Technical service manual and automatic transmission diagnosis
The operations guide provides step-by-step instructions for removing and installing, dismantling and assembling the Mercedes automatic transmissions. Describes in detail the rabotasistemy control. The possible faults and remedies, describes the design features of gearboxes and Mercedes 722.5 722.4. The annexes contain all necessary for operation, maintenance and repair of Mercedes Benz. Mercedes models 722.3, 722.4, 722.5, 722.6. hydraulic


Content:

Chapter i. Mercedes 722.3, 722.4 7
1. General device 8
2. control features an automatic transmission 11
Getting traffic 11
Stop 11
Towing Mersedes 11
Accidental engine starting with the tugboat 11
3 Hydraulic control system 11
Main and auxiliary pumps 11
Valve box 12
Formation of working pressure 12
The influence of vehicle speed 13
The influence of power, the engine developed 14
Formation pressure modulator 15
Pressure lubrication systems 16
Forming pressure control valve-throttle 16
Formation pressure speed control 19
Increased pressure regulator 20 speed
Pressure prop 20
21 gear shift control system
Reverse switch in motion (work multi-launch rocket valves) 25
Slide range modes of automatic gearbox 26
System battery 27
Control system forced lowering transfer 29
Work programme switch 30
4 gearbox lubrication system 31
Periods of service 31
Oil level 31
Oil capacity 31
Drain and change oil 31
5 adjust the 31
31 range switching system
Cable-throttle valve control 32
Range selection lever position sensor in position " N 33
Check the pressure in the control system of the automatic transmission 33
Pressure modulator 34
Working pressure of 35
Pressure regulator speed 35
Check the vacuum circuit 36
37 6 road test
Service vehicle 40
7 modification of elements of the control system of the gearbox and 40
40 modulator
Modification of valve-throttle Mercedes 722.3 1986 and subsequent years of issue 41
Modification of piston and piston rod B1 42 band brake
Later modifications to the valve box 43
Distribution identification plate valve box 44
Band brake piston modification 44 B2
8. Alerts and tips 45
Mount the modulator Mercedec 45
Location of nozzles and valves 46
Primary pump automatic transmission 722.4 47
Replace o-ring (RC-5601) in the aluminum pole sleeves K1 47
Replacing the o-ring in the aluminum pole sleeves K2 48
Lubrication system modification back 48
9. Troubleshooting Troubleshooting 49
Faults: transmission slips at all ranges 49
Slip on the second pass, or it switches from 1-St to 3-d transfer 49
Sliding of the breakaway with 1 or 2 second pass or even ~
You can't move forward but reverse movement occurs normally 4S
Slide 2-3 when you switch or slide
at the beginning of the switch and a sharp turn at the end of the transfer 49
Slide switch 3-4 43
The gearbox there is a tight connection between the lead and driven shafts or it breaks down after a short period of 50
Some time after the engine starts, the vehicle remains stationary in all positions of the range selection lever (especially after a long parking) 50
The gearbox there is a tight connection between the lead and driven shafts when the reverse gear 50
A sharp Jolt when installing the range selection lever at position " (D) " or " R 50
When you switch to transfer the vehicle sharply twitches 50
A sharp Jolt during brownout transfer 4-3 51
The dramatic switch with partial load engine 51
No forced downward transfer of 51
No brakes when switching (4-3 and 3-2) 51
Unwanted downgrading the transfer with a slight push on the throttle pedal 51
No more switching 51
Switch to a higher gear occurs only in the upper RPM range of the engine 52
Switch to a higher gear occurs only in the lower engine speed range 52
The motor does not start when you install the range selection lever at position " " " N or p 52
Reduce oil level (without external signs of leaks) and the emergence of more dark exhaust smoke 52
Oil leak in the transformer or main pump (oil on the vent grille) 52
A howling sound, increasing with increasing engine speed 52
Jarring sound when engine speed 1500 rpm on all bands except band (" R ") 5z
Scrape into a small lever to select the range in the " r " and " N 53
Jarring noise when driving on reverse transfer 53
Low acceleration when starting with 53 sites
The parking mode is 53
Range selection lever is not in the " R " and r " 53
The transmission oil coolant was hit by engine 53
Noisy gearbox runs in first gear and reverse gear 54
Strong noise in third gear 54
Howling noise only when switching and traffic with ultimate load 54
Later the gear shift forward on all bands (Mercedes 722.3/722.4 -1991 year 1980) 54
There are oil leaks at the front of the gearbox after replacing seals and overhaul 1
(Mercedes models 722.3 early 1980-84 (6 bolt Pan)) 54
Some 190 series gearboxes after overhaul there may be drastic modes switch reverse gears. All transmissions are normally forward and pressure modulator is within an acceptable range (Mercedes 722.4) 55
Hard to shift ranges " and " D " R " and knock in any PTO shaft lever when selecting a range of provisions of " D " " R or 55
Sharp turn on reverse transfer (Mercedes 722.4) 56
Overheating transmission oil; It has a very dark or black, but it doesn't smell (Mercedes 722.4 production from July 1986 to February 1987) 57
Random 4-3 and 3-2 gear 57
After the overhaul of the Mercedes, equipped with an automatic transmission, or a 722.3 722.4 runner when reverse gear or it is not included in General 57
Gliding initially and subsequently transfer is strictly backward; automatic transmission goes into neutral mode when you release the pedal, the throttle and hard work goes into reverse mode when it is moving; will not turn on, or the very hard-going pereklûčenie3-4 (Mercedes 722.4) 59
10. adjusting the friction controls automatic transmission 60
Band brake adjustment B1 60
Band brake adjustment B2 60
The length of the piston stroke in auxiliary muftah 61
Stroke in the disk brake VZ 61
11. repair of the valve chest 62 MB
Removing the valve box Mercedes Benz 62
Assembly and disassembly of the valve box 64
12. Speed control knob and the rear (auxiliary): pump removal and installation 67
13. removing and replacing the automatic gearbox 74
14. Disassemble automatic transmission 79
15. building automatic transmission 87
16. Assembly and disassembly of the front of the automatic gearbox 104
17. Assembly and disassembly of the planetary mechanisms 106
18. dismantling, assembling and adjusting the clutches K1 110
19. dismantling, assembling and adjusting the coupler K2 113
Chapter II. Mercedes 722.5 117
1. control features an automatic transmission 722.5 117
2. adjust the 121
Removal, installation and adjustment of the rope of vacuum pressure control element for vehicles with program selection switch of the control system of 122
3. check the operation of the automatic gearbox in 124 traffic
Check the movement of 124
Value corresponding to the speeds switching points 125
4. repair of valve box (supplement to 722.3 and 722.4) 126
5. dismantling, assembling and adjusting the brakes rear planetary series BS 128
6. dismantling, assembling and adjusting the locking sleeve KS 130
Installing couplings 130
Operations that must be performed after disassembling couplings 135
Assembly 135
Disassembly-Assembly clutch free running 137
7. range selection lever lock System on a 1990 model year issue 138
Switching delay 2-3 when the engine coolant temperature is below 40° c 139
9. protection of the automatic gearbox from overload 140
Backup system 140
10. Switch on fifth gear 140
Chapter III. Mercedes 722.6 141
1. General information of 141
2. identification of the gear box 141
3. the device of gear box 141
Carter Mersedès 141
Gearbox Mèrsedes 142
Electro-hydraulic control box 142
143 gearbox control
Device and system for selecting a range of gear 144
The locking bolt output shaft GEARBOX 146
Ignition key lock 146
Maintenance instructions GEARBOX 147
Torque converter 148
Planetary gear 148
The mechanism of blocking the output shaft AUTOMATIC TRANSMISSION 150
Mechanism of regulation of the oil level in GEARBOX 150
Crankcase ventilation system 151 AUTOMATIC TRANSMISSION
4. the AUTOMATIC TRANSMISSION control system of 151
Electronic control unit for AUTOMATIC TRANSMISSION (EGS) 151
Program switches 151
Interaction with 152 engine
The Office Converter clutch clutch 152
Adaptation of 152
The input and output signals of the AUTOMATIC TRANSMISSION control unit 152
Board converter clutch clutch 154
Electro-hydraulic control unit 154
Solenoids 155
The output shaft speed sensor AUTOMATIC 155
Safety sensor (ASK) 155
Oil temperature sensor 155
Oil pump 157
Working pressure (p-a) 157
Lubrication pressure (p-Sm) 157
Pressure modulation (Mod p) 157
Pressure switch (p-S) 158
Regulatory pressure solenoids (p-r) 158
Pressure switch solenoids (p-SV) 158
Lock the torque converter clutch control valve 158
Group gear 158
Group B1 switch K1/159
K2 switch panel/CZ 159
Toggle group CZ/B2 159
Pressure valve overlap (RS-U) 158
Boost valve gear 159
Pressure equalization valve 160
Valve switching 160
Switch 1-2 160
Processes that occur when translating from the range selection lever " N " D " " position (first gear) 161
5. diagnosis of gearbox Mèrsedes 162
Trouble codes transmission car with 722.6 162
Diagnostic connector (DLC) 166
Transmission identification 168
Design change adapter lock locking the output shaft GEARBOX (PLIL) 175
6. disassembly of the drive train 177
Disassembly and Assembly of disk brakes 178 B1
Assembly and disassembly of the disc brake 180 B2
Pressure inlet openings 181
Disc brake assembly and disassembly of the EOI 182
The front has led planetary number of 184
Locking sleeve K1 186
A driven shaft 186
Adjustment of axial shaft runout 190
7. electro-hydraulic control unit 191
Disassembly and Assembly of electric hydraulic control unit (722.6 transmission type 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230, 240; 722.6 transmission type 461.302/332/342/345, 463.206/209/232/233/240/241/243/244/245/246/247/248/249/250/254/308/309/322323/330/331/332/333) 197
Disassembly and Assembly of electric hydraulic control unit (transmission type 722.610 463.209/323/244/245/250; transmission type 722.6611 463.308/330/331; transmission type 722.630 463.206/240/241/243/246/247/248/249/254; transmission type 722.637 461.302/332/342/345, 463.322/722.638 transmission type 323; 463.309/332/333) 201
Application 1. General design of hydraulic control system of the gearbox 722.6 20 g
Annex 2. Plan of angular speeds and kinematic scheme of automatic gearboxes 722.3, 722.4, 722.5 (without taking into account the accelerating number of planetary) 204
Annex 3. Calculation of the loading gear 204 items
Annex 4. Color illustrations
Legend
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Year of release: 2010
The type of proceedings: an illustrated guide to the repair




 



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