Basis

Transfer gear by Dana & Spicer

Shift section

Filter
Var. displ. motor 1

Var. displ. motor 2

Special support
with rubber
element

Output to
rear axle

Page 2 L 544 - L 580 2plus2 Drive System

 Sensors on the Transfer Gear

Speed sensor B1 Pressure switch B5

Transfer gear output until Ser. No. 6996

Speed sensor B2
Variable displ. motor 1

Temperature switch
B14 / 120°C
Speed sensor B2a
Variable displ. motor 2

Page 3 L 544 - L 580 2plus2 Drive System

 Travel gear

Shift section
Var. displ. motor 2

Clutch 2
Filter

Var. displ. motor 1

Lubrication bores
Clutch 3

Clutch 1

Output shaft

Suction connection
with strainer

Page 4 L 544 - L 580 2plus2 Drive System

 Shift control unit and coupling 2

Var. displ. motor 2 Clutch 2

Piston Coupling disks Cup springs Channel clutch 1 Lubrication channel

Page 5 L 544 - L 580 2plus2 Drive System

 Transfer gear - Modulation

Smooth shifting is achieved by pressure modulation. The oil motor for the next
gear is accelerated continuously to its speed.
The fast filling period makes sure that the play of the clutch discs is nearly
zero. This period can be adjusted.
For modulation a defined small oil flow is directed to the clutch. In the
beginning of modulation the rest of the discs play is compensated. Then the
pressure on the clutch is increased and the clutch transmits the torque.

Page 6 L 544 - L 580 2plus2 Drive System

 Oil supply and cooling

Gear pump 16 cm³ Oil cooler

Shift section

Accumulator

Suction connec-
tion / Gear Filter

Page 7 L 544 - L 580 2plus2 Drive System

 Transfer gear - hydraulic circuit diagram

1 Variable displ. motor 1

2 Variable displ. motor 2
3 Coupling 2
4 Coupling 3 13 Pressure reducing valve
5 Coupling 1 14 solenoid valve -
6 oil supply for lubrication modulation
7 Gear pump 15 Modulation valve
16 Solenoid valve - coupling 1
8 Filter
17 Valve - coupling 1
9 Accumulator 18 solenoid valve - coupling 2
10 Oil cooler 19 Valve - coupling 2
11 safety valve 20 Solenoid valve - coupling 3
12 Pressure relief valve 21 Valve - coupling 3

Page 8 L 544 - L 580 2plus2 Drive System

 Transfer gear - shift control unit

Page 9 L 544 - L 580 2plus2 Drive System

 9. Check the shift pressure on the transmission

Procedure:
B5 P S M K2 K1 K3
 Connect a pressure gauge to test point P on the
gear shift section, on top.

 Start the machine and check at low and high

idle RPM if the shift pressure shows a value
of 20 ±3 bar.

 Adjustment: Insert shims on the pressure

relief valve in the shift section of the gear.

P = Pump pressure 20 bar

S = Lube oil pressure 1 bar

M = Control pressure 10 bar

K1 = Pressure in clutch 1

K2 = Pressure in clutch 2

K3 = Pressure in clutch 3

B5 = Pressure switch 13 bar

Page 10 L 544 - L 580 2plus2 Drive System

 10. Check the gear oil level

The gear oil level should be checked with the Diesel engine is running. The oil level should be checked at
approximately at 20 °Celsius.
If the oil temperature is higher, the oil level may be within the oil gage 2.

Procedure:

 Start the engine and check the oil level at low idle.

 Read oil level at gage 2 and 3.

 The oil level must be within oil gage 3.

 If the oil level is too low, add ATF-oil via plug.

Page 11 L 544 - L 580 2plus2 Drive System

 11. Change the gear oil

Change the oil with the machine at operating temperature. Change the filter at the same time.
Change transmission oil once at 500 und then all 1000 operating hours.

Procedure:

 Drain the oil via the drain plug into a suitable

container.

 Add ATF-oil via plug 1 (see check the oil level).

Dosage 11,5 liter.

 Then check the oil level and add oil as necessary.

Oil drain plug

The transmission is factory-filled with ATF 86 AVIA-FLUID DEXRON II D , Ident No. 861012601.
Mobil ATF 220 DEXRON II

Page 12 L 544 - L 580 2plus2 Drive System