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SECTION 2

TRANSMISSION
TABLE OF CONTENTS

CHAPTER SUBJECT PAGE

2.1 GENERAL DESCRIPTION ........................................................................................ 2-2

2.1.1 Transmission torque converter hydraulic diagram .................................................. 2-2

2.2 TROUBLESHOOTING ............................................................................................... 2-6

2.3 TESTS ...................................................................................................................... 2-10

2.3.1 Torque converter stall test .................................................................................... 2-10
2.3.2 Delivery pressure test procedure .......................................................................... 2-11
2.3.3 Transmission gearshifting electric control valve .................................................... 2-12

2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER ........................ 2-14
2.4.1 Removal ............................................................................................................... 2-14
2.4.2 Re-Installation ....................................................................................................... 2-15
2.4.3 Disassembly ......................................................................................................... 2-16
2.4.4 Reassembly .......................................................................................................... 2-25

2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION .................................. 2-26

2.5.1 Removal ............................................................................................................... 2-26
2.5.2 Re-Installation ....................................................................................................... 2-27
2.5.3 Disassembly ......................................................................................................... 2-28
2.5.4 Overhaul of forward the speed clutch .................................................................... 2-42
2.5.5 Overhaul of 3rd speed ............................................................................................ 2-44
2.5.6 Overhaul of the rev speed clutch .......................................................................... 2-49
2.5.7 Modulating valves (disassembly/assembly) .......................................................... 2-52
2.5.8 Pressure relief valve (disassembly/assembly) ...................................................... 2-53

2.6 SPECIFICATIONS AND DATA .................................................................................... 2-57

2.6.1 General data ......................................................................................................... 2-57
2.6.2 Tightening torques (Torque converter) ........................................................... 2-58
(Transmission housing) .................................................... 2-59
2.6.3 Data and dimension
transmission (Transmission clutches) ................................................... 2-60
(Transmission clutch discs) ............................................. 2-62
(1st - 2nd - 3rd speed transmission clutch modulating
valves) ............................................................................ 2-62
(Lube oil pressure relief valve) ......................................... 2-63
(Forward/reverse modulating valves) ............................... 2-64
(Transmission pressure relief and torque converter
safety valve) .................................................................... 2-65
(Torque converter - transmission feeding pump) .............. 2-66
(Oil filters) ....................................................................... 2-67
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1650K TRANSMISSION 2-1

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2-2 TRANSMISSION 1650K

2.1 GENERAL DESCRIPTION

2.1.1 TRANSMISSION TORQUE The oil flowing out the torque converter, passes through
CONVERTER HYDRAULIC DIAGRAM the heat exchanger, the manifold and it is distributed
to the lube and cooling ducts of the transmission
The transmission is of a "power-shift" type with three clutches.
forward and three reverse speeds. The system is pow- The maximum lube pressure is limited by valve (15)
ered by a dual pump feeding the transmission and the set at 3 bar (43.5 psi).
torque converter (1). Modulating valves (9) make the engagement of the
The pump sucks oil from the transmission housing clutches progressive, regulating the pressure incre-
through filter (6) and circulates it purifying further ment in the control circuits.
through filter (2). A valve (set at 2.5 bar) (36.25 psi) A low engine lube oil pressure or an excessive lube
protects filter (2) against over pressures due to the oil temperature are indicated on the dashboard in the
clogging of the cartridge or excessively thick oil. cab.
The oil delivered by feeding pump (1) after being puri- Quick discharge valves on the 2nd and 3rd speed
fied by filter (2) reaches pressure relief valve (3) es- clutches, during the speed engagement phase, are in
tablishing and maintaining the pressure setting of the closed position, under the action of pressurised oil.
oil controlling the transmission clutches. When shifting from one speed to another, the relevant
Safety valve (16) protects the torque converter and control cylinder is connected to the discharge and the
the heat exchanger against accidental pressure in- pressure drop causes the centrifugal force to prevail
crements, normally due to cold and excessively thick over the action of the oil, moving the balls outwards,
oil, discharging the flow excess into the pump deli- facilitating a quick discharge.
very line (1).

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2-3

L T

F AS
R
N
AL
P
S

MICROCONTROLLER

12 9
11
10

16 18 17

26
4 25

8
To brakes/clutches
feeding valve B
3
23
1 2 6
B 22
14 2

13 24
1 2
21
24
5 24
From transmission housing 20
15 19
Transmission lubrication

KSM0003

Fig. 2-1 Torque converter hydraulic diagram

B. To transmission housing - F. Forward speed - R. Reverse speed - P. Upshifting - S. Downshifting - N. Neutral - AS. Auto-shift function - AL. Auto kick-down function - L. Transmission control manipulator - T. Up-Down Shifting Button - 1. Dual transmission/torque converter
feeding pump 67 to 50 lt/min (17.70 to 13.21 gpm) - 2. Oil filter (delivery) - 3. Pressure relief valve (17 bar, 246.5 psi) - 4. TWIN-DISC torque converter - 5. Heat exchanger - 6. Oil filter (suction) - 7. Control valve - 8. Transmission housing - 9. FORWARD speed solenoid -
10. REVERSE speed solenoid - 11. 1st speed solenoid - 12. 3rd speed solenoid - 13. Steering torque converter scavenging pump (53 to 22 lt/min) (13.21 to 5.81 gpm) - 14. Mesh filter - 15. Lube oil pressure relief valve (3 bar, 43.5 psi) - 16. Torque converter safety valve -
17. FORWARD/REVERSE control valve spool - 18. 1st - 3rd control valve spool - 19. To 1st speed clutch pack - 20. To 3rd speed clutches pack - 21. 2nd speed clutch pack - 22. To FOR speed clutch pack - 23. To REV speed clutch pack - 24. 1st - 2nd - 3rd speed modulating
valves - 25. Filter clogging valve - 26. FOR/REV modulating valves.
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2-4 TRANSMISSION 1650K

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1650K TRANSMISSION 2-5

Transmission Brakes oil

oil filler neck suction filter
and oil dipstick

Control valve
solenoid

Transmission
control valve

Transmission Transmission oil

oil suction filter level sensor
1850-2R0105

Fig. 2-2 Transmission housing

Transmission

Torque converter

Transmission/torque
converter propeller
shaft

1850-2R0106

Fig. 2-3 Propeller shaft

Torque converter safety valve, Oil inlet

setting: 10 bar (145 psi) Pressure relief valve
(it provides 17 bar,
246.5 psi) for the
Equipment/steering operation of the
pump transmission)
Oil outlet at 17 bar
(246.5 psi), actuating
Brakes pump (53 lt/min,
the transmission
13.2 gpm)
Scavenger pump Transmission pump
(22 lt/min, 5.8 gpm) (67 lt/min, 17.7 gpm)
Torque converter pump
It recovers the oil at the
(50 lt/min, 13.2 gpm)
bottom of the torque
converter cover and Torque converter
flows it into the discharge
transmission Lube pressure switch
1850-2R0107

Fig. 2-4 Torque converter

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2-6 TRANSMISSION 1650K

2.2 TROUBLESHOOTING

TROUBLE PROBABLE CAUSE TOOLS REQUIRED TEST SOLUTION

Low lube oil pres- Transmission oil level Instruction Manual. Pull-out the dipstick Top-up oil up to pre-
sure. The indica- low. and check the level. scribed level.
tor light is ON with
engine running.
Torque conver ter Clean the filter.
pump suction filter
clogged.

Outer crack allowing If the oil is foaming, Eliminate the crack.

the seeping of air into check if a crack is
the pump. present.

Hose defective. Suction pipe clog- Change or clean the

ged. pipe.

Oil of a wrong type. Instruction Manual. Check oil speci- Drain the oil and
fications with data change it with oil of
provided by Manu- the prescribed type.
facturer.

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1650K TRANSMISSION 2-7

TROUBLE PROBABLE CAUSE TOOLS REQUIRED TEST SOLUTION

Control oil pres- Transmission oil level Instruction Manual. Check oil level on Top-up with pre-
sure low at al low. dipstick. scribed oil to cor-
speeds with trans- rect level.
mission in neutral.
Transmission pump Clean the filter.
suction filter clogged.

Outer crack allowing If the oil is foaming, Eliminate the lea-

the seeping of air into check if a crack is kage.
the pump. present.

Suction pipe. Suction pipe clog- Change or clean the

ged. pipe.

Pressure relief valve Check pressure of Correct the pres-

out of setting. system. sure setting.

Feeding pump deli- Check delivery of Replace pump, if

very insufficient. pump. defective.

Control oil pres- Transmission pump Check and wash

sure low at high suction filter clogged. the mesh filter.
engine speed with
transmission in Outer crack allowing If the oil is foaming, Eliminate the lea-
neutral. the seeping of air into check if a crack is kage.
the pump. present.

Tr a n s m i s s i o n Orifice of direction Clean the orifice.

pressure is nor- modulating valve
mal in neutral and plunger clogged.
low with speeds
engaged. The ma- Direction modulating Eliminate condition
chine starts with valve plunger seized. for seizure between
difficulty in one plunger and seat.
direction and the
torque is insuffi-
cient.

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2-8 TRANSMISSION 1650K

TROUBLE PROBABLE CAUSE TOOLS REQUIRED TEST SOLUTION

High transmission Pressure relief valve Eliminate seizure.

oil pressure at all seized open.
engine speeds.

High transmission Transmission oil level Instruction Manual. Check level on dip- Top-up with pre-
oil temperature. low. stick. scribed oil to cor-rect
level.

Transmission heat Measure tempera- Clean or replace the

exchanger clogged ture differential bet- heat exchanger.
keeps the safety ween inlet and out-
valve open. let of heat exchang-
er. With a clogged
unit, the differential
is marginal.

Operation pressure Measure operating Refer to remedies for

low. pressure of trans- low oil pressure fault.
mission.

Clutch discs burnt, Replace defective

seized with clutches components.
disengaged.

Transmission oil Oil pump delivery in- Test pump.

is normal, but the sufficient.
machine moves
only at high en-
gine speed.

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1650K TRANSMISSION 2-9

TROUBLE PROBABLE CAUSE TOOLS REQUIRED TEST SOLUTION

Transmission pres- Discs worn or war-ped. Replace defective

sure normal; low components.
power in certain
speeds and oil
overheating.

Transmission pres- Leakages in piping of Check if seals or Overhaul the trans-

sure low in a given defective speed. pipes are damaged. mission and re-
speed. place defective
parts.

Engine oil level in- Together with trou- Clean scavenger

creases and trans- ble for low power filter.
mission oil level output.
drops.
Crankshaft sealing Replace crankshaft
ring damaged. sealing ring.

Replace pump.

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2 - 10 TRANSMISSION 1650K

2.3 TESTS

2.3.1 TORQUE CONVERTER STALL TEST 2. Block the transmission output shaft, keeping the
brake pedal pressed, then engage the forward high
The stall test must be performed when the power group
speed range checking that the engine is at full
(engine and transmission) do not operate satisfacto-
speed. Record the engine speed. DO NOT let the
rily. The scope of the test is to determine if the trans-
temperature on the outlet of the torque converter
mission is defective. It is performed with the engine
exceed 120 °C (248 °F).
running at maximum speed and the transmission out-
put stalled. Perform the torque converter stall test pro-
Note – Let the transmission operate in neutral for
ceeding as follows:
an interval of about 2 minutes between the vari-
ous stall tests, to avoid overheating. During these
two minutes do not let the engine speed drop, ex-
cept when shifting through the neutral.
WARNING
3. Engage the other speeds and check that the en-
Do not run the engine of this machine in closed gine speeds drops the same value, independently
areas without proper ventilation to remove deadly from the speed being engaged. In the event the
exhaust gases. engine speed does not drop with a given speed
Be sure exposed personnel in the area of opera- engaged, it is probable that the relevant clutch slips.
tion are clear of the machine before moving it or In the event the engine speed does not drop with
its attachments. WALK COMPLETELY AROUND the all speeds, as indicated, this could be due to:
machine before mounting. Sound horn. Obey flag - the transmission, if the shaft between torque
man, safety signals and signs. converter and transmission is operating, or
Comply with all procedures for the starting and - the torque converter, if said shaft is inoperative
stopping of the machine and the "NOTICES" listed
in the Operation and Maintenance Manual. Result – Under stall test conditions, a compari-
son between the effective engine speed and the
normal one prescribed for such conditions, indi-
cates that the trouble is in the engine or in the
transmission.

1. Connect a precision revolution counter to the en- Note – Ambient conditions, such as ambient tem-
gine and bring the transmission housing to the op- perature, elevation, variations in the loss of en-
erating temperature: DO NOT PERFORM this test gine accessories, influence the power transferred
with cold oil. Record the engine speed (rpm). to the torque converter: These conditions can
cause variations in the stall speed of 50 rpm, with
Note – The stall conditions must not be kept for respect to the normal value. When the difference
over 30 seconds, in any case, to avoid excessive can be assigned to such causes, the effective
temperatures. speed can be accepted as normal.

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1650K TRANSMISSION 2 - 11

2.3.2 DELIVERY PRESSURE TEST Check the temperature and pressure gauges on the
PROCEDURE instrument panel. If the main pressure stays within
the limits (or in case the trouble persists after inter-
Prior to measuring the pressures and the oil flow of ventions to correct the main pressure) measure and
the torque converter and transmission, it is neces- record all pressures for a comparison.
sary to proceed with the following preliminary check.
The pressure gauge pick-up points of the pressures
Check the oil level of the transmission, with the oil at of the entire system are located on the control valve
normal operating temperature: DO NOT perform this illustrated at page 2-12. All connections can be made
test with cold oil: To bring the oil temperature to the simultaneously. The pressure gauge connected to each
prescribed value, it is necessary to operate the ma- point must have a capacity sufficient to measure the
chine or stall the converter. pressure involved; however it must not by so high to
make the reading of the correct pressure difficult.

WARNING
Keeping the stall speed too long, overheats the
torque converter.
Do not run the engine of this machine in closed
areas without proper ventilation to remove deadly
exhaust gases.
Prior to starting the engine, warn all persons
nearby the machine.
NEVER LEAVE THE MACHINE UNATTENTED with
the engine running.

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2 - 12 TRANSMISSION 1650K

2.3.3 TRANSMISSION GEARSHIFTING

ELECTRIC CONTROL VALVE

Specifications and data

- Normal operating temperature 50 to 120 °C (122 to 248 °F)

- Engine max. rated speed (idle) 2260 to 2360 rpm

- Torque converter stall engine speed 1940 to 2080 rpm

- Total stall engine speed 1660 to 1860 rpm

- Main pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)

1 - 1st speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)

2 - 2nd speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)

3 - 3rd speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)

F - Forward speed clutch pressure 14.5 to 15.5 bar (210.2 to 224.7 psi)

R - Reverse speed clutch pressure 14.5 to 15.5 bar (210.2 to 224.7 psi)

L - Lube oil pressure 3 bar (43.5 psi)

Pressures
SPEED LUBE

1 SPEED FORWARD
L

2 F
SPEED RESERVE

3 R

1850-2R0013

Fig. 2-5 Transmission pick-up point for machine arranged with diagnostic panel (optional)

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1650K TRANSMISSION 2 - 13

2nd gear

Forward gear

Lubrication

Trasmission
control valve

Slow speed
Fast
speed
Reverse gear F14329

Fig. 2-6 Pressure pick-up points on transmission

SM9011

Fig. 2-7 Pressure pick-up points on torque converter

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2 - 14 TRANSMISSION 1650K

2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER

2.4.1 REMOVAL
ON
Turn the main switch into position "OFF". Place a "DO
Key
NOT OPERATE" warning signal on the machine. please
refer to the Section "CAB" of this Manual to tilt the OFF DO NOT
cab. OPERATE

SM9261

Fig. 2-8
Remove the central lower guard.

1850-2R0014

Fig. 2-9
Drain the transmission oil through the draining plug.

1850-2R0015

Fig. 2-10
Drain the oil from the torque converter housing through
the draining plug.

1850-2R0016

Fig. 2-11

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1650K TRANSMISSION 2 - 15

Tilt the cab and perform the following operations.

Disconnect the transmission temperature sensor wire.

Disconnect the return piping between heat exchanger

and torque converter.

Disconnect the breather piping between torque con-

verter and transmission.

Disconnect the piping between the main pressure re-

lief valve and valve blocking in neutral.

Disconnect the feeding piping between brake pump

and steering and brake control valve.

Remove the propeller shaft between transmission

housing and torque converter.

Disconnect the brake pump suction pipe and the de-

livery and scavenger pipes from the torque converter
scavenger pump.

Remove the scavenger and brake pump from the

torque converter.
Disconnect the connection pipe from the front part of
the torque converter.

Make a lifting bracket and secure it to the propeller

shaft flange on the torque converter. Holding the torque
converter with an appropriate lifting device, remove
the securing screws to the flywheel housing and re-
move the torque converter.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks.

2.4.2 RE-INSTALLATION
The re-installation of the torque converter is performed
reversing the removal operations, with the following
exceptions.

Install the dowels on the flywheel housing.

1850-2R0017

Fig. 2-12

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2 - 16 TRANSMISSION 1650K

Smear with sealant the mating surfaces between

torque converter and flywheel housing.

Install the torque converter securing screws, tighten-

ing them at a torque of 6.8 to 7.4 daNm (50.15 to
54.58 ft lb).

1850-2R0108

Fig. 2-13
2.4.3 DISASSEMBLY
Remove the engine/torque converter adapter ring.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0109

Fig. 2-14
Place the torque converter on a rotary stand.

1850-2R0110

Fig. 2-15
Remove the hub.

1850-2R0018

Fig. 2-16

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1650K TRANSMISSION 2 - 17

Loosen and remove the screws securing the retaining

plate, then pull-out the plate, the O-Ring and the shaft
flange.

SM9023

Fig. 2-17

Remove the pressure relief valve assembly.

1850-2R0019

Fig. 2-18

Loosen the support securing screws, then turn the

torque converter with its bottom side upwards, so that
the securing screws can me removed from the sup-
port.

1850-2R0020

Fig. 2-19

Remove the screws securing the equipment pump

driven gear, lift the gear from the nose of the shaft
and put it aside.

1850-2R0111

Fig. 2-20

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2 - 18 TRANSMISSION 1650K

Secure a lifting chain to the torque converter; lift just

enough to rotate the support so that the remaining
gears are free, then pull the torque converter out the
housing.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks. 1850-2R0112

Fig. 2-21
Pull the equipment pump driven gear out the housing.

1850-2R0022

Fig. 2-22
Remove the circlips from the driven gears, then re-
move the gears from the shaft.

1850-2R0023

Fig. 2-23
Loosen the securing screws and remove the bearing
retaining plate.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0024

Fig. 2-24

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1650K TRANSMISSION 2 - 19

Using an appropriate punch and a soft metal hammer,

pull-out the pump drive shafts from the bearings.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0025

Fig. 2-25
Pull-out the bearings and spacers from the housing.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0026

Fig. 2-26
Remove the equipment pump drive shaft circlip.

1850-2R0027

Fig. 2-27
Pull-out the shaft and bearing from the housing.

1850-2R0028

Fig. 2-28

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2 - 20 TRANSMISSION 1650K

Pull-out the bearing left in the housing.

1850-2R0113

Fig. 2-29

Pull-out the seal assembly from the housing.

1850-2R0029

Fig. 2-30

Remove the bearing circlip from the equipment pump

drive, and pull-out the spacer and the bearing from
the shaft.

1850-2R0030

Fig. 2-31
Place the equipment pump drive shaft on a vertical
press of appropriate capacity to remove the inner race
of the bearing from the shaft.

SM9039

Fig. 2-32

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1650K TRANSMISSION 2 - 21

Place the torque converter assembly on an appropri-

ate work bench.

1850-2R0114

Fig. 2-33

Remove the front bearing retaining plate.

SM9041

Fig. 2-34
Remove the screws securing the wheel.

1850-2R0031

Fig. 2-35

Using puller screws, separate the turbine from the

housing, then lift the turbine.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks.

1850-2R0032

Fig. 2-36

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2 - 22 TRANSMISSION 1650K

Separate the turbine from the shaft prying it, in case

the turbine comes out with the shaft.

1850-2R0115

Fig. 2-37
Otherwise, in case the turbine is not coming out with
the shaft, lift it from the housing.

1850-2R0033

Fig. 2-38
Remove the shoulder disc from the housing.

1850-2R0034

Fig. 2-39

Pull-out the front bearing from the housing, hammer-

ing it.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0116

Fig. 2-40

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1650K TRANSMISSION 2 - 23

Place the pump wheel over blocks, remove the circlip

and pull-out the shaft from the wheel.

1850-2R0035

Fig. 2-41

Remove the screws securing the stator.

1850-2R0036

Fig. 2-42
Separate the stator from the pump wheel.

1850-2R0037

Fig. 2-43
Disassemble the bearing support from the pump wheel
and remove the sealing rings from the support.
Remove the bearing race from the support only in
case its replacement is required.

1850-2R0038

Fig. 2-44

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2 - 24 TRANSMISSION 1650K

Remove the pump drive gear from the wheel.

1850-2R0039

Fig. 2-45

Using a proper punch and a soft hammer, pull-out the

bearing support from the pump wheel.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0117

Fig. 2-46

Remove the sealing ring from the shaft.

1850-2R0040

Fig. 2-47

Pull-out the rear bearing from the shaft, using an ap-

propriate press.

SM9055

Fig. 2-48

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1650K TRANSMISSION 2 - 25

2.4.4 REASSEMBLY
To reassemble, reverse the disassembly procedures,
with the following modifications:

In case the dowels, the sleeve or the sealing ring have

been removed, install new parts.

Always install new O-Rings and seals.

In the event the heating of a bearing is required, use

an appropriate heater and warm-up at 121 °C
(250 °F).

In the event the freezing of a bearing of its compo-

nents is required, place the part in dry ice 4 hours
prior to the installation.

Pay attention to the correct installation of the oil de-

flector.

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2 - 26 TRANSMISSION 1650K

2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION

2.5.1 REMOVAL
ON
Turn the main switch into position "OFF". Place a "DO Key
NOT START" warning signal on the machine. Please
refer to the Section "CAB" of this Manual to tilt the OFF DO NOT
cab. Drain the transmission oil through the draining OPERATE

plug.

Remove the central lower guards.

SM9261

Fig. 2-49

Drain the oil from the torque converter housing through

the draining plug.

Remove the propeller shaft between torque converter

and transmission housing.

1850-2R0014

Fig. 2-50

Disconnect the hydraulic pump pipes (delivery and

return) to the distributor.

Disconnect the forward and 2nd speed pressure test

pipes between transmission and test panel.

Disconnect and label the three pipes between the upper

part of the control valve and the pilot valve.

Disconnect and label the 4 pipes on the rear side of

the transmission control valve: 2 run to the test panel,
one runs to the manual pilot valve and one runs to the 1850-2R0041

brake unlocking valve. Fig. 2-51

Hold the transmission housing with an appropriate

winch: its mass is about 450 kg (992.25 lb).

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1650K TRANSMISSION 2 - 27

Remove the screws and nuts retaining the transmis-

sion housing.

Note – It could be necessary to disconnect the

cylinder pipe on the hydraulic control valve to be able
loosening the nuts on the right upper side of the
transmission housing.

SM9059

Fig. 2-52

Remove the transmission housing from the pinion

support and lift it away from the machine.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks.

1850-2R0145

Fig. 2-53

2.5.2 RE-INSTALLATION
The installation is done reversing the removal proce-
dure.

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2 - 28 TRANSMISSION 1650K

2.5.3 DISASSEMBLY
Place the transmission assembly on a rotary stand.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks.
1850-2R0146

Fig. 2-54

Remove the lube manifold cover.

1850-2R0042

Fig. 2-55

Remove the modulating valves cover.

1850-2R0161

Fig. 2-56

Remove the modulating valves from the housing.

1850-2R0162

Fig. 2-57

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1650K TRANSMISSION 2 - 29

Remove the covers of the forward and medium range

clutch spools.

1850-2R0043

Fig. 2-58

Pull-out the clutch spools from the shafts.

1850-2R0044

Fig. 2-59
Remove the input shaft drive flange.

1850-2R0045

Fig. 2-60

Turn the transmission assembly and remove the trans-

mission control valve assembly, loosening the screws
(q.ty 5).

1850-2R0046

Fig. 2-61

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2 - 30 TRANSMISSION 1650K

Remove the side covers.

1850-2R0047

Fig. 2-62

Remove the screws securing the front cover (please

note that 2 screws must be removed from the bot-
tom).

SM9069

Fig. 2-63
Remove the front cover of the housing, lifting it with
an appropriate winch.

WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appropri-
ate slings and hooks. Use the lifting eyes provided
for this purpose.

1850-2R0147

Fig. 2-64

Turn the housing and remove the high range control

and lube pipes.

SM9071

Fig. 2-65

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1650K TRANSMISSION 2 - 31

Remove the low and high range clutches distribution

spools and pull them out from the shafts.

1850-2R0048

Fig. 2-66

Remove the low range clutch housing cover.

1850-2R0049

Fig. 2-67
Remove the rear cover.

SM9074

Fig. 2-68

Remove the reverse clutch pipe holder.

1850-2R0050

Fig. 2-69

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2 - 32 TRANSMISSION 1650K

Pull-out the reverse clutch distribution spool.

1850-2R0051

Fig. 2-70

Remove the reverse clutch shaft bearing holder.

1850-2R0052

Fig. 2-71
Remove the oil sump and the oil pipes with the
bracket, recording the position of the pipes for the
installation.

1850-2R0053

Fig. 2-72
Loosen the nuts securing the forward and medium
range clutch shafts.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0148

Fig. 2-73

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1650K TRANSMISSION 2 - 33

Block the transmission gears through the access panel

to prevent the shaft from turning, then loosen the for-
ward speed clutch shaft securing nut.

1850-2R0149

Fig. 2-74

Remove the forward speed piston assembly.

1850-2R0054

Fig. 2-75
Remove the forward speed clutch hub-pack assem-
bly.

1850-2R0055

Fig. 2-76

Loosen and remove the low range clutch shaft secur-

ing nut (blocking the transmission gears to prevent
the rotation of the shaft).

1850-2R0150

Fig. 2-77

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2 - 34 TRANSMISSION 1650K

Remove the low range clutch piston assembly.

1850-2R0056

Fig. 2-78

Remove the low range clutch hub-pack assembly.

1850-2R0057

Fig. 2-79
Remove the low range clutch drum-stop assembly.

1850-2R0058

Fig. 2-80

Pull-out the clutch shaft taper spacer.

Please keep in mind that when reassembling, the ta-

per part of the spacer must be placed in front of the
bearing.

1850-2R0159

Fig. 2-81

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1650K TRANSMISSION 2 - 35

Lift the low range and forward speed clutches shaft

from the transmission housing.

1850-2R0060

Fig. 2-82

Remove the gears and spacers through the access

panel.

1850-2R0061

Fig. 2-83

Remove the circlip from the driven gear of the forward

speed clutch drum.

1850-2R0062

Fig. 2-84

Remove the drum and the forward speed clutch gear,

using an appropriate punch, extracting the drum
through the gear and the housing.

1850-2R0063

Fig. 2-85

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2 - 36 TRANSMISSION 1650K

Install three clamps (P/N 75291531) on the high range

clutch assembly.

SM9092

Fig. 2-86

Remove the medium range clutch shaft securing nut.

1850-2R0151

Fig. 2-87
Remove the medium range clutch piston.

1850-2R0064

Fig. 2-88

Remove the medium range clutch hub-pack assem-

bly.

1850-2R0065

Fig. 2-89

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1650K TRANSMISSION 2 - 37

Remove the medium range clutch hub circlip.

SM9096

Fig. 2-90

Remove the medium/high range clutch shaft.

1850-2R0066

Fig. 2-91
Remove the medium range clutch drum.

1850-2R0067

Fig. 2-92

Remove the medium range clutch gear.

1850-2R0068

Fig. 2-93

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2 - 38 TRANSMISSION 1650K

Remove the medium range clutch assembly.

1850-2R0069

Fig. 2-94

To pull-out the medium range clutch drum bearing,

use an appropriate punch, after removing the two
screws with retaining nut.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
1850-2R0070
chances of injuries.
Fig. 2-95
Remove the screws securing the input drive gear seal
and the bearing support, then extract the shaft prying
it.

1850-2R0071

Fig. 2-96
Remove the input drive gear using a pry bar and ham-
mering the shaft.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries.
1850-2R0072

Fig. 2-97

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1650K TRANSMISSION 2 - 39

Remove the bearing and the retaining wing of the rel-

evant spacer.

1850-2R0153

Fig. 2-98

Remove the bearing spacer using a securing screw.

SM9105

Fig. 2-99
Remove the output shaft nose bearing circlip.

1850-2R0073

Fig. 2-100
Remove the output shaft gear circlip.

1850-2R0074

Fig. 2-101

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2 - 40 TRANSMISSION 1650K

Remove the output shaft and the bearing using an

appropriate punch.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0075

Fig. 2-102

Using an appropriate punch, pull-out the output shaft

through the bearing and the gear.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
1850-2R0076
chances of injuries.
Fig. 2-103
Remove the output shaft gear.

1850-2R0077

Fig. 2-104
Remove the PTO shaft securing screws and seal
holder.

1850-2R0078

Fig. 2-105

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1650K TRANSMISSION 2 - 41

Install two clamps (P/N 75291531) on the reverse

clutch.

1850-2R0079

Fig. 2-106

Loosen and remove the reverse clutch shaft locking

nut.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
D150-2R0081
chances of injuries.
Fig. 2-107
Pull-out the reverse shaft/PTO shaft through the clutch
and the housing.

1850-2R0154

Fig. 2-108
Remove the input gear and the reverse spacer.

1850-2R0080

Fig. 2-109

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2 - 42 TRANSMISSION 1650K

Pull-out the reverse clutch assembly.

1850-2R0155

Fig. 2-110

Remove the bearing remaining in the housing.

WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
with side shields, heavy gloves etc., to reduce the
chances of injuries.

1850-2R0156

Fig. 2-111
2.5.4 OVERHAUL OF THE FORWARD
SPEED CLUTCH
Note – The procedures for the overhaul of the low and
medium range clutches are the same as for the forward
speed clutch.

Remove the piston from the housing, then check that

these two elements are satisfying the prescribed re-
quirements. Reinstall the piston into the housing with
new sealing rings.
1850-2R0157

Fig. 2-112
Remove the clutch pack from the hub.

1850-2R0081

Fig. 2-113

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1650K TRANSMISSION 2 - 43

Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.

1850-2R0158

Fig. 2-114

Press the spring using a long threaded stud.

1850-2R0082

Fig. 2-115
Remove the circlip.

SM9122

Fig. 2-116

Remove the spring cup and the spring from the hub;
check that the spring complies with the prescribed
requirements.

1850-2R0083

Fig. 2-117

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2 - 44 TRANSMISSION 1650K

Reinstall the spring and the relevant cup on the hub;

press the cup and install the circlip.

1850-2R0084

Fig. 2-118
Reinstall the friction discs, the spacer springs and
the steel discs, alternatively, on the hub.

1850-2R0159

Fig. 2-119
To measure the height of the clutch pack, place the
clutch assembly on a press and load it at 197 daNm
(1452.88 ft lb), measuring as illustrated.

SM9126

Fig. 2-120

2.5.5 OVERHAUL OF THE 3RD SPEED

Remove the blocks holding the high range clutch.

1850-2R0085

Fig. 2-121

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1650K TRANSMISSION 2 - 45

Separate the high range gear housing and the piston

from the clutch assembly.

1850-2R0086

Fig. 2-122

Remove the high range piston from the relevant hous-

ing.
Check that the piston and housing satisfy the pre-
scribed requirements. Install a new sealing ring on
the piston and housing hub, then reinstall the piston
into the relevant housing.

1850-2R0087

Fig. 2-123

Remove the hub and the high range clutch pack from
the clutch drum.

Note – In the event it is necessary to replace the

bearings in the clutch drum assembly, it is imperative
that the shoulder washer with lube holes is properly
mounted, with the inner taper side on the opposite side
of the bearings.

1850-2R0088

Fig. 2-124

Remove the clutch pack from the hub.

1850-2R0081

Fig. 2-125

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2 - 46 TRANSMISSION 1650K

Measure the thickness of all friction and steel discs;

replace them if not within the prescribed requirements.

1850-2R0160

Fig. 2-126

Press the return spring using a long thread screw.

1850-2R0082

Fig. 2-127

Remove the circlip.

SM9134

Fig. 2-128

Remove the spring and the relevant cup from the hub;
check that the spring complies with the prescribed
requirements.

1850-2R0083

Fig. 2-129

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1650K TRANSMISSION 2 - 47

Insert the spring cup and the spring into the hub; press
the spring and install the circlip.

1850-2R0084

Fig. 2-130

Reinstall the friction discs, return springs and steel

discs, alternatively on the hub.

1850-2R0159

Fig. 2-131
To measure the height of the clutch pack, place the
clutch assembly on a press and load it at 197 daNm
(1452.88 ft lb), measuring as illustrated.

SM9126

Fig. 2-132

Install the central hub assembly and clutch pack on

the high range clutch drum.

1850-2R0089

Fig. 2-133

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2 - 48 TRANSMISSION 1650K

Install the alignment tool (P/N 75291532) in the hub

grooves.

1850-2R0090

Fig. 2-134

Arrange the gear assembly on the hub assembly and

align the relevant grooves with the grooves on the
hub.

SM9137

Fig. 2-135
Check the alignment of the grooves using the high
range shaft, prior to introducing the high range clutch
assembly into the transmission housing.

Note – It is important that the grooves are perfectly

aligned, otherwise they could be damaged during the
installation of the shaft.

1850-2R0091

Fig. 2-136

Install three brackets (P/N 75291531)on the high range

clutch assembly.

1850-2R0092

Fig. 2-137

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1650K TRANSMISSION 2 - 49

2.5.6 OVERHAUL OF THE REV SPEED

CLUTCH
Remove the locking tools from the reverse clutch as-
sembly.

1850-2R0093

Fig. 2-138

Separate the reverse clutch drum from the clutch as-

sembly.

1850-2R0094

Fig. 2-139
Remove the clutch pack-hub from the piston-housing
assembly.

1850-2R0095

Fig. 2-140

Remove the clutch pack from the hub.

1850-2R0251

Fig. 2-141

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2 - 50 TRANSMISSION 1650K

Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.

1850-2R0160

Fig. 2-142

Press the return spring using a long thread screw.

1850-2R0082

Fig. 2-143
Remove the circlip.

SM9134

Fig. 2-144
Pull-out the spring stop and the return spring from the
hub; check that the spring complies with the pre-
scribed requirements.

1850-2R0083

Fig. 2-145

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1650K TRANSMISSION 2 - 51

Insert the return spring and the relevant stop in the

hub; press the stop and install the circlip.

1850-2R0084

Fig. 2-146

Install the friction discs, the spacer springs and the

steel discs, alternatively, on the hub.

1850-2R0159

Fig. 2-147
To measure the height of the clutch pack, place the
clutch assembly on a press and load it at 197 daNm
(1452.88 ft lb), measuring as illustrated.

SM9126

Fig. 2-148

Pull-out the piston from the housing and check that

the two components comply with the prescribed re-
quirements. Install new sealing rings on the piston
and reinstall the piston into the housing.

1850-2R0157

Fig. 2-149

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2 - 52 TRANSMISSION 1650K

Install the hub-clutch assembly on the reverse clutch

hub-housing assembly. Check that the outer steel ring
is correctly oriented with respect to the housing.

1850-2R0095

Fig. 2-150

Install the reverse clutch drum on the clutch assem-

bly.

1850-2R0094

Fig. 2-151
Install two brackets (P/N 75291531) on the reverse
clutch assembly.

1850-2R0093

Fig. 2-152

2.5.7 MODULATING VALVES

(disassembly / assembly)

Note – The three modulating valves are identical.

Remove the circlip from the modulating valve.

1850-2R0096

Fig. 2-153

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1650K TRANSMISSION 2 - 53

Pull-out the cup, the springs, the plunger and the valve
from the valve body.

Check that the springs comply with the prescribed

requirements.

SM9148

Fig. 2-154

Assembly
Insert the valve, the plunger, the springs the cup into
the valve body; block with the circlip.

1850-2R0096

Fig. 2-155

2.5.8 PRESSURE RELIEF VALVE

(disassembly / assembly)
The pressure relief valve is located on the torque con-
verter. It is equipped with two spools: one controls the
main pressure, the other operates as a safety valve,
protecting the torque converter against pressure over-
loads, which could occur with oil cold or too thick.

Disassembly
Disconnect the pressure sender.

Note – Record the number of shims located under the

sender, which shall be the same when reinstalling it.

1850-2R0097

Fig. 2-156

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2 - 54 TRANSMISSION 1650K

Remove the plug.

1850-2R0098

Fig. 2-157

Pull-out the spool assembly from the valve body.

1850-2R0099

Fig. 2-158

Disassemble the spool assembly.

Check that the spring complies with the prescribed

requirements.

Re-install the spool assembly, as illustrated in the fig-

ure.

For the moment, do not tighten the setting ring.

1850-2R0100

Fig. 2-159

Remove the valve seat from the valve body.

1850-2R0101

Fig. 2-160

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1650K TRANSMISSION 2 - 55

Push the plunger retaining ring out its seat.

1850-2R0102

Fig. 2-161

Pull-out the plunger, the spring and the shims from

the seat.

Check that the spring complies with the prescribed

requirements.

Assembly
Install the shims, the spring and the plunger into the
seat, press the spring and secure the pin.
1850-2R0103

Fig. 2-162
Install a new O-Ring and a new washer on the seat.

SM9156

Fig. 2-163

Place the seat assembly into the valve body.

SM9158

Fig. 2-164

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2 - 56 TRANSMISSION 1650K

Place the spool assembly into the valve body.

SM9152

Fig. 2-165

Install the plug on the valve body.

D150-2R0087

Fig. 2-166
Set the pressure, actuating the valve, as indicated.

D150-2R0088

Fig. 2-167

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1650K TRANSMISSION 2 - 57

2.6 SPECIFICATIONS AND DATA

2.6.1 GENERAL DATA

TORQUE CONVERTER

Make ................................................................................................................................................ TWIN-DISC

Model .................................................................................................................................. PX-1615 - C MS335
Number of elements ...................................................................................................... 3 (pump, turbine, stator)
Torque ratio at stall .................................................................................................................................... 2.33:1

TORQUE CONVERTER AND TRANSMISSION PROPELLER SHAFT

Type ...................................................................................................... Tubular with universal joints at the ends

Technical description ......................................................................................................... Italcardano 148 - M70
Working angle ............................................................................................................................................... 10°
Lube fittings ..................................................................................................................................................... 2
Tightening torque of universal joint screws ............................................... 12.8-14.2 daNm (94.4 to 104.73 ft lb)

TRANSMISSION HOUSING

Type ........................................................................................................................................... Full Power Shift

No of speeds ....................................................................................................................... 3 forward, 3 reverse
No of clutches .................................................................................................................................................. 5

SPEED POWER-SHIFT CLUTCHES ENGAGED RATIO

1st Forward Low - Forward 1:2.531

2nd Forward Medium - Forward 1:1.484
3rd Forward High - Forward 1:0.888

1st Reverse Low - Reverse 1:2.016

2nd Reverse Medium - Reverse 1:1.182
3rd Reverse High - Reverse 1:0.707

QUANTITY

CLUTCH DISCS Forward 3rd 2nd 1st Reverse

Bimetal discs with outer toothing 10 6 8 8 8

Intermediate toothed steel discs 9 5 7 7 7

Shoulder toothed steel discs 1 1 1 1 1

Spacer springs 10 6 8 8 8

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2 - 58 TRANSMISSION 1650K

2.6.2 TIGHTENING TORQUES - Torque converter

DESCRIPTION daNm (*) ft lb

1. Securing screws, front bearing stop 4.1 to 4.9 30.24 to 36.14

2. Securing screws, shaft hub stop 4.1 to 4.9 30.24 to 36.14
3. Securing screws, drive shaft 10.8 to 11.7 79.65 to 86.29
4. Securing screws, torque conv. housing 6.8 to 7.4 50.15 to 54.57
5. Securing screws, rear wheel 2.3 to 2.8 16.96 to 20.65
6. Securing screws, stator 3.4 to 3.9 25.07 to 28.76
7. Securing screws, pump drive gear 4.1 to 4.9 30.24 to 36.14
8. Securing screws, steering-brakes pump 1.2 to 1.4 8.85 to 10.32
9. Securing screws, pressure relief valve 6.8 to 7.4 50.15 to 54.58
10. Securing screws, rear bearing support 8.0 to 8.8 59 to 64.9
11. Secur. screws, rear output flange stop 4.1 to 4.9 30.24 to 36.14
12. Securing screws, oil deflector 3.0 to 3.3 22.13 to 24.34
13. Securing screws, oil deflector support 6.8 to 7.4 50.15 to 54.57

Screws, equipm. pump driven gear 7.5 to 8.3 55.31 to 61.21

Sec. screws, trans./torque conv. pump 6.8 to 7.4 50.15 to 54.57
Nut, pump drive hub 2.1 to 2.3 15.49 to 16.96
Secur. screws, hydraulic pump

2 3

1
10
7 11

12 13 8

SM9259

Fig. 2-168 Section view of torque converter housing

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1650K TRANSMISSION 2 - 59

Transmission housing

Thread daNm (*) ft lb

1. Nuts, rear cover studs 10 x 1.25 6.1 to 7.7 44.99 to 58.79

2. Screws and nuts, low range clutch cover and housing 10 x 1.25 6.1 to 7.7 44.99 to 58.79
3. Screws, reverse clutch front bearing cover 10 x 1.25 6.2 to 6.8 45.73 to 50.15
4. Screws, reverse clutch spool 10 x 1.25 5.7 to 6.3 42.04 to 46.46
5. Screws, reverse clutch seal 10 x 1.25 4.8 to 6.0 35.4 to 44.25
6. Screws, side cover 10 x 1.25 4.8 to 6.0 35.4 to 44.25
7. Screws, clutch spool cover 10 x 1.25 3.4 to 5.7 25.08 to 42.04
8. Screws, rear bearing holder 10 x 1.25 5.4 to 6.8 39.83 to 50.15
9. Self-locking screws, high range driven gear and
medium/high ranges drive gear 12 x 1.25 11 to 12 81.13 to 88.5
10. Nuts and screws, securing the transmission
housing to bevel gear pinion housing 16 x 1.5 24 177
11. Nuts, transmission shafts locking 40 x 1.5 92 to 95.5 (**) 679 to 704.31

(*) Lubricate with engine oil - (**) Apply Loctite 242

8 1

7 11

11

11
7
3
2

4
5

10 SM9260

Fig. 2-169 Section view of transmission housing

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2 - 60 TRANSMISSION 1650K

2.6.3 DATA AND TRANSMISSION DIMENSION

Transmission clutches

DATA mm in

A Ø Out. diameter of forward-reverse speeds 169.894 to 169.957 6.688 to 6.691

and 1st - 2nd ranges clutches fixed piston (large)
Ø Inner diameter forward speed mobile piston (large) 170.000 to 170.063 6.692 to 6.695
Piston play 0.043 to 0.169 0.001 to 0.006
B Ø Out. diameter of forward-reverse speeds 59.924 to 59.970 2.359 to 2.361
and 1st - 2nd ranges clutches fixed piston (small)
Ø Out. diameter of forward-reverse speeds 60.000 to 60.046 2.362 to 2.364
and 1st - 2nd ranges mobile piston (small)
Piston play 0.030 to 0.122 0.001 to 0.004
C Ø Outer diameter of 3rd range drive piston 194.600 to 194.700 7.661 to 7.665
Ø Inner diameter of high range on 1st range gear piston 195.000 to 195.072 7.677 to 7.679
Piston play 0.300 to 0.472 0.011 to 0.018
D Ø Inner diameter of 3rd range drive piston 80.036 to 80.066 3.151 to 3.152
Ø Out. diameter of high range 79.940 to 79.970 3.147 to 3.148
on 1st, 2nd and 3rd ranges drive gear hub
Piston play 0.066 to 0.126 0.002 to 0.004
E Ø Outer diameter of clutch control spools 19.770 to 19.800 0.778 to 0.779
Ø Inner diameter of clutches control spools 20.016 to 20.020 0.788 to 0.788
Clearance between seat and spool 0.22 to 0.25 0.008 to 0.009
G Specifications of clutch springs
Spring free length (3rd speed) 83.5 3.29
Spring free length (1st, 2nd, FOR, REV) 83.0 3.27
Press. load at 35 mm (1.378 in) 3rd 65.5 to 72.5 daNm 261.8 to 534.7 lbft
Press. load at 65 mm (2.559 in) (1 - 2 - FOR - REV) 315.5 to 348.5 daNm 2327 to 2570.18 lbft

DATA OF CLUTCH DISCS PACK ASSEMBLY

Clutch (X) Piston stroke (*) (Y) Clutch pack dimens. (**)

mm in mm in
FORWARD 4 to 5 0.16 to 0.20 60.4 to 60.8 2.38 to 2.39
REVERSE 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
1st SPEED 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
2nd SPEED 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
3rd SPEED 2 to 3 0.08 to 0.12 36.1 to 36.5 1.42 to 1.44

(*) Check by measuring the stroke of the mobile piston.

(**) Check pre-loading the clutch pack with a load of 197 daNm (1452 ft lb). When the discs are worn,
spare discs are available to reastablish the setting, to be used in lieu of as many inner toothed
discs.

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1650K TRANSMISSION 2 - 61

X Y Y X X Y

G G
G

A D
C

SM9163

Fig. 2-170 Section 1st Speed Section 3rd Speed Section FORWARD
2nd Speed
REVERSE

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2 - 62 TRANSMISSION 1650K

Transmission clutch discs

A

C D
B SM9164

Fig. 2-171 Section view of clutch discs

DATA mm in

A Thickness of inner toothed intermediate discs 2.42 to 2.58 0.09 to 0.10

B Thickness of inner toothed driving discs 2.42 to 2.58 0.09 to 0.10

3.4 to 3.6 0.13 to 0.14

C Thickness of outer toothed friction discs

wear tolerance of syntherised friction discs 0.90 to 1.20 0.03 to 0.04

D Length of return springs without permanent deformation 3.8 to 4.2 0.15 to 0.16

1st - 2nd - 3rd Speed transmission clutch modulating valves

C B A

SM9165

Fig. 2-172 Section view of modulating valve

DATA mm in

A Ø Outer diameter of piston 19.987 to 20.000 0.787 to 0.787

Diameter of piston seat in valve body 10.020 to 20.033 0.394 to 0.788
Installation tolerance between piston and seat 0.020 to 0.046 0.001 to 0.002

B Specifications of outer spring:

Free length 65 2.56
Load for spring compressed at 47 mm (1.85 in) 2.47 to 2.73 daNm 18.22 to 20.13 ft lb

C Specifications of outer spring:

Free length 48 1.89
Load for spring compressed at 32.5 mm (1.28 in) 9.11 to 10.11 daNm 67.19 to 74.56 ft lb

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1650K TRANSMISSION 2 - 63

Lube oil pressure relief valve

A Specifications of outer spring:

Free length 40 mm (1.57 in)
Load for spring compressed at 14 mm (0.55 in) 7.31 to 8.09 daN (16.44 to 18.20 lb)

B Valve pressure setting 3 bar (43.5 psi)

Lube pressure
relief valve

Valve section
SM9166

Fig. 2-173 Pressure relief valve

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2 - 64 TRANSMISSION 1650K

Forward reverse modulating valves

Transmission control valve

FORWARD REVERSE B A
C

MODULATING VALVES VALVE SECTION

SM9167

Fig. 2-174 Transmission control valve and modulating valves

DATA mm in

A Specifications of modulating valve inner spring:

Free length 48 1.89
Load for spring compressed at 22 mm (0.866 in) 4.44 to 4.90 daNm 32.745 to 36.14 ft lb

B Ø Outside diameter of plunger 23.987 to 24.000 0.944 to 0.945

Ø Inner diameter of modulating valve body 24.020 to 24.041 0.946 to 0.946
Clearance between plunger and seat 0.020 to 0.054 0.001 to 0.002

C Specifications of modulating valve outer spring:

Free length 64 2.52
Load for spring compressed at 46 mm (1.811 in) 2.05 to 2.25 daNm 15.12 to 16.59 ft lb

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1650K TRANSMISSION 2 - 65

Transmission pressure relief valve and torque converter safety valve

A C E P B D S
Q

Q P SM9168

Fig. 2-175 Section of pressure relief valve Section of torque converter safety valve

DATA mm in

A Ø Outside diameter of valve spool 19.979 to 20.000 0.786 to 0.787

Ø Inner diameter of spool seat in body 20.020 to 20.041 0.788 to 0.789
Clearance between spool and seat 0.020 to 0.062 0.001 to 0.002

B Ø Outside diameter of piston 13.982 to 14.000 0.550 to 0.551

Ø Inner diameter of piston seat 14.016 to 14.043 0.553 to 0.552
Clearance between piston and seat 0.016 to 0.061 0.001 to 0.002

C Specifications of spool return spring:

Free length 48 1.89
Load for spring compressed at 37 mm (1.46 in) 45.6 daN 102.37 lb

D Specifications of spool return spring:

Free length 43.5 1.71
Load for spring compressed at 32 mm (1.26 in) 15.64 to 17.30 daN 35.19 to 32.92 lb

E Pressure change setting ringnut

Setting of transmission pressure relief valve

- Adjust ringnut (E) so that the valve opens under a pressure in "Q" of 13.75 ± 0.5 bar (199.37 ± 7.25 psi)
with an oil flow at 40 °C (104 °F) of 10 lt/min (2.64 gpm).
- Each turn of the ringnut changes the pressure 1.5 bar (21.75 psi).
- Operating pressure: 17 bar (246.5 psi) with a flow of 66 lt/min (17.45 gpm).

Setting of torque converter safety valve

- Shim spring (D) so that the valve opens under a pressure in "P" of 10.5 ± 0.5 bar (152.25 ± 7.25 psi)
with an oil flow at 40 °C (104 °F) of 10 lt/min (2.64 gpm).
- Each shim changes the pressure 0.7 bar (10.15 psi) (thickness 1 mm) (0.03937 in).

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2 - 66 TRANSMISSION 1650K

Torque converter / transmission feeding pump (Ref. 1 hydraulic diagram)

Twin gear pumps, one feeding the transmission, the other feeding the torque converter.

Maximum speed .......................................................................................... 2650 rpm

Bench test of transmission/torque converter pumps:
- Nominal output (at max. speed) ................................................ 117 lt/min (30.9 gpm)
- Nominal output of transmission feeding section ......................... 67 lt/min (17.7 gpm)
- Nominal output of torque converter feeding section.................... 50 lt/min (13.2 gpm)
- Oil temperature ............................................................... 45 to 55 °C (113 to 131 °F)

(*) The torque converter oil scavenger pump is connected to the steering clutches pump,
thus it is described in the Steering Clutch Section.

Torque converter Transmission feeding

feeding section section

The arrow indicates the rotation direction

of the shaft and the delivery side
SUCTION SUCTION

DELIVERY DELIVERY
SM9169

Fig. 2-176 Torque converter - transmission feeding pump

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1650K TRANSMISSION 2 - 67

Oil filters
Filter on the total flow transmission torque converter F2
delivery with paper filtering element, replaceable every
500 hours work (25 µ - nominal tightening torque 4
daNm (29.5 ft lb) and by-pass valve set at 2.5 bar
36.25 psi).

D150-2R0082

Fig. 2-177 Oil filter on delivery line

F2. Transmission/torque converter oil filter.

3
1
4

SM9171

Fig. 2-178 Oil filter section on delivery line

1. Filter support - 2. Filter cartridge - 3. Filtering element -
4. Cover - 5. O-Ring.

Total flow filter on torque converter-transmission pump

suction line, with steel mesh filtering element (to be 2
1
cleaned every 1000 hours work) and magnetic plug 4
(100 µ nominal, without by-pass). 6 7

3 Fa

5
8
9

SM9172

Fig. 2-179 Oil filter on suction line

Fa. Steel mesh filtering element - 1. Cover locking nut -
2. O-Ring - 3. Cover - 4. Stud - 5. Magnetic rod - 6. Filtering
element retaining spring - 7. Circlip - 8. Gasket - 9. Support.

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