HM D 23000 Series Transmission - Synergy Industries

HM D 23000 SeriesTransmissionCOMPONENT TECHNICALMANUALHMO 23000 Series Service ManualCTM201 1OMAY05 (ENGLISH)John Deere Power SystemsLITHO IN U.S.A.- a () N-::;:- f-

IntroductionForewordThis manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.AThis is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable essential tools, service equipment and tools,other materials needed to do the job, specifications,wear tolerances, and torque values.Component Technical Manuals (CTM) are conciseguides for specific machines. They are on-the-jobguides containing only the vital information needed fordiagnosis, analysis, testing, and repair.DX.TMIFC-19-22MAY92-1/1Warning TagNOTE: This service manual contains data referred to bywarning tag on each transmission.The above tag is attached to each unit when it is shipped.It is for your protection and should not be removed untilthe unit has been properly serviced under the instructionsof this manual.II.DO NOTl ERATETHIS TRANSMISION DOESI NOT CONTAIN LUBRICATION.TO PREVENT DAMAGE, FILLWITH OIL WHICH MEETSOR EXCEEDS EP GEARLUBRICATION SPECMfL L-2105C OR APICLASSIFICATION GL-5PER RECOMMENDATIONSOUTLINED IN SERVICEMANUAL"'"'.009z::iIWarning TagDPSG,YZ07927,196 -19-28SEP99-1/1CTM201 (10MAY05)HMD 23000 Series Transmission051105PN ?

ContentsHMO 23000 TransmissionGroup 05-SafetyGroup 10-General InformationGroup 15-Major Component GroupsGroup 25-lnput Adapter GroupGroup 30-Shift Cap GroupGroup 20-Gear and Case GroupGroup 45-Brake AssemblyAll information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.COPYRIGHT 1999, 2005DEERE & COMPANYMoline, IllinoisAll rights reservedA John Deere ILLUSTRUCTION" ManualCTM201 (1 OMA Y05)HMO 23000 Series Transmission051105PN 1

HMO 23000 TransmissionContentsPageGroup 05-Safety . 05-1Group 10-General InformationSpecification . .' . 10-1Abbreviations and Acronyms . 10-1Parts Ordering Instructions . 10-2Description . 10-2Operation . 10-3Rules of Operation . 10-3Service . 10-4Extended Storage . 10-5Installation Side View . 10-6lnstallationRear View . 10-7Metric Bolt And Cap Screw Torque Values . 10-8Unified Inch And Cap Screw Torque Values . 10-9Suggested Wrenching Torque For TaperedPipe Thread 1 . 10-10Group 15-Major Component GroupsOther Materials . 15-1Specifications . 15-1HMD23000 Major Component Groups . 15-2Group 25-lnput Adapter GroupRemove and Assemble Input AdapterAssembly . 25-1Group 30-Shift Cap GroupShift Cap Assembly (Locking) . 30-2Shift Cap Assembly (Non-Locking) . 30-4Shift Cap Group . 30-6Group 20-Gear and Case GroupGear and CaseMocte1 2355 . 20-2Gear and CaseMocte12315, 2325, 2325 . 20-4Group 45-Brake AssemblyBrake Assembly and Adjustment . 45-2CTM201 (10MAY05)1HMO 23000 Series Transmission051105PN 1

Group 05SafetyRecognize Safety InformationThis is a safety-alert symbol. When you see this symbolon your machine or in this manual, be alert to thepotential for personal injury.Follow recommended precautions and safe operatingpractices.DX.ALERT -19-07DEC88-1 /1Prepare for EmergenciesBe 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.roro('):: ')'z:: IDX.FIRE2 -19-03MAR93-1/1Wear Protective ClothingWear close fitting clothing and safety equipmentappropriate to the job.Prolonged exposure to loud noise can cause impairmentor loss of hearing.roro('):: Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises. :: IOperating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.DX.WEAR -19-10SEP90-1/1CTM201 (1 OMAY05)05-1HMD 23000 Series Transmission051105PN 7

SafetyWork In Ventilated AreaEngine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.cocoC!JIf you do not have an exhaust pipe extension, open thedoors and get outside air into the area.:::: z:::: I0NN(fJI-DX.AIR-19-23AUGBB-1/1Work in Clean AreaBefore 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 -1/1Illuminate Work Area SafelyIlluminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.cocoC!J:::: C")')'z:::: IC")NN(fJI-DX.LIGHT -19-o4JUN90-1/1Use Proper Lifting EquipmentLifting heavy components incorrectly can cause severeinjury or machine damage.Follow recommended procedure for removal andinstallation of components in the manual.cocoC!J:::: ;;;')'z:::: I ! NN(fJ1-Dx:uFT -19-o4JUN90-1/1CTM201 (10MAY05)05-2HMD 23000 Series Transmission051105PN 8

SafetyUse Proper ToolsUse tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.Use power tools only to loosen threaded parts andfasteners.O X 0z X For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches. :::: IUse only service parts meeting John Deere specifications.DX.REPAIR-19-04JUN90-1/1Using Special ToolsFaulty or broken tools can result in serious injury. Whenconstructing tools, use proper, quality materials and goodworkmanship.Do not weld tools unless you have the proper equipmentand experience to perform the job.O ' tto0x JSpecial ToolsDPSG,YZ07927,121CTM201 (10MAY05)05-3-19-06JUL99-1/1HMO 23000 Series Transmission051105PN 9

SafetySupport Machine ProperlyAlways lower the attachment or implement to the groundbefore you work on the machine. If you must work on alifted machine or attachment, securely support themachine or attachment.Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do notwork under a machine that is supported solely by a jack.Follow recommended procedures in this manual."'"'"'(/)f-DX.LOWER-19--04JUN90-1/1Handle Fluids Safely-Avoid FiresWhen you work around fuel, do not smoke or work nearheaters or other fire hazards.Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.coco(.'):::i {"''l'Make sure machine is clean of trash, grease, and debris.z:::iI,.Do not store oily rags; they can ignite and burnspontaneously."'"'(/)f-DX.FLAME -19--04JUN90-1/1Prevent Battery ExplosionsKeep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.coco(.')::: {"'Do not charge a frozen battery; it may explode. Warmbattery to 16 C (60 F). :::iI""'f0(/)DX.SPARKSCTM201 (10MAY05)05-4-19--03MAR93-1 /1HMO 23000 Series Transmission051105PN rn

SafetyPrevent Acid BurnsSulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.Avoid the hazard by:1.2.3.4.5.Filling batteries in a well-ventilated area.Wearing eye protection and rubber gloves.Avoiding breathing fumes when electrolyte is added.Avoiding spilling or dripping electrolyte.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 15-30 minutes. Getmedical attention immediately.roroIf acid is swallowed:('):: ("''z1'1. Do not induce vomiting.2. Drink large amounts of water or milk, but do notexceed 2 L (2 quarts).3. Get medical attention immediately.:: IDX.POISON-19-21APR93-1/1Avoid Heating Near Press.Urized Fluid LinesFlammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines can beaccidentally cut when heat goes beyond the immediateflame area.0"'I"' - (::;;zl'DX. TORCH -19-03MAR93-1/1CTM201 (1 OMAY05)05-5HMD 23000 Series Transmission051105PN 11

SafetyAvoid High-Pressure FluidsEscaping fluid under pressure can penetrate the skincausing serious injury.Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.iiixIf an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.DX.FLUID-19-03MAR93-1/1Live With SafetyeBefore returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields. SAFETYlive with itDX.LIVECTM201 (10MAY05)05-6-19-25SEP92-1/1HMD 23000 Series Transmission051105PN 12

Group 10General onMaximum operating oiltemperatureTemperature107 C (225 F)OilFirst time fillApproximately 3 quartsOil typeRecommended LubricantsMust conform to MIL-L-2105C orAPl-GL-5 specificationsOil changeFirst timeNormal operating conditionsAfter 500 hoursEvery six months of operationAmbient temperature23 C (10 F)75WAmbient temperature-22 C-37 C (-10 F-100 F)80W-90WAmbient temperatureAbove 37 C (Above 100 F)85W-140WInput adapter capscrew-to-housingTorque144 N m (106 lb-ft.)Oil SpecificationsDPSG,YZ07927, 181-19-24SEP99-1/1Abbreviations and Acronyms CTM: Component Technical Manual HMO: Hydraulic Motor Driven Attn.: Attention Spec: Specification C: Degrees Celsius. 1 unit is 1/100th of the differencebetween the temperature of melting ice and boilingwater at standard temperature and pressure. F: Degrees Fahrenheit. 1 unit is 1/80th of thedifference between the temperature of melting ice andboiling water at standard temperature and pressure. FEPM: Funk Engineering Procedures Manual RTV: Room Temperature VulcanizingDPSG,YZ07927,209 -19-200CT99-1/1CTM201 (10MAY05)10-1HMO 23000 Series Transmission051105PN 13

General Information Parts Ordering InstructionsShould repair parts be required, please specify the model,specification and serial numbers of your unit as well asthe name and number of the parts accompanying yourpurchase order.MODELOsPEcThis information tag is attached to your unit. o !: I"'"' ('-I----------''SERIALCOFFEYVILLE. KANSAS U.S.A.You may write to: Funk Manufacturing CompanyAttn.: Parts DepartmentIndustrial Park, Hwy. 169 N.P.O. Box 577Coffeyville, KS 67337-0577::;;9z::::lIIdentification Tagor Telephone: Area Code (316) 251-3400 or 800-844-1337Ask for Customer Service Representative.Fax: (316) 252-3252DPSG,YZ07927,195 -19-28SEP99-1/1DescriptionThe series 23000 is a three or four speednon-syncronized, mechanical shift transmission. Thegear ranges are selected by means of sliding shiftcollars.The power from the engine is transmitted to the series23000 by means of drive line components or ahydrostatic transmission.DPSG, YZ07927, 182 -19-24SEP99-1/1CTM201 (1 OMA Y05)10-2HMD 23000 Series Transmission051105PN 14