GBA 25 GEARBOX

B1
MECHANICAL PART
B2
HYDRAULIC PART
B3
ELECTRONIC PART

Chapter B
Technical support
Ares 507-607 60 05 031 190 – 06.2005 publication
 CONTENTS

B1 – MECHANICAL PART

GENERAL DESCRIPTION
GENERAL DESCRIPTION ..............................................................................................................................................B1.2

"HEXASHIFT" MODULE
DESCRIPTION ................................................................................................................................................................B1.4
SPEED INCREASER GEARING .....................................................................................................................................B1.5
SPEED INCREASER GEARING R = 1 ...........................................................................................................................B1.6
SPEED INCREASER GEARING R = 1,4 ........................................................................................................................B1.7
MODULE 4 PS.................................................................................................................................................................B1.8
MODULE 4 PS R = 0,58 ..................................................................................................................................................B1.9
MODULE 4 PS R = 0,69 ................................................................................................................................................B1.10
MODULE 4 PS R = 0,83 ................................................................................................................................................B1.11
MODULE 4 PS R = 1 .....................................................................................................................................................B1.12
MODULE SUMMARY 6 PS ...........................................................................................................................................B1.13

REVERTER MODULE UNDER TORQUE

DESCRIPTION ..............................................................................................................................................................B1.14
FORWARD ....................................................................................................................................................................B1.15
REVERSE......................................................................................................................................................................B1.16

ROBOT-DRIVEN RANGES MODULE

DESCRIPTION ..............................................................................................................................................................B1.17
KINEMATICS RANGE "A" .............................................................................................................................................B1.18
KINEMATICS RANGE "B" .............................................................................................................................................B1.19
KINEMATICS RANGE "C".............................................................................................................................................B1.20
KINEMATICS RANGE "D".............................................................................................................................................B1.21
SYNCHRONIZER MOVEMENT ....................................................................................................................................B1.22
DESCRIPTION OF THE RANGE JACKS......................................................................................................................B1.23
MONITORING OF SYNCHRONIZER POSITION .........................................................................................................B1.25
SUMMARY OF ROBOT-DRIVEN RANGES MODULE .................................................................................................B1.27

CRAWLER RANGES MODULES

DESCRIPTION ..............................................................................................................................................................B1.28
SLOW VERSION R = 1 .................................................................................................................................................B1.30
SLOW VERSION R = 0,25 ............................................................................................................................................B1.31

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EXTRA SLOW VERSION R = 1 ....................................................................................................................................B1.32
EXTRA SLOW VERSION R = 0,07 ...............................................................................................................................B1.33

CHARACTERISTICS GBA 25
CHARACTERISTICS GBA 25 .......................................................................................................................................B1.34

KINEMATICS GBA 25
KINEMATICS GBA 25 ...................................................................................................................................................B1.35

REMOVAL PROCEDURE
REMOVAL PROCEDURE .............................................................................................................................................B1.37

MAIN ADJUSTMENTS
MAIN ADJUSTMENTS ..................................................................................................................................................B1.38

TIGHTENING TORQUES AND SEALANTS

ENGINE/"HEXASHIFT" MODULE COUPLING .............................................................................................................B1.40
"HEXASHIFT" MODULE/RANGE MODULE COUPLING..............................................................................................B1.40
RANGE MODULE/REAR AXLE COUPLING.................................................................................................................B1.41

"HEXASHIFT" MODULE
EXPLODED VIEW .........................................................................................................................................................B1.43
REMOVAL (STAGE 1 PAGE 37)...................................................................................................................................B1.45
REMOVAL .....................................................................................................................................................................B1.46
REFITTING....................................................................................................................................................................B1.50
REFITTING....................................................................................................................................................................B1.54

REVERTER MODULE UNDER TORQUE

EXPLODED VIEW .........................................................................................................................................................B1.57
REMOVAL (STAGE 2 PAGE 37)...................................................................................................................................B1.58
REMOVAL .....................................................................................................................................................................B1.59
REFITTING....................................................................................................................................................................B1.62
REFITTING....................................................................................................................................................................B1.63

ROBOT-DRIVEN RANGES MODULE

EXPLODED VIEW .........................................................................................................................................................B1.65
REMOVAL .....................................................................................................................................................................B1.66
ADJUSTING THE SHAFTS IN THE HOUSING ............................................................................................................B1.73
REFITTING....................................................................................................................................................................B1.75

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 SLOW RANGE
EXPLODED VIEW .........................................................................................................................................................B1.82
REMOVING/REFITTING THE HOUSING .....................................................................................................................B1.84
REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM......................................................................B1.85
SETTING THE CONTROLS ..........................................................................................................................................B1.86

EXTRA SLOW RANGE

EXPLODED VIEW .........................................................................................................................................................B1.87
REMOVING/REFITTING THE HOUSING .....................................................................................................................B1.89
REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM......................................................................B1.90
SETTING THE CONTROLS ..........................................................................................................................................B1.91

B2 – HYDRAULIC PART

LOW PRESSURE CIRCUIT 20 BAR

DESCRIPTION ................................................................................................................................................................B2.2
THE VALVE 20 ON 60 L/MIN AND 100 L/MIN CIRCUIT ................................................................................................B2.3
20 BAR VAVLE ON 110 L/MIN CIRCUIT ........................................................................................................................B2.3
DESCRIPTION ................................................................................................................................................................B2.4
"HEXASHIFT" DRIVING LOGIC......................................................................................................................................B2.5
REVERTER DRIVING LOGIC UNDER TORQUE...........................................................................................................B2.5
DRIVING LOGIC OF ROBOT-DRIVEN RANGES...........................................................................................................B2.5
DESCRIPTION OF THE "HEXASHIFT"/REVERTER BLOCK.........................................................................................B2.6
DESCRIPTION OF ROBOT-DRIVEN RANGES .............................................................................................................B2.7

LOW PRESSURE LUBRICATION CIRCUIT

DESCRIPTION ................................................................................................................................................................B2.8
LUBRICATION FOR 60 L/MIN AND 100 L/MIN CIRCUIT...............................................................................................B2.8
LUBRICATION WITH 110 L/MIN CIRCUIT .....................................................................................................................B2.9
LUBRICATION GBA 25 .................................................................................................................................................B2.10
"HEXASHIFT" LUBRICATION AND REVERSE CLUTCH.............................................................................................B2.11
LUBRICATION OF RANGE UPPER SHAFT AND FORWARD CLUTCH .....................................................................B2.11
LUBRICATION OF RANGE LOWER SHAFT AND REVERSE COUNTERSHAFT ......................................................B2.12

CHARACTERISTICS OF LOW PRESSURE CIRCUITS

60 L/MIN CIRCUIT.........................................................................................................................................................B2.13
100 L/MIN CIRCUIT.......................................................................................................................................................B2.14
110 L/MIN CIRCUIT.......................................................................................................................................................B2.15

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 OPEN CENTER 60 L/MIN
HYDRAULIC DIAGRAM ................................................................................................................................................B2.17
COMPONENT LAYOUT ................................................................................................................................................B2.18
PRESSURE RESTRICTORS ........................................................................................................................................B2.19
LUBRICATION...............................................................................................................................................................B2.20

"LOAD SENSING" 100 L/MIN

HYDRAULIC DIAGRAM ................................................................................................................................................B2.21
COMPONENT LAYOUT ................................................................................................................................................B2.22
PRESSURE RESTRICTORS ........................................................................................................................................B2.23
LUBRICATION...............................................................................................................................................................B2.24

"LOAD SENSING" 110 L/MIN

HYDRAULIC DIAGRAM ................................................................................................................................................B2.25
COMPONENT LAYOUT ................................................................................................................................................B2.26
DISTRIBUTION VALVE.................................................................................................................................................B2.27
LUBRICATION...............................................................................................................................................................B2.28

CONTROL CIRCUIT TIGHTENING TORQUES

CONTROL CIRCUIT TIGHTENING TORQUES............................................................................................................B2.29

SOLENOID VALVE MEASUREMENT AND CHECKING POINTS

ELECTRICAL TESTS ON THE SOLENOIDS ...............................................................................................................B2.30

CONTROL UNIT GBA 25 MEASURING AND CHECKING POINTS

CHECKING THE DISTRIBUTION UNIT AND RANGE SOLENOID VALVE FEED PRESSURE..................................B2.31
CHECKING THE "REVERSHIFT" FEED PRESSURES................................................................................................B2.31
CHECKING THE "HEXASHIFT" MODULE FEED PRESSURES..................................................................................B2.32

GBA 25 "HYDRAULIC INSPECTION RESULTS" SHEET

GBA 25 "HYDRAULIC INSPECTION RESULTS" SHEET ............................................................................................B2.33

60 L/MIN OPEN CENTRE MEASUREMENT AND CHECKING POINTS

CHECKING THE FLOW COMING FROM THE STEERING BOX.................................................................................B2.34
CHECKING THE CONTROL PRESSURE ....................................................................................................................B2.34
COOLER INLET FLOW RATE CHECK.........................................................................................................................B2.35
COOLER INLET PRESSSURE CHECK........................................................................................................................B2.35
CHECKING THE LUBRICATION FLOW RATE FROM THE SPOOL VALVES AND THE 10 CM³ PUMP ...................B2.36
LUBRICATION PRESSURE CHECK ............................................................................................................................B2.37

Ares 507-607 – 06.2005 – GB

LUBRICATION FLOW RATES AT DIFFRENT POINTS OF THE CIRCUIT..................................................................B2.38

60 L/MIN OPEN CENTRE "INSPECTION RESULTS" SHEET

60 L/MIN OPEN CENTRE "INSPECTION RESULTS" SHEET .....................................................................................B2.39

"LOAD SENSING" 100 L/MIN MEASURING AND CHECKING POINTS

CHECKING THE FLOW COMING FROM THE STEERING BOX.................................................................................B2.40
CHECKING THE CONTROL PRESSURE ....................................................................................................................B2.40
COOLER INLET FLOW RATE CHECK.........................................................................................................................B2.41
COOLER INLET PRESSSURE CHECK........................................................................................................................B2.41
CHECKING THE LUBRICATION FLOW RATE FROM THE SPOOL VALVES AND THE 10 CM³ PUMP ...................B2.42
LUBRICATION PRESSURE CHECK ............................................................................................................................B2.43
LUBRICATION FLOW RATES AT DIFFRENT POINTS OF THE CIRCUIT..................................................................B2.44

"LOAD SENSING" 100 L/MIN "INSPECTION RESULTS" SHEET

"LOAD SENSING" 100 L/MIN "INSPECTION RESULTS" SHEET................................................................................B2.45

"LOAD SENSING" 110 L/MIN MEASURING AND CHECKING POINTS

CHECKING THE CONTROL PRESSURE ....................................................................................................................B2.46
LUBRICATING OIL FLOW RATE THROUGH THE COOLER AT 2 000 RPM..............................................................B2.46
LUBRICATION / BOOST PRESSURE CHECK.............................................................................................................B2.47
LUBRICATION FLOW RATES AT DIFFRENT POINTS OF THE CIRCUIT..................................................................B2.48

"LOAD SENSING" 110 L/MIN "INSPECTION RESULTS" SHEET

"LOAD SENSING" 110 L/MIN "INSPECTION RESULTS" SHEET................................................................................B2.49

B3 – ELECTRONIC PART

ELECTRONIC TRANSMISSION CONTROL

GENERAL DESCRIPTION ..............................................................................................................................................B3.2
PRESENTATION "AUTO 5" ............................................................................................................................................B3.3
INPUTS/OUTPUTS "AUTO 5.51" ....................................................................................................................................B3.6
INPUTS/OUTPUTS "AUTO 5.52" ....................................................................................................................................B3.8
INPUTS/OUTPUTS "AUTO 5.53" ..................................................................................................................................B3.10
COMMUNICATION NETWORK ....................................................................................................................................B3.12
GEARS AND SAFETY...................................................................................................................................................B3.14
FUNCTIONAL LOGIC....................................................................................................................................................B3.15

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 ELECTRONIC MANAGEMENT OF THE GEARBOX
POWER SUPPLIES.......................................................................................................................................................B3.16
"HEXASHIFT" ................................................................................................................................................................B3.18
ROBOT-DRIVEN RANGE .............................................................................................................................................B3.22
FUNCTIONAL LOGIC: EXAMPLE OF CONFIGURATIONS .........................................................................................B3.24
REVERSER UNDER TORQUE.....................................................................................................................................B3.26
MODES MANAGEMENT...............................................................................................................................................B3.34
"OVERDRIVE" ...............................................................................................................................................................B3.40
FUNCTIONAL LOGIC....................................................................................................................................................B3.41
SLOW RANGE ..............................................................................................................................................................B3.42
DISPLAY........................................................................................................................................................................B3.43

COMPONENT LAYOUT
COMPONENT LAYOUT ................................................................................................................................................B3.45

ELECTRICAL TESTS
SUPPLY CIRCUIT SWITCH..........................................................................................................................................B3.50
EARTHING SWITCH .....................................................................................................................................................B3.51
MANIPULATOR.............................................................................................................................................................B3.52
CONTACT SENSOR .....................................................................................................................................................B3.52
TEMPERATURE SENSOR (THERMISTOR) ................................................................................................................B3.52
VARIABLE RELUCTANCE INDUCTION SENSOR.......................................................................................................B3.53
HALL-EFFECT SENSOR ..............................................................................................................................................B3.54
FLEXIBLE BLADE SENSOR .........................................................................................................................................B3.54
"AUTO-5" ELECTRONIC UNIT .....................................................................................................................................B3.54
PROPORTIONAL SOLENOID VALVE .........................................................................................................................B3.55
ON/OFF SOLENOID VALVE .........................................................................................................................................B3.57

ADJUSTMENTS AND CALIBRATION

CLUTCH PEDAL ("BOC" SWITCH AND POSITION SENSOR)....................................................................................B3.58
STATIC CALIBRATION OF CLUTCHES.......................................................................................................................B3.59
MODIFICATION OF FORWARD/REVERSE PROGRESSIVITY ..................................................................................B3.60

"SPEED AND SAFETY" MEASUREMENT AND CHECKING POINTS

CHECKING THE LOW PRESSURE SWITCH (118) .....................................................................................................B3.61
CHECKING THE BOOST PRESSURE SWITCH ON THE 110 L/MIN "LOAD SENSING" CIRCUIT (127) ..................B3.61
CHECKING ENGINE SPEED, THEORETICAL SPEED AND REVERSER OUTPUT
SPEED SENSORS (38) (37) (27)..................................................................................................................................B3.62
CHECKING THE TRANSMISSION TEMPERATURE SENSOR (114) .........................................................................B3.65

Ares 507-607 – 06.2005 – GB

 "SUPPLY" MEASUREMENT AND CHECKING POINTS
CHECKING THE UNIT SUPPLY VOLTAGES...............................................................................................................B3.66

"HEXASHIFT" MEASUREMENT AND CHECKING POINTS

CHECKING THE UPSHIFT AND DOWNSHIFT SWITCHES (63 - 220A) (63 - 220B)..................................................B3.67
CHECKING THE "HEXASHIFT" PROPORTIONAL SOLENOID VALVES (271/272/273) ............................................B3.67

"ROBOT-DRIVEN RANGE" MEASUREMENT AND CHECKING POINTS

CHECKING THE GEAR UPSHIFT, GEAR DOWNSHIFT AND SHIFT SWITCHES (63 - 220A) (63 - 220B) (63)........B3.68
CHECKING THE RANGE CHANGE CONTACT SENSORS (278 - 279 - 280 - 28) .....................................................B3.68
CHECKING THE RANGE SOLENOID VALVES (274 - 275 - 276 - 277) ......................................................................B3.68

"SHUTTLE REVERSER" MEASUREMENT AND CHECKING POINTS

CHECKING THE TRANSMISSION TEMPERATURE SENSOR (114) .........................................................................B3.69
CHECKING THE LOW PRESSURE SWITCH (118) .....................................................................................................B3.69
CHECKING THE REVERSER CONTROLLER (188)....................................................................................................B3.70
CHECKING THE "BOC" LOW CLUTCH PEDAL SWITCH............................................................................................B3.70
CHECKING THE THEORETICAL SPEED AND REVERSER OUTPUT SPEED SENSORS (37) (27).........................B3.70
CHECKING THE CLUTCH PEDAL POSITION SENSOR (187) ...................................................................................B3.71
CHECKING THE PROPORTIONAL FORWARD DRIVE SOLENOID VALVES (192 - 193) .........................................B3.71

"MODE MANAGEMENT" MEASUREMENT AND CHECKING POINTS

CHECKING THE WORK/TRANSPORT AND "ECO/POWER" SWITCHES (152) (153) ...............................................B3.72
CHECKING THE UPSHIFT AND DOWNSHIFT SWITCHES (63 - 220A) (63 - 220B)..................................................B3.73
CHECKING THE ACCELERATOR PEDAL POSITION SENSOR (197) .......................................................................B3.73

"OVERDRIVE" MEASUREMENT AND CHECKING POINTS

CHECKING THE THEORETICAL SPEED AND REVERSER OUTPUT SPEED SENSORS (37) (27).........................B3.74
CHECKING THE ACCELERATOR PEDAL POSITION SENSOR (197) .......................................................................B3.74

"SLOW" MEASUREMENT AND CHECKING POINTS

CHECKING THE SLOW SWITCH (47) .........................................................................................................................B3.75

"DISPLAY" MEASURING AND CHECKING POINTS

CHECKING THE TRANSMISSION LCD DISPLAY.......................................................................................................B3.76

Ares 507-607 – 06.2005 – GB