COMPONENT CODE 15

REF NO. AT03084

DATE May. 19, 2003
Page 1 of 10

SUBJECT: TRANSMISSION INCHING CLUTCH IMPROVEMENT PARTS

(SPRING) ON GD825A-2

PURPOSE: To introduce a new valve part (spring) for improving durability of inching
clutches by lowering hydraulic oil pressure.

APPLICATION: GD825A-2 Motor Graders, Serial Nos. 12099 thru 12116

GD825A-2 (-50°C) Motor Graders, Serial Nos. 12099 thru 12116

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FAILURE CODE: 15F0FA

DESCRIPTION:

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1. Introduction
Durability of inching clutches (both R and R) can be improved by lowering the hydraulic

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oil pressure of the inching clutches. This Sevice News introduces a valve part (spring) for
the purpose.
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2. List of parts

Part No. Part Name Q'ty Remarks

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235-15-26181 Spring 1
[23901-15-496] [1] For prototypes
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(235-15-26190) (Spring) (1)

(235-15-26180) (Spring) (1) 
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
(235-15-25181) (Spacer) (1)  Discontinued

(103-15-35270) (Shim) (4) 
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Printed in Japan AT03084

(02)19
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3. Detail of Improvement

(1) Background
The inching work is mainly for finishing road surfaces and is generally completed in
about 10 seconds. In this case, durability of the inching clutch is not related with any
problem.
When the inching pedal is used, an operator may use it for a long time (more than 1
minute) unconsciously. In case stopping on a slope, for example, the operator may not
set the gear to the neutral position and use the inching pedal instead. For this abnor-
mal operation, decals are stuck to draw attention, and lamps blink and the buzzer
alarms when the transmission controller is inched for hours. When the operator is
concentrated in operation, however, the alarm may not work effectively due to sounds

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from the radio or in the environment.

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It has been also informed that the machine is not used for finishing road surface like
middle size motor grader in mine and is mainly used for maintenance of dump truck
traveling road and for dozing work.

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(2) Coexistence of Inching Performance and High Durability
In view of the above background, it will be introduced how to improve the durability of

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the inching clutch without influence on the traditional inching performance.

(3) Concrete Explanation

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The inching oil pressure (the upper limit value in the pressure adjustment range for
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inching) can be lowered as shown above by replacing the spring inside the inching
valve (installed on the top of the transmission). Therefore, even if the operator inches
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it for a long time by mistake, the clutch heat building up will decrease and the dura-
bility of the inching clutch is improved.
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When the inching oil pressure is lowered, some operators may feel conflicting phenom-
ena like
1 When the inching pedal is used, fine travels become harder than before the im-
provement or
2 When the inching pedal is used, the starting shock becomes larger than before the
improvement.
This can be solved by returning the inching pedal more slowly than before. A report
from the U.S.A. evaluated that the operation in a mine "did not cause any problem."

AT03084
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4. Details of Modification
(1) Modification and Purpose
The heat building up at the time of sliding the clutch has been reduced with the inch-
ing pedal operation range remaining and by decreasing the pressure adjustment
range, and consequently the clutch durability has been improved.

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(2) List of Parts for Modification

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Parts prepared
Part No. Description Quantity per unit Remarks
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235-15-26181 Spring 1 Parts to be mounted, Free height 64,

Total number of windings 21.6

Unnecessary parts after replacement

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Part No. Description Quantity per unit Remarks

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235-15-26190 Spring 1 To be removed, Free height 17.6

235-15-26180 Spring 1 To be removed, Free height 39.4
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235-15-25181 Spacer 1 To be removed, Overall length 23.6

103-15-35270 Shim About 4 All shims are removed.
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(3) Time required for modification (by one worker)

Removal of external cover 15 minutes
Removal of inching linkage 15 minutes
Cleaning around valve 10 minutes
Removal of parts around valve 30 minutes
Disassembling valve and replacing spring 30 minutes
Repair of valve and reassembly of parts 30 minutes
Repair of inching linkage 15 minutes
Re-setting of inching potentiometer 15 minutes
Setting of external cover 15 minutes
Total 175 minutes = 3 hours approx.

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5. Modification Procedures
(1) Removal of External Cover
1) Remove A.
Bolt : 01010-81225 (6)
Washer : 232-43-58360(6)
2) Remove B.
Bolt : 01010-81255 (1)
01010-81225 (2)
Washer : 232-43-58360(3)

(2) Removal of Inching Linkage and Connector Cover

1) Remove the covers, No. 37 and 38.

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Bolt : 01010-80812 (4)

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Washer : 01643-30823 (4)
2) Remove No. 22, Snap Pin (04052-01664) and
pull out No. 21, Pin (04205-11642). Then, re-
move No. 30, Snap ring (04064-01610) and re-

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move No. 26, Bracket.
Washer : 01643-31032 (1) — No. 29

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3) Removal of Connector Cover

Remove the covers, No. 1 and 2 on the sole-
noid valve seat.
Bolt : 01010-80812 (4) — No. 3
Washer : 01643-30823 (4) — No. 4

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(3) Cleaning of Parts around Valve

As the parts in the area in the circle are removed, remove dust, stain and paint waste
completely so that no dust will enter inside at the time of removing.

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(4) Removal of Parts around Valve

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At first, loosen the indicated nuts of the tube (235-15-26310) to separate it from the
cover. Then, loosen the head nuts at the indicated 2 places of the solenoid valve (17A-
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15-17271) and remove the coil frame to make free space. At the time, it is not neces-
sary to remove the solenoid base. At the end, remove the bolt (01010-80875) and the
washer (01643-50823).
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(5) Disassembly of Valve and Replacement of Spring

Pull out the cover (235-15-25230) in the arrow direction. It can be pulled out together
with the inching spool.

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The inside is as shown in the figure below. Assemble the spring and other parts cor-
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rectly.
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(6) Reassembly of Valve and Parts around

Assemble these parts by reversing the procedure mentioned in (4). Tightening
torques are as shown in the figure below.

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(7) Installing Connector Cover

Assemble it by reversing the procedure mentioned in (2)-3). The tightening torques
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are as follows:
(8) Reassembly of Inching Linkage
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Assemble it by reversing the procedure mentioned in (2)-2). The tightening torques

are as follows:
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Adjust the inching controller according to the procedures mentioned on the next page.
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(9) Re-setting of Inching Potentiometer

Re-set it according to the detailed procedure mentioned on page 9.
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(10) Installation of External Cover

Assemble it by reversing the procedure mentioned in (2)-1). The tightening torques
are as follows.

Bolt Tightening torque

01010-808** 14.7 – 34 Nm (1.5 – 3.5 kgm)
01010-810** 34 – 74 Nm (3.5 – 7.5 kgm)
01010-812** 54 – 123 Nm (5.5 – 12.5 kgm)

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(11) Adjust the inching control according to the following procedure:

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AT03084
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(12) Re-set the inching potentiometer according to the following procedure:

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AT03084
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6. High Durability Inching Clutches in the past

Improvement
Original Improvement 1 Improvement 2
history
Service News No. –––– BT00046 BT00046
Serial No. #11001 – 12098 #12099 – 12116 #12117 –
T/M ass'y No. 235-15-21010, 21011 235-15-21012, 21013 235-15-21014
(Standard specification) (Standard specification) (Standard specification)
–––– 235-15-21020 (Extreme 235-15-21021 (Extreme
cold area specification) cold area specification)
Purpose –––– Improvement of F Improvement of R
clutch durability clutch durability

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Number of F 4 (Sintered) 7 (Paper) 7 (Paper)

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clutch disks
(Material) R 4 (Sintered) 4 (Paper) 5 (Sintered)
Transmission 63 cc/rev 80 cc/rev 80 cc/rev
pump capacity

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Inching clutch
structure

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Reduction of inch- Has not been Has already

ing clutch hydrau- –––– incorporated. incorporated.
lic oil pressure
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The hydraulic oil pressures of the F

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and R inching clutches can be reduced

by changing the valve spring, and the
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clutch durability can also be improved.

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AT03084