Control system, reconditioning

Op nbr

Total procedure time (hr): NaN

For check-measuring the control system's electric components and cable harness, see Check-measuring electric components.

Figure 1

Pos. Designation Pos. Designation

1 Cover 4 Lubrication oil section
2 Oil distributor plate 5 Cover
3 Main pressure section 6 Gear selector section

Main pressure section, dismantling

Figure 2
1. Main pressure section
2. Main pressure valve (MP)
3. Plugs
4. Pressure limiting valve for torque converter (CR)

1. Pressure limiting valve for torque converter (CR), removing

Place the control system on wooden blocks with the PWM-valves facing down.
NOTE!
Work carefully so that the cable connections for the PWM-valves are not damaged.
Weight, control system: approx. 16 kg (35.3 lbs)

Figure 3

1. Pressure limiting valve (CR)

2. Remove the pressure limiting valve (CR).

3. Remove the O-rings and the back-up rings from the grooves in the pressure limiting valve (CR).

Figure 4

1. Pressure limiting valve (CR)

2. O–ring
3. Back-up ring

4. Press down the slide in the valve and blow clean.

 Figure 5

5. Clean and check the parts for damage and wear. Punch marks and scratches are not permitted. No rust is permitted on
machined surfaces on valve slides and on the valve housings' side holes.
Change parts if needed.

6. Lube the valve slide with transmission oil (see operator's manual).

7. Install new O-rings and back-up rings.

Figure 6

1. Pressure limiting valve (CR)

2. O–ring
3. Back-up ring

8. Main pressure valve (MP), removing

Remove the main pressure valve (MP).

Figure 7

1. Main pressure valve (MP)

 9. Remove the O-rings and the back-up rings from the grooves in the main pressure valve.

Figure 8

1. Main pressure valve (MP)

2. O–ring
3. Back-up ring

10. Press down the slide in the valve and blow clean.

Figure 9

11. Clean and check the parts for damage and wear. Punch marks and scratches are not permitted. No rust is permitted on
machined surfaces on valve slides and on the valve housings' side holes.
Change parts if needed.

12. Install new O-rings and back-up rings.

Figure 10

1. Main pressure valve

2. O–ring
3. Back-up ring
13. Main pressure section, removing
Remove the plugs on the main pressure section.

Figure 11

1. Plug

14. Remove the bolts that hold the main pressure section.
NOTE!
The cover on the opposite side of the control system is held by the same bolts that hold the main pressure section.
Therefore the cover releases when the bolts are loosened.

Figure 12

= M8x40 (1.57 in)

= M8x60 (2.36 in)

15. Remove the main pressure section and the cover from the oil distribution plate.
 Figure 13

1. Main pressure section

2. Cover
3. Oil distributor plate

16. Clean and check the parts for damage and wear. Punch marks and scratches are not permitted. No rust is permitted on
machined surfaces or on the valve housings' side holes.
Change parts if needed.

Figure 14

Pos. Designation Pos. Designation

1 Lubrication oil pressure section 4 Washer
2 Spring 5 Plug
3 Piston

Lubrication oil pressure section, dismantling

17. Valve, lubrication oil pressure (LRV), removing

Remove the plug for the lubrication oil pressure valve.
NOTE!
There is a spring-loaded piston behind the plug.
 Figure 15

= M8x60 (2.36 in)

1. Lubrication oil pressure section

2. Spring
3. Piston
4. Washer
5. Plug

18. Remove the piston.

19. Remove the bolts that hold the lubrication oil pressure section.
NOTE!
The cover on the opposite side of the control system is held by the same bolts that hold the lubrication oil pressure
section. Therefore the cover releases when the bolts are loosened.

20. Remove the lubrication oil pressure section and the cover from the oil distribution plate.

Figure 16
 1. Lubrication oil pressure section
2. Oil distributor plate
3. Cover

21. Clean and check the parts for damage and wear. Punch marks and scratches are not permitted. No rust is permitted on
machined surfaces on valve slides and on the valve housings' side holes.
Change parts if needed.

Figure 17

1. Gear selector valve

2. Pilot valve PWM4201, control of main pressure (CVMP)
3. Gear selector section
4. SE4214 monitor, oil pressure transmission (PL)

Gear selector section, dismantling

22. Gear selector section, removing

Loosen the bolts that hold together the oil distributor plate and the gear selector section.

Figure 18
 = M8x40 (1.57 in)

23. Part the oil distribution plate and the gear selector section.

Figure 19

1. Oil distributor plate

2. Gear selector section

24. Clean and check the parts, see General repair instructions
Change parts if needed.

25. SE4214 monitor, oil pressure transmission (PL), removing

Check function of SE4214, monitor oil pressure transmission (PL), see applicable parts of Check-measuring electric
components.

Figure 20

1. SE4214 monitor, oil pressure transmission (PL)

26. Loosen and remove SE4214 monitor oil pressure from the gear selector section.

27. Clean and check the parts, see General repair instructions
Change parts if needed.

28. Blow clean the seat for the pressure monitor with compressed air.
 Figure 21

29. Pilot valve PWM4201, control of main pressure (CVMP), removing

Check function of pilot valve PWM4201, control of main pressure (CVMP), see applicable parts of Check-measuring
electric components.

Figure 22

1. Lock nut
2. Spool
3. Pilot valve PWM4201, control of main pressure (CVMP)

30. Remove the lock nut for the spool for pilot valve PWM4201.

31. Remove the spool.

32. Remove the pilot valve.

33. Clean and check the parts for damage and wear, see General repair instructions. Punch marks and scratches are not
permitted. No rust is permitted on machined surfaces on valve slides and on the valve housings' side holes.
Change parts if needed.

34. Blow clean the seat for the pilot valve with compressed air.
 Figure 23

35. Clean and check the parts, see General repair instructions
Change parts if needed.

36. Gear selector valves, removing

Check the function of PWM4203 and the gear selector valves PWM4205 – PWM42012, see Check-measuring electric
components.

Figure 24

1. Gear selector valve

37. Remove the gear selector valves.

38. Blow clean the valve seats with compressed air.

Figure 25

39. Clean and check the parts, see General repair instructions.
Change parts if needed.
 40. Change the O-rings on the gear selector valves.

Figure 26

1. Gear selector valve

2. O–ring

NOTE!
Lube all valve slides with transmission oil before installing (see operator's manual).
Control system, assembling
Gear selector section, assembling

41. Install the gear selector valves and tighten the bolts.
Tightening torque, see: Hydraulic transmission, tightening torque

Figure 27

1. Gear selector valve

42. Install the pilot valve PWM4201, control of main pressure (CVMP).
Tightening torque, see: Hydraulic transmission, tightening torque

Figure 28
 1. Lock nut
2. Spool
3. Pilot valve PWM4201, control of main pressure (CVMP)

43. Install the spool for the pilot valve and the lock nut.
Tightening torque, see: Hydraulic transmission, tightening torque

44. Install SE4214 monitor, lubrication oil pressure (PL).

Tightening torque, see: Hydraulic transmission, tightening torque

Figure 29

1. SE4214 monitor, lubrication oil pressure (PL)

45. Install the gear selector section on the oil distributor plate. Install the bolts and tighten.
Tightening torque, see: Hydraulic transmission, tightening torque

Figure 30

= M8x40 (1.57 in)

Lubrication oil pressure section, assembling

46. Blow clean the seat for the valve in the lubrication oil pressure section.
 Figure 31

47. Check that there is no rust in the valve seat on the lubrication oil pressure section.

48. Install the lubrication oil pressure section and the bolts.

Figure 32

1. Lubrication oil pressure section

2. Oil distributor plate
3. Cover

49. Install the cover and fasten with the bolts. Tighten the bolts.
Tightening torque, see: Hydraulic transmission, tightening torque
 Figure 33

= M8x60 (2.36 in)

1. Lubrication oil pressure section

2. Spring
3. Piston
4. Washer
5. Plug

50. Clean and lube the lubrication oil pressure valve's piston with transmission oil (see operator's manual).

51. Install the piston in the lubrication oil pressure section.

52. Install and tighten the plug.

Tightening torque, see: Hydraulic transmission, tightening torque

Main pressure section, assembling

53.
Blow clean the seats for the valves and holes on the main pressure section.

Figure 34
54. Install the main pressure section and the bolts.

Figure 35

1. Main pressure section

2. Cover
3. Oil distributor plate

55. Install and tighten down the bolts that only hold the main pressure section.

Figure 36

1. = M8x40 (1.57 in)

2. = M8x60 (2.36 in)

56. Install the cover and tighten the bolts that hold both the main pressure section and cover. Torque-tighten all bolts.
Tightening torque, see: Hydraulic transmission, specifications

57. Install the plugs on the main pressure section.

Tightening torque, see: Hydraulic transmission, tightening torque
 Figure 37

1. Plug

58. Install the main pressure valve (MP) on the main pressure section.
Tightening torque, see: Hydraulic transmission, tightening torque

Figure 38

1. Main pressure valve (MP)

59. Install the pressure limiting valve (CR).

Tightening torque, see: Hydraulic transmission, tightening torque

Figure 39

1. O-ring, suction strainer

2. Pressure limiting valve (CR)

60. Change the O-ring for the suction strainer. Lube the O-ring with vaseline.