted to the appropriate cylinder. The system is 'full

load sensing' which means that oil from the hydraulic

pump is only supplied to the control when a function is

operated thus reducing the wear on the hydraulic

components.

GS4400,317 -19-01FEB97

GS4400,318 -19-01FEB97


PN=162

JOYSTICK

The joystick control system has several different

components working together to give the operator control

over the hydraulic system. These components are: the

joystick, control valve, pilot oil supply valve (in the inlet

section of the control valve), control valve solenoids, seat

pad switch and the wiring harnesses.

BASIC METHOD OF OPERATION

Non-proportional solenoids - auxiliary and extension.

When the operator is sat on the seat, 12 volts are

supplied to the joystick via the seat pad switch. The

four buttons at the top of the joystick can now be

operated (two for auxiliary and two for extension).

Once one of the buttons is depressed, 12 volts are

supplied to one of the terminals on the solenoid (third

or fourth valve from the inlet section). This activates

two of the valves 3 and 2 (A fig. 6) inside the

solenoid to divert the pilot hydraulic oil to one end of

the spool pushing it against the neutral spring to

operate the function. When the other button is

depressed, 12 volts are supplied to the other terminal

operating valves 1 and 4 (A, fig. 6), diverting pilot

hydraulic oil to the other end of the spool pushing it

to operate the function in the opposite direction.

Proportional solenoids - lift and tilt. With the operator

sat on the seat 12 volts are supplied to the joystick

via the seat pad switch. While the joystick is in the

center position (hands free) there is no voltage to the

control valve solenoids. When the joystick is moved

slightly away from the center position, the neutral

switch is activated and voltage now passes to the

solenoids on the control valve (first and second

valves from the inlet section).

Firstly 12 volts are fed constantly to one terminal on

the solenoid and a variable signal voltage is sent to

the other terminal (remaining terminal is ground). With

the neutral switch operated and the joystick in the

neutral position (just away from the center position),

the variable potentiometer sends a signal of 6 volts to

the solenoid which opens valves 1 and 3 (B, fig. 6)

and closes valves 2 and 4. This feeds pilot hydraulic

oil to both ends of the spool hydraulically locking the

spool in neutral. As the joystick is moved to operate

a function, the signal voltage will vary from 6 volts to

a maximum of 9 volts or if the the joystick is moved

the opposite way the signal will vary from 6 volts to a

minimum of 3 volts. The signal voltage is monitored

by electronics inside the solenoid. The position of the

spool is monitored by the positional transducer pin

resting on the end of the spool. These signals are

compared and the internal valves of the solenoids (1,

2, 3 and 4, B fig. 6) are either opened or closed

allowing pilot oil to move the spool until the two

signals are equal.

GS4400,319 -19-01FEB97

GS4400,320 -19-01FEB97


PN=163

JOYSTICK OPERATION Ð WIRING

1ÐSwitches, mechanical 5ÐConnection on solenoid 8ÐControl valve body and S2ÐBoom extension switch

2ÐSwitch neutral position valve spool S3ÐAuxiliary switch

3ÐPotentiometer 6ÐSeat pad safety switch 9ÐSolenoid valves S4ÐAuxiliary switch

4ÐConnection at joystick 7ÐMechanical lever - control S1ÐBoom extensoin switch

valve

GS4400,321 -19-01FEB97


PN=164

GS4400,322 -19-01FEB97

GS4400,323 -19-01FEB97


PN=165

REMOVAL OF THE CONTROL VALVE

Cable Type

Lift the hydraulic tank cover and retain in the lifted

position with the prop provided. Undo the hydraulic

hoses (fig. 7) that supply the functions and plug them.

Fit covers to the adapters in the control valve to prevent

contamination entering the valve block. Remove the

actuating cables by undoing the cable retaining locknuts

that clamp the cables to the mounting plate and slide the

spool actuating arm of the actuating spindle. Remove the

auxiliary depressurise lever from the auxiliary function.

Remove the bolts retaining the control valve to the

hydraulic tank. Place the control valve block on a clean,

dry work surface prior to removing any items from the

control valve. The stripdown procedure is detailed later in

this Group of the manual.

Joystick

Lift the hydraulic tank cover and retain in the lifted

position with the prop provided. Undo the hydraulic

hoses (fig. 7) that supply the functions and plug them.

Fit covers to the adapters in the control valve to preventAÐHurschman plug

contamination entering the valve block. Identify andBÐHoses

remove each of the electrical (hurschman) plugs on the CÐAuxiliary depressurise levercontrol valve. Identification is required to ensure that DÐRetaining bolts

upon reassembly the correct plug is mated with the

correct function or operation of the system may be

affected. Remove the auxiliary depressurise lever from

the auxiliary function. Remove the bolts retaining the

control valve to the hydraulic tank. Place the control

valve block on a clean, dry work surface prior to

removing any items from the control valve. The

stripdown procedure is detailed later in this Group of the

manual.

GS4400,324 -19-01FEB97


PN=166

CONTROL VALVE DISASSEMBLY PROCEDURE

Remove the three nuts (1) on the tie bolts holding the

contol valve assembly together (fig. 8). Put the

control unit on a firm surface on its end plate (2). Lift

off the valve slices individually taking note of which

order they are removed.

Remove the retaining screws (item 1, fig. 9) and lift

off the mechanical module (item 2, fig. 9). Remove

and discard the O-ring seals. Remove the solenoid

retaining screws (item 4, fig. 9) and the solenoid

(item 5, fig. 9), discard the O-ring seals. Slide out the

spool valve (item 3, fig. 9) and inspect it. Check that

the load sense line holes are clear and that there is

no damage to the surface of the spool. The spool is

not a serviceable item and must be replaced if there

is any damage to it. Inspect the valve body as this is

not a serviceable item and must be replaced if any

damage is found. Unscrew the function line relief

valve assemblies (items 6-9 and 10-13, fig. 9).

Items 15 and 16 in figure 9 are the load sense line

shuttle valves which are non serviceable items and

cannot be removed as they are located in the valve

body. If there is a fault with them, the valve body

must be replaced. To reassemble the control valve

slices, reverse the procedure described above and fit

all new O-ring seals.

Torque figures for the retaining screws:

Item D, figure 7 22 N´m (15 lb-ft) Item 4, figure 9 8 N´m (6 lb-ft)

Item 1, figure 8 8 N´m (6 lb-ft) Items 6 & 10, figure 9 40 N´m (30 lb-ft)

GS4400,328 -19-01FEB97


PN=167

CONTROL VALVE Ð EXPLODED VIEW

1ÐRetaining screw 5ÐSolenoid 9ÐSafety relief valve 13ÐSafety relief valve

2ÐManual module 6ÐSafety relief valve cap 10ÐSafety relief valve cap 14ÐFilter

3ÐMain spool 7ÐO-ring 11ÐO-ring 15ÐShuttle ball

4ÐRetaining screw 8ÐSpring 12ÐSpring 16ÐShuttle valve cover

GS4400,330 -19-01FEB97


PN=168

The inlet section of the control diverts the hydraulic oil to

the control functions. The section also houses the servo

pressure maintenance valve, a compensation spool and

a relief valve assembly.

1ÐInlet section housing

2ÐCompensating spool

3ÐCompensating spring

4ÐServo valve spring

5ÐServo cone

6ÐServo spool

7ÐSealing O-ring

8ÐServo filter

9ÐFilter plug

10ÐRelief valve seat

11ÐThrust pad

12ÐRelief valve spring

13ÐSealing O-ring

14ÐAdjusting screw

15ÐPlastic plug

16ÐRetaining dowel

GS4400,331 -19-01FEB97


PN=169

TESTING THE INLET SECTION

A failure of the inlet section will be determined by

carrying out a full hydraulic test procedure as explained

in the hydraulic fault finding guide later in this section of

the manual. If the pressure relief valve is set low, this

may affect all hydraulic operations, but if the

compensation spool is partially or fully open, it will only

affect the control valve functions (both manual and

electrical operation). The servo pressure valve will only

affect the electrical operation of the control valve.

GS4400,332 -19-01FEB97


PN=170

REPAIR

To remove the compensating spool from the inlet

section, undo the three retaining nuts holding the

control valve assembly together (fig. 7) and remove

the inlet section from the control valve. Screw an M6

bolt into the retaining plug on the end of the

compensating spool and remove the retaining plug.

N CAUTION: When removing the retaining

plug, the spring behind the spool will force

the spool out of the inlet section housing.

If the spool does not come out, then screw an M6

bolt into the end of the compensating spool and using

suitable extractor, remove the spool. Should there be

any sign of damage or wear on the compensating

spool or in the housing, then a new inlet section

should be fitted. To remove the servo pressure valve,

unscrew the filter plug. The filter will stay inside the

plug. The spool, servo cone and spring can then be

removed.

The servo filter can be extracted from the filter plug

once the plug has been removed from the inlet

section. The relief valve is set to 21000 kPa (210 bar;

3045 psi) on the 4400 and 24100 kPa (241 bar) on

the 4500 and is the main system relief valve for the

hydraulic system. When the relief valve opens, this

also operates the compensating spool allowing oil

flow to return to tank. Should the compensating spool

stick, no oil will flow around the control valve.

Setting the relief valve

1. Fit a 30000 kPa (300 bar; 4350 psi) pressure

gauge to the test port on the main control valve.

2. Run the machine, operate a function to full stroke

and note the pressure.

3. Remove the plastic plug covering the relief valve in

the inlet section.

4. Screw in the main relief valve on the control valve

until the reading on the test gauge is 21000 kPa; 210

bar (4400) or 24100 kPa; 241 bar (4500). If the

pressure does not continue to rise when adjusting the

relief valve, the compensating spool in the inlet

section may be prematurely stuck or partially stuck

open.

GS4400,333 -19-01FEB97


PN=171

PRIORITY VALVE PRINCIPLES OFOPERATION

The reason for the fitment of the priority valve is to

enable the machine to have only one hydraulic oil pump

to supply all the functions, namely steering, brakes and

control valve hydraulics. The priority valve receives all oil

flow from the hydraulic pump and divides it depending

on which circuit requires oil, so if the steering or brakes

are being operated, these two circuits will receive oil

prior to the control valve circuit. If, however, the steering

and brakes are either not in use or have reached full

stroke of the cylinder, then oil flow is diverted to control

valve hydraulics, but steering and brakes will always take

the priority flow.

GS4400,334 -19-01FEB97


PN=172

TESTING THE PRIORITY VALVE

Brake circuit

Place the machine on firm level ground, shut the engine

off, discharge the braking circuit by operating the brake

pedal at least thirty times. Fit a pressure test gauge with

a range of 17000 kPa (170 bar; 2465 psi) in the brake

circuit close to the brake accumulator.

Start the engine and note the pressure in the brake

circuit which should be 15000 kPa (150 bar; 2175 psi)

when the brakes are charged, so it will take a few

seconds to reach this pressure. If this pressure is

correct, then operate the brake circuit until the brake

circuit starts to charge and note the pressure at which

the brakes start to charge. It should be 12000 kPa (120

bar; 1740 psi).

If either of the two brake charge pressures are incorrect,

then the brake charge valve may be faulty. Unscrew the

brake charge valve and inspect it. If the problem is

contamination, then remove and refit the valve. The

valve is a non-service item and therefore the priority

valve should be replaced if the fault is more than

contamination. Flow to the braking circuit from the

priority valve is 5 l/min (1.32 gal/min).

GS4400,335 -19-01FEB97


PN=173

STEERING CIRCUIT

Place the machine on firm level ground, shut off the

engine, fit a pressure gauge with a range of 20000 kPa

(200 bar; 2900 psi) into the steering circuit. Start the

machine, operate the steering unit until full lock is

reached, then try to turn the steering further. Note the

pressure which should be 17500 kPa (175 bar; 2537.5

psi). If the pressure is significantly lower, then the relief

valve in the steering orbitrol may need adjusting. The

relief valve in the priority valve is still fitted, but set to a

higher pressure than that of the orbitrol relief valve. If

having checked the orbitrol relief valve steering pressure

is still too low, then remove and inspect the steering

relief valve. Refit the valve. Start the machine and

operate the steering. Note the pressure and adjust the

steering relief valve until the correct setting has been

reached, then turn another 1/4 turn.

The hydraulic cylinders which are in the lift, tilt and

extension circuits all have safety lock valves built into

them to prevent the circuit from dropping rapidly in the

event of a hose failure. The testing of these lock valves

must be carried out to ensure the fault is with the

cylinder.

GS4400,336 -19-01FEB97


PN=174

SAFETY LOCK VALVE TEST PROCEDURE

Lift function - operate the lift function until it has

completed approximately 50 % of its travel. Shut off the

engine and note the rate of drop of the boom. Operate

the slice manually. If the rate of drop increases, the fault

is within the safety lock valve; in this case replace the

valve. If the rate of drop remains constant, the fault is

either in the safety lock valve seals or the cylinder seals.

Tilt function - operate the tilt function until it has

completed approximately 50 % of its travel, shut off the

engine and note the rate of drop of the attachment.

Operate the slice manually. If the rate of drop increases,

the fault is within the safety lock valve; in this case

replace the valve. If the rate of drop remains constant,

the fault is either in the safety lock valve seals or the

cylinder seals.

Extension function - operate the lift function until it has

completed approximately 90 % of its travel. Also operate

the extension function until it has completed

approximately 50 % of its travel. Shut off the engine and

note the rate of retraction of the inner boom. Operate the

slice manually. If the rate of retraction increases, the

fault is within the safety lock valve. In this case replace

the valve. If the rate of retraction remains constant, the

fault is either in safety lock valve seals or in the cylinder

seals.

GS4400,337 -19-01FEB97


PN=175

SAFETY LOCK VALVE REMOVAL

Lift function safety lock valve removal

Lower the boom until it is resting on the floor and has no

weight upon the cylinder. Shut off the engine, operate

the function manually to remove any pressure left within

the system and unscrew the safety lock valve situated at

the base of the lift cylinder. To refit the lock valve, screw

it back into the cylinder and torque it to 60 N´m.

Tilt cylinder safety lock removal

Raise the boom and extend the inner boom until the

hole in the top of the inner boom, housing the tilt

cylinder safety lock valve is visible. Remove any

attachment from the carrier and replace the carrier face

down onto the floor. Shut off the engine and remove any

residual pressure in the circuit by operating the function

manually. Unscrew the lock valve from the cylinder. To

refit the lock valve, screw it back into the cylinder and

torque it to 60 N´m.

Extension cylinder safety lock removal

Lift the boom to full lift height. Place a suitable support

underneath the boom to prevent it from lowering to the

floor. The extension lock valve is situated at the rear

underside of the boom. Use a suitable socket to unscrew

and remove the lock valve. To refit the lock valve, screw

it back into the cylinder and torque it to 60 N´m.

GS4400,338 -19-01FEB97


PN=176

LIFT CYLINDER REMOVAL

Operate the lift function until the boom is

approximately horizontal and place a suitable stand

underneath the boom (fig. 11). Shut off the engine

and release any residual pressure within the lift circuit

by operating the function manually. Remove the

hoses from the cylinder manifold and plug the hoses.

Remove the locking bolts retaining the pivot pins.

Support the cylinder and remove the lift

cylinder-to-chassis pin, then remove the lift cylinder.

To refit the cylinder, reverse the procedure described

above.

GS4400,339 -19-01FEB97


PN=177

LIFT CYLINDER REPAIR

Place the cylinder on a suitable work surface and place

a drain tin nearby. Unscrew the stuffing gland using a

suitable tool. Use the drain tin to catch any oil left in the

cylinder. Slide off the stuffing gland from the cylinder rod,

pull out the cylinder rod from the outer cylinder. Remove

the locking hex. socket screw from the piston head and

unscrew the piston. Slide the stuffing gland off the piston

rod. Inspect all items within the cylinder and replace any

faulty or damaged parts. Remove the seals and replace

prior to refitting the cylinder. Lubricate all seals with

hydraulic oil before reassembly. Press out the bushings

in the eye end and in the cylinder. Replace if required.

To reassemble the cylinder, reverse the procedure

described above.

GS4400,340 -19-01FEB97


PN=178

CYLINDER REPAIR

AÐCylinder DÐSeals GÐSeals IÐEye end

BÐBushings EÐPiston HÐBushing JÐStuffing gland

CÐHex. socket screw FÐPiston rod

GS4400,341 -19-01FEB97


PN=179

TILT/CROWD CYLINDER REMOVAL

Run the machine and extend the inner boom so that

the rear pivot pin of the tilt/crowd cylinder is exposed.

Tilt the carrier so that it is flat on the floor (fig. 13).

Remove the boom nose cover (if fitted) by

unscrewing the four retaining bolts. Remove the 'Z'

linkage to tilt cylinder pin and the compensating link

to compensating lever pivot pin. Move the

compensating link away from the cylinder pivot eye.

Remove the cylinder lock valve situated in the top of

the inner boom by the rear tilt cylinder pivot pin.

Undo the tilt cylinder hoses inside where the boom

nose cover is fitted. Remove the rear tilt cylinder

pivot pin and slide out the cylinder.

GS4400,342 -19-01FEB97


PN=180

TILT CYLINDER REPAIR

AÐSpiral pin DÐSpacer GÐPiston rod IÐCylinder

BÐPiston EÐStuffing gland HÐBushing JÐBushings

CÐSeals FÐSeals

Place the cylinder on a suitable work surface and

place a drain tin nearby. Unscrew the stuffing gland

using a suitable tool. Use the drain tin to catch any

oil that may be left in the cylinder. Slide off the

stuffing gland from the cylinder. Pull out the cylinder

rod from the outer cylinder. Remove the locking spiral

pin in the piston and unscrew the piston. Slide the

stuffing gland off the piston rod and remove the seals

if required (fig. 14). Inspect all items within the

cylinder and replace any faulty or damaged parts.

Remove the seals and replace prior to reassembling

the cylinder. Lubricate all seals with hydraulic oil

before reassembly. Remove the bushings in the eye

ends of the piston and cylinder by pressing them out

using suitable equipment. To reassemble the cylinder,

reverse the procedure described above.

GS4400,343 -19-01FEB97


PN=181

TILT CYLINDER REPAIR

AÐCylinder CÐHex. socket screw EÐStuffing gland GÐSeals

BÐPiston DÐSeals FÐEye end




oil that may be left in the cylinder. Slide the stuffing

gland from the cylinder. Pull out the cylinder rod from

the outer cylinder. Remove the locking hex. socket

screw in the piston and unscrew the piston. Slide the

stuffing gland off the piston rod and remove the seals

if required (fig. 15). Inspect all items within the

cylinder and replace any faulty or damaged parts.

Remove the seals and replace prior to reassembling

the cylinder. Lubricate all seals with hydraulic oil

before reassembly.


described above.

GS4400,344 -19-01FEB97


PN=182

COMPENSATOR CYLINDER REMOVAL

AÐBushing DÐPiston GÐStuffing gland JÐBushing

BÐCylinder EÐSeals HÐSeals KÐEye end

CÐSpiral pin FÐSpacer IÐPiston rod

Lift the boom until it is approximately horizontal.

Place a suitable stand underneath the boom (fig. 16).

Release all residual pressure in the tilt/crowd circuit

by operating the function manually. Disconnect the

hoses and fit plugs to the hoses. Support the cylinder

and remove the pivot pins. Lift out the cylinder.

GS4400,345 -19-01FEB97


PN=183

COMPENSATOR CYLINDER REPAIR 4400(FIG. 16)


a drain tin nearby. Unscrew the stuffing gland using a

suitable tool. Use the drain tin to catch any oil that may

be left in the cylinder. Pull out the cylinder rod from the

outer cylinder. Remove the piston seal, knock out the

retaining spiral pin and unscrew the piston head from the

piston rod. Slide the stuffing gland off the piston rod.

Upon reassembly use Loctite 270 to help retain the

piston head and also renew the spiral pin.

Inspect all items within the cylinder and replace any

faulty or damaged parts. Remove the seals and replace

prior to reassembling the cylinder. Lubricate all seals

with hydraulic oil before reassembly.

Remove the bushings from the cylinder and pivot eye by

pressing them out. Inspect and replace, if required.

To reassemble the cylinder reverse the procedure

described above.

GS4400,346 -19-01FEB97


PN=184

COMPENSATOR CYLINDER REPAIR 4500 (FIG. 17)

AÐBushing DÐSeals GÐSeals JÐSeals

BÐCylinder EÐHex. socket screw HÐStuffing gland KÐEye end

CÐBushing FÐPiston IÐPiston rod




oil that may be left in the cylinder. Pull out the

cylinder rod from the outer cylinder. Remove the

piston seal and unscrew the retaining hex. socket

screw. Unscrew the piston head from the piston rod.

Slide the stuffing gland off the piston rod. Upon

reassembly use Loctite 270 to help retain the piston

head and also renew the spiral pin. Inspect all items

within the cylinder and replace any faulty or damaged

parts. Remove the seals and replace prior to

reassembling the cylinder. Lubricate all seals with

hydraulic oil before reassembly. Remove the bushings

from the cylinder and pivot eye by pressing them out.

Inspect and replace, if required. To reassemble the

cylinder, reverse the procedure described above.

GS4400,347 -19-01FEB97


PN=185

EXTENSION CYLINDER REMOVAL

Extend the inner boom to full extension. Tilt the

carrier until it is possible to place it upon the floor

face down (fig. 18). Remove the front wear pads

fixed to the outer boom (fig. 18). Support the inner

boom section. Lift the engine hood. Remove the

hoses attached to the extension cylinder at the rear

of the cylinder by using a crowfoot spanner through

the cutout of the rear chassis. Remove the rear

extension pivot pin. Remove the boom nose cover.

Undo the steel hoses where they enter the donkey

head. Disconnect the rubber hoses on the

changeover valve. Gently reverse the machine until it

is possible to remove the inner boom. Remove the

front pivot pin and lift out the cylinder.

GS4400,348 -19-01FEB97


PN=186

EXTENSION CYLINDER REPAIR - 4400

AÐSpiral pin DÐSpacer GÐPiston rod IÐCylinder

BÐPiston EÐStuffing gland HÐBushing JÐBushing

CÐSeals FÐSeals


place a drain tin nearby. Undo the stuffing gland


oil that may be left in the cylinder. Pull the cylinder

rod out from the outer cylinder. Remove the piston

seal, knock out the retaining spiral pin (fig.19) and

unscrew the piston head from the cylinder rod. Upon

reassembly use Loctite 270 to help retain the piston

head. Inspect all items within the cylinder and replace

any faulty or damaged parts. Remove the seals and

replace prior to refitting the cylinder. Lubricate all

seals with hyraulic oil before reassembly. Remove the

bushings in the cylinder and pivot eye by pressing

them out. Inspect and replace, if required. To

reassemble the cylinder, reverse the procedure

described above.

GS4400,349 -19-01FEB97


PN=187

EXTENSION CYLINDER REPAIR - 4500

AÐHex. socket screw DÐSeals GÐSeals JÐCylinder

BÐSeals EÐSpacer HÐStuffing gland KÐBushing

CÐPiston FÐPiston rod IÐBushing


place a drain tin nearby. Undo the stuffing gland


oil that may be left in the cylinder. Pull the cylinder

rod out from the outer cylinder. Remove the piston

seal, knock out the retaining hex. socket screw (fig.

20) and unscrew the piston head from the cylinder

rod. Upon reassembly use Loctite 270 to help retain

the piston head. Inspect all items within the cylinder

and replace any faulty or damaged parts. Remove

the seals and replace prior to refitting the cylinder.

Lubricate all seals with hyraulic oil before reassembly.

Remove the bushings in the cylinder and pivot eye by

pressing them out. Inspect and replace, if required.


described above.

GS4400,350 -19-01FEB97


PN=188

PLUNGER CYLINDER REMOVAL

AÐSeals CÐSeals EÐSeals FÐCylinder

BÐSnap ring DÐStuffing gland

Lift the boom until the carrier is at a comfortable

height. Remove the hoses and fit plugs. Remove the

plunger cylinder retaining bolt and lift out the cylinder.

PLUNGER CYLINDER REPAIR


a drain tin nearby. Remove the stuffing gland using a

suitable tool. Use the drain tin to catch any oil that may

be left in the cylinder. Pull out the cylinder rod from the

outer cylinder. Remove the piston seal and the seals

from within the stuffing gland. Inspect all items within the

cylinder and replace any faulty or damaged parts. Renew

the seals prior to refitting the cylinder. Lubricate all seals

with hydraulic oil before reassembly. To reassemble the

cylinder, reverse the procedure described above.

GS4400,351 -19-01FEB97

GS4400,352 -19-01FEB97


PN=189

_

ITEM FAULT TEST POSSIBLE CAUSE REMEDY

1 No hydraulics (either Flow test the pump, is there

steering, brakes or any flow? Yes Flow must be low or the pump Check supply to the pump or

control valve) will fail. the pump.

No Hydraulic oil level low Fill hydraulic tank to

correct level.

Supply of oil to the pump or a Check the suction filter,

pump failure. hose supplying the pump, hose

connections to ensure air is

not being sucked in. Check

hydraulic pump condition

or hydraulic pump drive.

2 No steering Are there any control valve

hydraulics? Yes Priority valve jammed open. Remove spool and clean or

replace the priority valve.

No See item 1

3 No control valve Do the control valve hydraulics

hydraulics, but steering work manually?. Yes See item 4

o.k. No Main relief valve jammed open. Remove,clean,inspect,repair

and reset to the correct

setting.

Compensating spool jammed Remove inlet section, clean

open. spool or replace inlet

section.

GS4400,353 -19-01FEB97

Group 30Hydraulics - Fault Finding


PN=190

_


4 No electrical operation Is there any electrical power

of the control valve at the control valve, either

hydraulics, but o.k. 12 V or a variable voltage

manually (lift/tilt only) when the

controls are operated? Yes Servo hydraulic line fault. Remove the servo filter and

clean.

Servo pressure maintenance, Remove, clean and repair or

faulty solenoid. replace the solenoid.

No See item 5

5 No electrical operation Is there battery voltage

of the control valve entering the controls? Yes See item 6

hydraulics, works o.k. No Ignition not turned on. Turn on ignition.

manually, no electrical Fuse blown Replace fuse. If fuse

power at the control continully blows, a

valve. short circuit has occured

after the fuse.

Seat pad switch not activated Sit on the seat or replace

or faulty. seat pad sensor.

Faulty electrical connection. Trace faulty connection

before the control unit.

6 No electrical operation Is there either battery voltage

of the control valve or a variable voltage (lift/

hydraulics, works o.k. tilt only) coming out of the

manually, electrical controls? Yes See item 7

power entering the No Electrical failure of the Change the controls.

controls controls or a faulty connection Trace the electrical fault

within the control unit. within the control unit.

GS4400,354 -19-01FEB97


PN=191

_


7 No electrical operation of Test the electrical power in

the control valve harness connections from the

hydraulics, works o.k. control unit to the control

manually, electrical power valve. Is there power at each

coming out of the controls connection? Yes Faulty connection between the Repair the connection by

plugs in wiring harness or a replacing the connector pins.

fault in the hurschmann plug Replace the connectors in the

on the control valve. hurschmann plug.

No Fault between that connection

and the control unit, or tilt

lock out switch turned on

(tilt circuit only).

8 Slow control valve Operate a function manually.

hydraulics on all Does the function operate at

functions the correct speed? Yes Servo line pressure Remove the servo pressure

maintenance valve. Inspect,

clean the filter, replace any

faulty parts and refit.

No Hydraulic oil flow low See item 9.

9 Slow control valve Test hydraulic pump flow. Fit

hydraulics on all flow gauge in the pump outlet

functions, still slow and run the engine at high

when operated manually idle. Is the pump flow correct

(81 L/min; 21.4 gal/min)? Yes Compenseting spool partially Remove the compensating

jammed open. spool. Inspect, clean or

replace the inlet section as

required.

See item 13.

No Blocked suction strainer. Clean suction strainer.

Faulty pump. Change the pump.

GS4400,355 -19-01FEB97


PN=192

_


10 One function does not Does the function operate

operate correctly manually? Yes Electrical fault. See item 4, 5, 6 & 7.

Faulty solenoid See item 12

Change The solenoid.

No Flow adjusters set incorrectly. Reset the flow adjusters.

Faulty lock valve (lift, tilt Change the lock valve.

and extension circuits only).

Fault with the function Change the seals.

cylinder seals.

Another function already at Operator fault trying to

full cylinder stroke and operate more than one

relief valve open. function at a time (most

likely auxiliary switch

stuck open).

11 One function only works Does the function work at the

slowly correct speed manually?

Yes Low servo pressure caused by a Remove the control valve

blocked load sense line spool and clean the load

internal to the control valve sense ports within the spool

slice. valve.

Faulty solenoid. Change the solenoid.

Incorrect supply voltage to Find the faulty connection in

the solenoid. the voltage supply.

Leaking load control valve Replace the seals.

seals.

Faulty load control valve. Replace the load control

valve.

Faulty cylinder seals. Replace the cylinder seals.

No Flow adjusters set incorrectly. Reset the flow adjusters.

Faulty lock valve (lift, tilt Change the lock valve.

and extension circuits only).

12 One function does not Swop over a hurschman plug

operate electrically but from one function to another.

does operate correctly NOTE: Function must be of the

manually same type i.e. proportional

or On/Off. Does the fault

move function? Yes Electrical fault See items 4, 5, 6, & 7.

No Solenoid fault Change the solenoid

GS4400,356 -19-01FEB97


PN=193

_


13 Lack of hydraulic power Pressure test the hydraulic

when operating a function circuit by placing a pressure

test gauge in the test port.

Operate the auxiliary function

until the relief valve opens.

Is the pressure correct? Yes See item 9.

No Low relief valve setting. Remove, inspect, clean,

replace any faulty parts,

refit and reset valve.

Faulty pump. Flow test pump. If also low

on flow, replace the pump.

Compensating spool partially Remove the compensating

jammed open. spool, clean, inspect, refit

or replace as required.

Faulty cylinder seals Replace cylinder seals.

14 No power in the tilt/crowd Test as in item 13. If o.k., Faulty safety check valves. Remove the safety check

cylinder to tear out proceed with other possible valves from the valve slice.

material faults. Inspect the valve and seat,

replace if required.

Faulty lock valve. Test lock valve and replace,

if required.

Faulty cylinder seals. Replace cylinder seals.

15 Extension function retracts Faulty safety check valve. Remove the safety check

easily when pushed against valve from the valve slice.

an object without operating Inspect both valve and

the function. seat, replace if required.

Faulty lock valve. Test lock valve and replace,

if required.

Faulty cylinder seals (one way) Replace the cylinder seals.

GS4400,357 -19-01FEB97


PN=194

_


16 Heavy steering Pressure test the steering at

the test port on the priority

valve. Is the pressure correct

(17500 kPa; 175 bar; Yes Check that the steering column Adjust the steering column as

2537.5 psi)? is free to turn i.e. orbitrol required.

valve is returning to neutral.

Test the orbitrol out pressure. See item 17.

No Test main relief valve pressure Replace pump if required.

as in item 13, adjust if

required. If low, also flow

test as in item 9, if o.k . . . . . . . . See item 18

17 Heavy steering, steering Fit a pressure test gauge in

pressure o.k one of the outlet hoses from

the orbitrol to a steering

cylinder. Is the pressure the

same as the steering relief

valve setting? Yes Faulty cylinder seals. Change the cylinder seals

Seized swivel housing in the Strip swivel housings and

axles. lubricate.

Cross line relief valves in Change the orbitrol valve

the orbitrol valve faulty.

No Orbitrol relief valve setting Adjust the relief valve

low.

Internal orbitrol valve Change orbitrol

fault. valve.

18 Low steering pressure, main Steering relief valve setting Remove the plug in the

pump pressure O.K., heavy low. orbitrol covering the relief

steering valve and adjust the relief

valve. If unable to

adjust, replace steering

orbitrol.

GS4400,358 -19-01FEB97


PN=195

_


19 Unable to select anything Test the voltage supply at the

but two wheel steer steer mode valve in either crab

or four wheel steer. Is there

12 V? Yes Faulty solenoid on the steer Change the solenoid.

mode valve.

Steer mode valve stuck in the Change the steer mode valve.

neutral position.

No Check the voltage into the Supply fuse.

steer mode switch. If there Steer mode switch.

is voltage, then the problem Electrical connection between

is the switch or after. wiring harnesses.

If no voltage, the problem

is the supply or the fuse.

20 Machine suffering from Does the steering operate

steer wander when operating correctly otherwise? Yes Faulty steering cylinder seals.

at speed Faulty cross line relief valves.

Faulty orbitrol valve.

No Faulty orbitrol valve.

21 Steering changes mode on its Spring broken in the steer mode Replace the spring or the

own valve. steer mode valve.

Voltage supply to the steer Trace electrical fault.

mode valve being broken when

in either four wheel or crab

steer resulting in the steering

reverting to two wheel steer.

GS4400,359 -19-01FEB97


PN=196

_


22 No brakes - brake low Release all pressure in the

pressure warning light on line by operating the brake

all the time pedal and fit a pressure gauge

into the outlet hose.

Is the pressure correct

(12000 - 15000 kPa; 120 - 150

bar; 1740 - 2175 psi)? Yes See item 23.

No Brake charge valve faulty. Remove the brake charge

valve, clean, inspect. If

faulty, replace the priority

valve.

23 No brakes - brake pressure Release all pressure in the

from the priority valve brake line by operating the

correct. brake pedal. Fit a pressure

gauge into the brake line from

the brake pedal to the axle.

Is the pressure correct

(8500 kPA; 85 bar; 1232.4 Yes Check the level in the Strip the hub and replace

psi)? reduction hubs. If high, piston seals.

brake pistons are leaking

(usually shows as an oil leak

from the hub seal).

Hose burst. Replace hose.

An internal oil leak in the Remove the hub and inspect,

hub. take care to inspect the

small O-ring that supplies

oil to the back of piston.

No Faulty foot brake valve. Replace the foot brake valve.

24 Hydraulics overheating Do all functions work

correctly? Yes Auxiliary spool stuck. Operate function manually

to ensure the spool is

returning to the center

position.

Return line filter blocked. Change the return line

filter.

Steering relief valve faulty. Test the steering pressure

17500 kPa (175 bar;2537.5 psi)

Adjust as required, relief

valve is in the steering

orbitrol.

Auxiliary switch stuck in ON Clean the switch (dust) to

position (also applies to the free the operation or

trailer hitch and trailer tip replace the switch.

functions).

No Function not operating Remove and clean the spool or

correctly, has a stuck spool. replace the function slice.

GS4400,361 -19-01FEB97


PN=197

_


24A Hydraulics overheating Is the engine under load when

everything is in neutral i.e.

is the low idle speed at

approx 800 rpm?

NOTE: Engine speed will only

drop by 50 rpm under hydraulic

stall. Yes A relief valve is opening Test the functions to

either steering, main or determine which relief valve

bypass relief valves. is opening. If it is the

steering relief valve, it

could be that the steering

column is tight not allowing

the orbitrol to return to

neutral.

No A spool must be sticking when Determine which spool is

it is being operated. sticking and clean/replace as

required.

24B Hydraulics overheating Pressure test the hydraulics

with engine running and all

functions in neutral. Is the

stand-by pressure 1000 - 1300

kPa (10 - 13 bar;140.5 - Yes Hydraulics are not operating a Check if line relief valves

188.5 psi)? function causing a relief valve are not opening early.

to open. Check hoses and hose

runs, ensure that when a

function is operated that it

works correctly.

No If higher, a relief valve Remove and inspect the main

is opening early. If test relief valve in the control

equipment is in main control valve, refit and reset.

valve, then the fault is in

that system. If the test Inspect the steering relief

equipment is in the steering valve, refit and reset

system, then the fault is as required. If necessary,

possibly within the steering replace the steering

relief valve. orbitrol.

GS4400,362 -19-01FEB97


PN=198

HYDRAULICS - HYDRAULIC SCHEMATIC

1 37901 Hydraulic tank - 115 l (30.3 gal) 4400 & 135 l (35.6 gal) 4500

2 35394/002 Suction filter - 25 Micron

3 35364/009 Return line filter - 10 Micron absolute

4 37791 Gear pump (37 cm3/rev 4400 & 46 cm3/rev 4500)

5 37792 Priority valve

Brake accumulator flow - 5 l/min (1.32 gal/min) - Cut in/cut out pressure ratio 80 %

6 36329/029 Accumulator pressure switch

7 36387/005 Accumulator - 1 l (0.2642 gal), gas charge pressure 3400 kPa (34 bar)

8 37793 Brake pedal/valve assembly

Pressure setting 8500 kPa (85 bar)

9 40416/001 Brake pressure switch (lights)

10 40416/001 Brake pressure switch (transmission disconnect)

11 37669 & 37670 Front & rear axle

12 31715/002 Steering control pump 125 cm3/rev 4400 & 200 cm3/rev 4500

13 35792/001 Steering valve block (used as a manifold)

14 Integral steering cylinder (in axle)

15 Integral steering cylinder (in axle)

16 40563/003 Steering mode valve

17 38035/001 Main control valve (4 bank standard, 6 bank option)

17A Valve inlet section - open center with pilot supply

17B Lift circuit - 100 l (26.42 gal) spool - proportional

17C Carrier tilt circuit - 100 l (26.42 gal) spool - proportional

17D Boom extension circuit - 100 l (26.2 gal) spool - On/Off

17E Auxiliary circuit - 65 l (17.17 gal) spool - On/Off

17F Option (HY.801) pick-up hitch circuit - 40 l (10.56 gal) spool - On/Off

17G Option (HY.801) trailer tip circuit - 65 l (17.17 gal) spool - On/Off

17H Valve end plate

18 36216 Lift cylinder

18A 37490/003 Load control valve

19 36213 Tilt cylinder


20 36219 Tilt compensating cylinder

21 34497/003 Extension cylinder


22 36598/002 Manual diverter valve - 6 port

23 38008/026 3/8ª quick release coupling

24 35780 Locking cylinders

25 38122 Trailer hitch - hydraulic

26 19914/004 1/2ª quick release coupling

GS4400,363 -19-01FEB97


PN=199


PN=201

Section 80

CHASSIS AND BOOMContents

Page

Group 05ÐRemoval and Repair

Boom removal . . . . . . . . . . . . . . . . . . . 80-05-1

Disassembly . . . . . . . . . . . . . . . . . . . . 80-05-2


PN=242


PN=243

BOOM REMOVAL

AÐPivot pins BÐCompensating cylinder CÐLift cylinder DÐBoom pivot pin

To remove the boom, set the attachment flat on the

floor and shut off the engine. Undo and remove the

hydraulic hoses. Fit plugs to the hydraulic hoses to

prevent oil leakage. Remove the upper lift cylinder

pivot pin and support the cylinder. Using suitable

lifting equipment, support the boom assembly.

Remove the compensating cylinder upper pivot pin

and support the cylinder. Remove the top

boom-to-chassis pivot pin. Lift the boom assembly out

of the chassis.

GS4400,365 -19-01FEB97

Group 05Removal and Repair


PN=202

DISASSEMBLY

AÐExtension cylinder BÐInner boom section CÐFront extension cylinder DÐFront wear pads

pivot pin

To remove the inner boom, extend the inner boom to

full extension. Tilt the carrier until it is possible to

place it upon the floor face down. Remove the front

wear pads fixed to the outer boom. Support the inner

boom section. Remove the boom nose cover. Undo

the steel hoses where they enter the donkey head.

Disconnect the rubber hoses on the changeover

valve. Remove the front extension cylinder pivot pin.

Support the inner boom as shown in figure 2.

Gently reverse the machine until it is possible to

remove the inner boom. To reassemble the boom,

reverse the disassembly procedure. If the wear pads

are being replaced, then replace the wear pads with

the same quantity of shims. As long as the wear

pads have not been adjusted, the setting should be

correct. If, however, the wear pads have been

adjusted, then the distance between the wear pad

and the boom should be 0.5 to 1.0 mm (0.02 to 0.04

in.). Add or subtract shims to ensure this distance is

achieved.

GS4400,366 -19-01FEB97


PN=203

Section 90

OPERATOR'S CABContents

Page

Group 00ÐCab - Disassembly and Reassembly

Cab removal . . . . . . . . . . . . . . . . . . . . 90-00-1

Group 05ÐCab Heater/Cab Seat - Removal

Disassembly of cab heater . . . . . . . . . . 90-05-1

Disassembly and reassembly of cab seat . 90-05-2


PN=244


PN=245

CAB REMOVAL

The cab does not require removal from the machine

unless it needs to be replaced. To remove the cab,

place the machine on firm level ground and fit wheel

chocks under all wheels. Shut off the engine.

Disconnect the negative terminal on the battery.

Disconnect the positive terminal on the battery.

Release all hydraulic pressure in the braking circuit

by operating the brake pedal at least thirty times.

Place a drain tin underneath the cab. Remove the

hoses to the brake pedal valve. Remove the lower

steering column cover from inside the cab. Remove

the steering hoses from the distribution block inside

the cab. Mark each hose to ensure correct

reassembly. Remove the under cab cover by

removing the four retaining screws. Remove the

chassis-to-cab wiring harness connectors underneath

the cab. Remove the cover at the lower front right

hand side of the cab interior covering the wiring

harnesses. Disconnect the cab harnesses inside the

cab and feed them through the opening in the base

of the cab.

Disconnect and remove the wiring harness to the

head/clearance lights. Remove the throttle cable at

the pedal end and remove the cable clamp. Remove

the cable away from the cab underside. Remove the

handbrake cable from the operating lever. Drain the

water from the engine radiator. Remove the cab

heater hoses. Screw in the two lifting eyes as shown

in figure 1. Remove the four cab mounting bolts.

Carefully lift the cab ensuring that none of the cables

or hoses catch on the chassis. To refit the cab,

reverse the removal procedure. Torque the retaining

bolts to 290 N´m (213.7 lb-ft).

GS4400,367 -19-01FEB97

Group 00Cab - Disassembly and Reassembly


PN=204


PN=205

DISASSEMBLY OF CAB HEATER

The cab heater is located underneath the operator's

seat within the cab. The heater controls are located

at the lower right hand side of the heater face cover

and the fan control switch is within the switch panel.

The cab heater system has an air filter which should

be cleaned regularly. If the machine is being used in

very dusty conditions, daily cleaning may be required.

Access to the heater unit is from underneath the

seat. Remove the four seat retaining bolts and lift out

the seat. Remove the seat pan cover plate. The

heater unit can now be removed by unscrewing the

three retaining bolts and lifting the unit out.

GS4400,368 -19-01FEB97

Group 05Cab Heater/Cab Seat - Removal


PN=206

GS4400,369 -19-01FEB97


PN=207

DISASSEMBLY AND REASSEMBLY OF CAB SEAT

Removal of the seat can be achieved by removing

the four bolts retaining the seat to the seat pan. Also

disconnect the wiring harness from the joystick pod to

the rear of the cab. Lift out the seat taking care as

the weight of the seat can make it very awkward to

lift the seat out of the cab.

Repair of the seat

Remove the seat by unscrewing the four retaining

bolts around the seat. Also unplug the joystick wiring

harness and the seat pad safety switch harness.

Remove the clips retaining the rubber boot around

the seat base. Release all the tension on the

suspension springs by unscrewing the adjuster screw.

This will allow the suspension springs to be hooked

off their retaining pins. The shock absorber is

retained in its position by means of two pins and also

two clips on each pin. Remove the clips and extract

the pins.

The seat is fitted with a seat pad safety switch

situated underneath the cushion. It is activated once

the operator is seated. This prevents operation of the

hydraulic system without the operator sitting safely in

the cab. To remove the seat pad switch, unscrew the

two screws on the front face of the seat which retain

the cushion to the seat frame. Lift off the cushion and

remove the cover. Access to the switch is then

possible. To reassemble the seat, reverse the

disassembly procedure.

GS4400,600 -19-01FEB97


PN=208


PN=209

Section 240

ELECTRICAL SYSTEMContents

Page

Group 05ÐSystem Information

Special tools . . . . . . . . . . . . . . . . . . . . 240-05-1

Battery operation . . . . . . . . . . . . . . . . . 240-05-2

Battery troubleshooting . . . . . . . . . . . . . 240-05-3

Battery test . . . . . . . . . . . . . . . . . . . . . 240-05-3

Battery specifications . . . . . . . . . . . . . . 240-05-4

Electrical circuit malfunctions . . . . . . . . . 240-05-4

Open circuit . . . . . . . . . . . . . . . . . . . . 240-05-5

Grounded circuit . . . . . . . . . . . . . . . . . 240-05-6

Shorted circuit . . . . . . . . . . . . . . . . . . . 240-05-7

How to read a functional schematic . . . . . 240-05-8

Symbols in functional schematic, wiring

and harness diagrams . . . . . . . . . . . . 240-05-9

Group 10ÐSystem Diagrams

Fuses . . . . . . . . . . . . . . . . . . . . . . . . 240-10-1

Relays . . . . . . . . . . . . . . . . . . . . . . . . 240-10-2

Connector survey . . . . . . . . . . . . . . . . . 240-10-4

Section designations in functional

schematics . . . . . . . . . . . . . . . . . . . . 240-10-8

Part designations in functional schematics . 240-10-9

Functional schematics . . . . . . . . . . . . . 240-10-10


PN=246


PN=247

SPECIAL OR ESSENTIAL TOOLS

SPECIAL TOOLS

Battery load tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . FKM10409

Battery, checking on

DX,TOOLS -19-20JUL95

LX,24005,002387-19-29JAN92

Group 05System Information


PN=210

BATTERY OPERATION

A battery is a device for converting chemical energy

to electrical energy. It is not a storage tank for

electricity, but stores electrical energy in chemical

form.

Because of the constant chemical to electrical change

(self-discharge, discharge, or charge), the battery has

a limited life. Proper care (cleaning, charging) will

extend the life of the battery.

The battery is made up of positive plates, negative

plates, separators, plate straps, and chemical solution

(electrolyte). The electrolyte is a solution of sulfuric

acid and water. Sulfuric acid is not lost during

overcharging.

In a fully charged battery, the positive plate is lead

peroxide (PBQ2), the negative plate is ªspongyº lead

(Pb), and the electrolyte solution is about 1.270 times

heavier than water. The amount that the solution is

heavier than water is called specific gravity.

All batteries will self discharge at a rate of 0.001

specific gravity point per 24 hour period at a constant

30ÊC (85ÊF). The discharge rate increases as

temperature increases and decreases as temperature

decreases. If the machine is not used for a period of

time, the batteries must be stored fully charged in a

cool place.

Wipe batteries with a damp cloth. If terminals are

corroded, use a stiff brush and wash with an

ammonia solution. After washing, flush battery and

compartment with clear water.

Batteries should be maintained at an open circuit

voltage of 12.4 volts or greater. To determine open

circuit voltage use the following chart.

CHECK OPEN CIRCUIT VOLTAGE FOR STATE OF

CHARGE

STABILIZED OPEN PERCENT CHARGED

CIRCUIT VOLTAGE

12.6 Volts or More 100%

12.4 75%

12.2 50%

12.0 25%

11.7 or less 0%

GS4400,A -19-01JUL97


PN=211

TROUBLESHOOTING ON BATTERY

Symptom Problem Solution

Capacity too low Cable connections loose or Check cable

oxidized; cable defective

Defective regulator Replace regulator

Defective generator See component manual

Excessive water consumption Defective regulator Replace regulator

Battery case cracked Replace battery

Battery not charging Loose or corroded battery Check battery connections

connections

Loose or damaged fan belt Re-tension or replace fan belt

Worn-out battery Replace battery

PROCEDURE FOR TESTING BATTERIES

1. VISUAL CHECK

a. Check for damage such as cracked or broken case

and electrolyte leakage.

If damage is seen, replace battery.

b. Check terminals for corrosion. If corroded, clean

using a wire brush or battery post cleaner.

c. Check terminals for looseness.

If terminals are loose, replace battery.

2. LOAD TEST

a. Check battery capacity with a load tester such as

JT05832 Battery Load Tester. Follow tester

manufacturer's instructions for proper load test

procedures.

If battery fails load test, replace.

GS4400,B -19-01JUL97

GS4400,C -19-01JUL97


PN=212

BATTERY SPECIFICATION

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt

Nominal capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Ah

ELECTRICAL CIRCUIT MALFUNCTIONS

1ÐFuse 2ÐLoad

The four possible circuit malfunctions are:

1. High resistance circuit

2. Open circuit

3. Grounded circuit

4. Shorted circuit

There are only three ªareasº in a simple electrical

circuit where circuit malfunction can occur (see simple

circuit above).

1. Before the controlling switch (A)

2. After the controlling switch but before the load (B)

3. After the load (C)

Component malfunctions can easily be confused with

circuit malfunctions. Caution must therefore be

exercised when isolating the cause of the problem.

Example: A component may not operate before an

electrical connection is disconnected, but it operates

when the connector is reconnected.

Reason: High resistance in the circuit created a

voltage drop at the connector terminals, preventing

the proper amount of current from flowing to the

component.

GS4400,D -19-01JUL97

ZX,TMSPFH000377-19-22JUL91


PN=213

OPEN CIRCUIT

AÐVoltage Source CÐComponent Terminal EÐOpen Circuit GÐLoad

BÐControlling Switch DÐHigh Resistance Circuit FÐComponent Terminal HÐGround

A high resistance circuit can result in slow, dim or no

component operation (i.e. loose, corroded, dirty or

oily terminals, gauge of wire too small or broken

strands in cable).

An open circuit results in no component operation, as

the circuit is incomplete (E) (i.e. broken wire,

terminals disconnected, open protection device or

switch).

Test for a high resistance circuit (D) or an open

circuit (E) as follows:

1. With controlling switch (B) closed and load (G)

connected, check for proper voltage at an easily

accessible location between (C) and (F).

a. If voltage is low, move toward voltage source (A)

to locate point of voltage drop.

b. If voltage is correct, move toward load (G) and

ground terminal (H) to locate point of voltage drop.

2. Repair circuit as required.

3. Repeat operational check after completing the

repair.



PN=214

GROUNDED CIRCUIT

AÐComponent Terminal CÐControlling Switch EÐGrounded Circuit GÐLoad

BÐComponent Terminal DÐComponent Terminal FÐComponent Terminal HÐComponent Terminal

A grounded circuit results in no component operation

and the fuse will blow (i.e. power wire to ground).

Test for a grounded circuit (E) as follows:

1. Controlling switch (C) open, fuse not blown.

a. If there is continuity, there is a grounded circuit

between (B) and (C).

b. No continuity, go to 2.

2. Disconnect load (G) at (F).

3. With controlling switch (C) open, check for

continuity to ground between (D) and (H).

If there is continuity, there is a grounded circuit

between (D) and (H).

4. Repair circuit as required.


repair.



PN=215

SHORTED CIRCUIT

AÐComponent Terminal DÐComponent Terminal FÐLoad-type Component HÐControlling Switch

BÐCircuit Connector EÐLoad-type Component GÐSwitch IÐShorted Circuit

CÐCircuit Connector

A shorted circuit usually results in two components

operating when one of the switches is closed

(i.e. improper wire-to-wire contact).

Test for a shorted (I) or improperly wired circuit as

follows:

1. Turn on switch (G) for correct component (F) to

operate.

2. Start at controlling switch (H) of component (E)

which should not be operating and disconnect wire at

terminal (A).

3. Follow circuit and disconnect wire at connectors

(B, C or D) until component ceases to operate.

4. The shorted circuit or improper connection will be

between the last two locations at which the wire was

disconnected. In the example above, between (B) and

(C).

5. Repair circuit:

a. Wires not in a loom: Wrap individual wires with

electrical tape and band as required.

b. Wires in a loom: If hot spots exist in the shorted

area of harness, replace harness. If hot spots are not

noticeable, install a new wire of proper gauge

between last two connections. Tape wire to outside of

harness.


repair.



PN=216

HOW TO READ A FUNCTIONAL SCHEMATIC

A-Power supply wires:

ÐWire 012 (terminal 30), battery

ÐWire 022 (terminal 15), ignition

ÐWire 212 (terminal 54), not supplied with power

during engine starting

ÐWire 072 (ELX), power supply for electronics

ÐWire 202 (ACC), power supply for accessories

The functional schematic is divided into functional

sections. The part designations, wire numbers and

symbols are identical with the corresponding data in

the wiring and harness diagram. Switches and relays

are shown in ªOFFº position.

B-Wire or cable number

C-Part designation

D-Section designation

E-Section to which cable is routed

F-Wire 310 (terminal 31), ground

LX,24005,003962-19-01MAR93


PN=217

SYMBOLS IN FUNCTIONAL SCHEMATIC, WIRING AND HARNESS DIAGRAMS

AÐAlternator with rectifier EÐBattery IÐRadio NÐSwitch, actuated by

and regulator FÐFuse KÐLoudspeaker pressure

BÐStarting motor with GÐBulb with one luminous LÐHorn OÐSwitch, actuated by

solenoid element MÐValve, operated temperature

CÐFuel pump HÐBulb with two luminous electro-mechanically PÐVariable resistor

DÐCompressor elements

LX,24005,002399-19-29JAN92


PN=218

SYMBOLS IN FUNCTIONAL SCHEMATIC, WIRING AND HARNESS DIAGRAMS

AÐElectric clutch FÐMechanical switch IÐHall sending unit NÐCoolant/fuel gauge

BÐWindshield wiper motor (microswitch) KÐResistor OÐBattery ground

CÐBuzzer GÐDiode LÐEngine speed meter PÐCable ground

DÐMechanical switch HÐSensor MÐTachometer QÐVehicle ground

EÐCenter-zero relay

LX,24005,002400-19-29JAN92


PN=219

FUSES

IMPORTANT: To prevent unnecessary damage to the

electrical system, never use a fuse with

a higher rating than the one already

installed.

No. Amps Circuit

1 15 Starter circuit; transmission disconnect;

brake lights; K2 relay

2 7.5 Clearance lights; rear lights; instrument

lighting; dome light; K9 relay

3 15 Gauges; indicator lights

4 15 Head lights (high beam)

5 15 Head lights (low beam); fog lights

6 15 Overload system; speedometer

7 15 Work light

8 15 Beacon light; hazard warning lights

9 15 Brake disconnect; K1 relay

10 7.5 Four wheel drive; steering mode;

fuel shut-off; F-N-R solenoid

11 15 Seat switch (hydr. multi-function lever)

12 10 Turn signal lights

13 10 Front wipers/washer; horn

14 10 Blower

15 10 Rear and roof wipers/washers

GS4400,E -19-01JUL97

Group 10System Diagrams


PN=220

RELAYS (LOADERS WITH TWO EXTERNALRELAYS)

No. Designation

K1 Brake disconnect relay

K2 Transmission disconnect relay

K3 Starter relay

K4 Starting aid relay

K5 Ignition relay

K6 Reverse clutch relay

K7 Turn signal relay

K8 Forward clutch relay

K9 Head light relay

GS2001 -UN-12SEP97

No. Designation

K10 External starting motor relay

K11 External starting aid relay

GS4400,F -19-01JUL97


PN=221

RELAYS (LOADERS WITH THREEEXTERNAL RELAYS)

No. Designation

K1 Brake disconnect relay

K2 Transmission disconnect relay

K3 Starter relay

K5 Ignition relay

K6 Reverse clutch relay

K7 Turn signal relay

K8 Forward clutch relay

K9 Head light relay

No. Designation

K4 Starting aid relay

K10 External starting motor relay

K11 External starting aid relay

GS4400,G -19-01JUL97


PN=222

CONNECTOR SURVEY

CONNECTOR PIN COLOUR CIRCUIT

Engine harness to A Brown Battery positive

chassis harness B Brown Battery positive

C White/red Starter solenoid relay exciter wire

D Brown/red Glow plug relay exciter wire

E Black Ground (only used in engine harness)

F Black Ground (only used in engine harness)

G Black Ground

H Black Ground

I to L Not used

1 Orange Load indicator pin 1

2 Yellow Load indicator pin 2

3 Grey Load indicator pin 3

4 Green Fuel shut off solenoid

5 Green/blue Water temperature sender

(changes to light green/blue)

6 Brown/black Alternator exciter wire

7 Green/black Transmission oil temperature sender

8 Brown/white Engine oil pressure switch

9 Yellow/black Transmission oil temperature switch

10 to 19 Not used

Chassis harness to 1 Blue/yellow Trailer tip

rear cab harness 2 Blue/black Auxiliary

3 Blue/red Tilt - variable voltage

4 Blue/green Extension

5 Blue Lift - variable voltage

6 Black/rose Pick up hitch

7 White/black Auxiliary

8 Brown/green Extension

9 Red/black Pick up hitch

10 Brown/orange Lift/tilt - 12 volts

11 Brown/yellow Trailer tip

12 Blue/rose Beacon light

13 Brown/green Top wiper

14 Green/blue Rear window washer

15 Green/brown Rear worklight

16 Orange Load indicator

17 Yellow Load indicator

18 Green/black Rear wiper

19 Yellow Speaker

A Red Heater terminal 3

B Brown Seat switch

C Yellow Heater terminal 2

D Black Ground

E Blue/yellow Front worklight

F Blue Speaker

G Grey Speaker

H Orange/red Load indicator

I Brown/orange Interior light

J Grey Speaker

K Black/pink Handbrake

L Green/grey Front washer

GS4400,602 -19-10SEP97


PN=223

CONNECTOR SURVEY (CONTINUED)


Rear cab to joystick 1 Blue/red Tilt - variable voltage

harness - cab harness 2 Brown/orange Lift/tilt - 12 volts

end 3 Blue Lift - variable voltage


5 Blue/yellow Trailer tip


7 Blue/black Auxiliary

8 Black/rose Pick up hitch

9 Brown/yellow Trailer tip


11 White/black Auxiliary

12 Black Ground

13 Not used

14 Brown Seat switch

Chassis harness to 1 Not used

control valve 2 Black Ground

harness - connector 3 Not used

on the chassis 4 White/black Not used

harness 5 Brown/yellow Trailer tip

6 Black/pink Pick up hitch


8 Blue/black Auxiliary

9 Blue/yellow Trailer tip



12 Blue/red Tilt - variable voltage

13 Brown/orange Lift/tilt - 12 volts

14 Blue Lift - variable voltage

GS4400,603 -19-10SEP97


PN=224



Chassis harness to 1 Not used

control valve 2 Black Ground

harness - connector 3 Not used

on control valve 4 Brown/green Auxiliary

harness 5 Black/pink Trailer tip

6 Brown/yellow Pick up hitch

7 White/black Extension

8 Blue/green Auxiliary

9 Red/black Trailer tip

10 Blue/yellow Pick up hitch

11 Blue/black Extension

12 Blue Tilt - variable voltage

13 Brown/orange Lift - 12 volts

14 Blue/red Lift - variable voltage

Chassis harness to Yellow/red Changes to yellow/black to gear lever

gear lever harness Green Changes to yellow/black to gear lever

Chassis harness to 1 Red/black Clearance light

right-hand lights 2 Black Ground

3 Green/red Indicator

4 Green/grey Stop light

5 Red/brown Fog light

6 Green/brown Reverse alarm

7 Not used

Chassis harness to 1 Red/white Clearance light

left-hand lights (changes to red/black wire in

light harness)

2 Black Ground

3 Green/red Indicator

4 Green/grey Stop light



7 Not used

GS4400,604 -19-10SEP97


PN=225



Chassis harness to 1 Orange/red Brake disconnect relay

panel harness 2 Yellow Brake pressure warning light switch

3 Red/black Not used

4 Brown/white Engine oil pressure warning light

5 Black/blue Four wheel drive

6 Light green/

blue Engine coolant temperature

7 Brown/black Alternator indicator light

8 Yellow/black Transmission oil temperature warning light

9 Green/black Transmission oil temperature sender

(gauge)

10 Green/grey Transmission oil pressure gauge

11 Green/red Not used

12 Green/brown Fuel gauge

13 Black/white Reverse solenoid

14 Black/green Forward solenoid

15 Brown/yellow Transmission oil pressure warning light

16 Purple/black Horn

17 Yellow/red Brake disconnect relay

18 Black/pink Speedometer

19 Green Engine stop solenoid

A Brown Battery positive

B Brown Battery positive

C White/red Starter relay

D Brown/red Glow plug

E to L Not used

GS4400,605 -19-10SEP97


PN=226



Chassis harness to 1 Black/rose Handbrake switch (changes to black/pink)

panel harness 2 Light green/

(red stripe) blue Rear window washer

3 Light green/

black Rear wiper

4 Blue/rose Beacon light

5 Brown/green Top wiper


7 Green Gear lever switch

8 Yellow/red Transmission disconnect

9 Green/red Left-hand indicator

10 Green/white Right-hand indicator

11 Green/grey Front washer

12 Green/brown Reverse light


14 White/grey Four wheel steering

15 White/blue Crab steering

16 Blue Speaker

17 Grey Speaker

18 Yellow Speaker

19 Brown/orange Interior light

A Yellow Heater

B Yellow Heater

C Brown/red Joystick feed

D Green Not used

E Blue/yellow Front worklights

F Blue/red Low beam headlights

G White/green Full beam headlights

H Red/black Clearance lights

I Not used

J Grey/black Seat switch

K to L Not used

SECTION DESIGNATIONS IN FUNCTIONAL SCHEMATICS

SE1 Ð Starting motor and charging circuit

SE2 Ð Ignition relay

SE3 Ð Instrument and control circuit

SE4 Ð Steering circuit

SE5 Ð Stop lights, wiper/washer and drive train

shut-off circuit

SE6 Ð Light circuit

SE7 Ð Flasher circuit

SE8 Ð Hydraulic function, beacon and front

worklight circuit

SE9 Ð Load indicator circuit

SE10 Ð Blower, horn, and front wiper/washer circuit

GS4400,606 -19-10SEP97

GS4400,H -19-01JUL97


PN=227

PART DESIGNATIONS IN FUNCTIONAL SCHEMATICS

B01 Ð Sending unit, transm. oil temperature

gauge (SE3)

B02 Ð Sending unit, transm. oil pressure

gauge (SE3)

B03 Ð Sending unit, fuel gauge (SE3)

B04 Ð Sending unit, coolant temperature

gauge(SE3)

B05 Ð Sending unit, speedometer (SE3)

B06 Ð Sending unit, load indicator (SE9)

B07 Ð Sending unit, handbrake indicator

light (SE3)

B08 Ð Sending unit, engine oil pressure indicator

light (SE3)

B09 Ð Sending unit; transmission oil pressure

indicator light (SE3)

B10 Ð Sending unit, transmission oil temperature


B11 Ð Sending unit, brake oil pressure


B12 Ð Sending unit, full beam indicator

light (SE3)

E01 Ð Transmission oil pressure


E02 Ð Transmission oil temperature


E03 Ð Brake oil pressure indicator light (SE3)

E04 Ð Reverse lights (SE4)

E05 Ð Top rear work light (SE4)

E06 Ð Reverse alarm (SE4)

E07 Ð Instrument lighting (SE6)

E08 Ð Dome light (SE6)

E09 Ð Clearance light, left (SE6)

E10 Ð Clearance light, right (SE6)

E11 Ð Tail lights (SE6)

E12 Ð Fog lights (SE6)

E13 Ð Low beam headlights (SE6)

E14 Ð High beam headlights (SE6)

E15 Ð Front work lights (SE8)

E16 Ð Horn (SE10)

F01 Ð Starter circuit; transmission disconnect;

brake lights; K2 relay

F02 Ð Clearance lights; rear lights; instrument

lighting; dome light; K9 relay

F03 Ð Gauges; indicator lights

F04 Ð Head lights (high beam)

F05 Ð Head lights (low beam); fog lights

F06 Ð Overload system; speedometer

F07 Ð Work light

F08 Ð Beacon light; hazard warning lights

F09 Ð Brake disconnect; K1 relay

F10 Ð Four wheel drive; steering mode;

fuel shut-off; F-N-R solenoid

F11 Ð Seat switch (hydr. multi-function lever)

F12 Ð Turn signal lights

F13 Ð Front wipers/washer; horn

F14 Ð Blower

F15 Ð Rear and roof wipers/washers

G01 Ð Battery (SE1)

G02 Ð Alternator (SE1)

H01 Ð Handbrake indicator light (SE3)

H02 Ð Engine oil pressure indicator light (SE3)

H03 Ð Alternator indicator light (SE3)

H04 Ð Full beam indicator light (SE3)

H05 Ð Turn signal and hazard warning


H06 Ð Turn signal light, left (SE7)

H07 Ð Turn signal light, right (SE7)

H08 Ð Beacon light (SE8)

H09 Ð Stop lights (SE5)

K01 Ð Brake disconnect relay (SE5)

K02 Ð Transmission disconnect relay (SE5)

K03 Ð Starter relay (SE1)

K04 Ð Starting aid relay (SE1)

K05 Ð Ignition relay (SE2)

K06 Ð Reverse clutch relay (SE4)

K07 Ð Turn signal relay (SE7)

K08 Ð Forward clutch relay (SE4)

K09 Ð Head light relay (SE6)

K10 Ð External starting motor relay (SE1)

K11 Ð External starting aid relay (SE1)

M01 Ð Starting motor (SE1)

M02 Ð Rear wiper motor (SE5)

M03 Ð Rear washer pump motor (SE5)

M04 Ð Front wiper motor (SE10)

M05 Ð Front washer pump motor (SE10)

M06 Ð Blower motor (SE10)

M07 Ð Optional top wiper motor (SE5)

P01 Ð Transmission oil temperature gauge (SE3)

P02 Ð Transmission oil pressure gauge (SE3)

P03 Ð Fuel gauge (SE3)

P04 Ð Coolant temperature gauge (SE3)

P05 Ð Speedometer (SE3)

P06 Ð Load indicator (SE9)

R01 Ð Electric starting aid glow plug (SE1)

S01 Ð Main switch (SE1)

S02 Ð Four wheel drive shut-off switch (SE4)

S03 Ð Four wheel drive switch (SE4)

S04 Ð Steering mode switch (SE4)

S05 Ð Handbrake switch (SE4)

S06 Ð Gear lever switch (SE5)

S07 Ð Stop light switch (SE5)

S08 Ð Rear wiper switch (SE5)

S09 Ð Optional top wiper switch (SE5)

S10 Ð Rear washer switch (SE5)

S11 Ð Brake disconnect switch (SE5)

S12 Ð Brake override switch (SE5)

S13 Ð Light switch (SE6)

S14 Ð Combination switch (SE6)

S15 Ð Fog light switch (SE6)

S16 Ð Hazard warning light switch (SE7)

S17 Ð Seat switch (SE8)

S18 Ð Beacon light switch (SE8)

S19 Ð Front work light switch (SE8)

S20 Ð Blower switch (SE10)

S21 Ð Front washer switch (SE10)

S22 Ð Front wiper switch (SE10)

Y01 Ð Engine stop solenoid valve (SE4)

Y02 Ð Front wheel drive solenoid valve (SE4)

Y03 Ð Steering solenoid valve (SE4)

Y04 Ð Reverse drive solenoid valve (SE4)

Y05 Ð Forward drive solenoid (SE4)

GS4400,J -19-01JUL97


PN=228


PN=233

Page

BBattery specification . . . . . . . . . . . . . . . 240-05-4

Battery test . . . . . . . . . . . . . . . . . . . . . 240-05-3

Battery, operation . . . . . . . . . . . . . . . . . 240-05-2

Battery, troubleshooting . . . . . . . . . . . . . 240-05-3

EElectrical system

General information . . . . . . . . . . . . . . 240-05-4

FFunctional schematic

Part designations . . . . . . . . . . . . . . . 240-10-9

Section designations . . . . . . . . . . . . . 240-10-8

Functional schematics . . . . . 240-10-10, 240-10-11,

240-10-12, 240-10-13

Fuses . . . . . . . . . . . . . . . . . . . . . . . . 240-10-1

PPart designations in functional schematic . 240-10-9

R

Relays . . . . . . . . . . . . . . . . . 240-10-2, 240-10-3

SSection designations in funct. schematics . 240-10-8

Special tools . . . . . . . . . . . . . . . . . . . . 240-05-1

Index

Index-1 230101

PN=250

Index-2 230101

PN=251

johndeere tm4541 technical manual

Documents

telescopic handlers230101pn

safetyalert symbol

cab disassembly

safety informationsection

safety informationthis

safety messages

23jan01contentstm4541

248tm4541 23jan01