REPAIRS

REPAIRS

Our company is rebuilding hydraulic transmissions and axles for construction equipment for over 40 years now. The brands we specialize in are CLARK, DANA, ALLISON, VOLVO and ZF. By constantly investing in the education of our technical personnel and under the personal engagement of the owner of the company, Mechanical Engineer Mr. Christos Mourafetis, we verify that the quality of our services is always in agreement with the manufacturer’s specifications.

By using our complete technical library for all these brands, even the dismantling is being done according to the manufacturer’s specifications, and by using the correct tools. All subassemblies are cleaned and inspected so that we can estimate the damage, and most important, find the cause of the failure. We estimate the cost of the repair, and in conciliation with the customer, we decide if we will only repair the damage, or if we will make a complete overhaul of the transmission.

By cooperating with the best companies worldwide, we can offer the option to have all “one piece” converters to be rebuilt. We also stock our most commonly used torque converters so that we can offer service exchange units and save time and money to our clients.

Our close to zero failure rate is the proof that we are always doing our best when we repair your hydraulic transmission.

Finally, each hydraulic transmission or axle that is coming in our workshop is uniquely identified and an electronic file is kept for each repair, so that we can always go back to the data of the last repair, even if it was made many years ago.

TEST STAND

We have our own automatic transmission test stand, where we have the ability to test a wide range of transmissions, from Allison AT545 (235hp) used in buses, to Allison H8610AR (1.100hp) used in 100 ton dumpers. During the test, the transmission is brought into working temperature, and all hydraulic pressures, speed, level and temperature sensors are being measured and the proper function of all analogue hydraulic valves (if they are used) is being verified. We make all the gear changes using our custom built electronic platform and we also check the horsepower that is consumed by the transmission in all the cases. All this data is electronically stored for each unique transmission for future use.

This way we are always certain about the proper function of the transmission, before it is put back to your machine, and we verify that there are no leaks or other mechanical or hydraulic problems that may required the transmission to be taken down again.

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The complete overhaul of your hydraulic transmission in our workshops includes:

  • Outer washing of the transmission before dismantling.
  • Complete dismantling of the transmission and all subassemblies (pump, pistons, control valve etc.).
  • Thorough cleaning of all subassemblies and judgement of their wear by comparing to the manufacturer’s specifications.
  • Replacement of all consumable parts according to manufacturer’s guidelines. These are all friction discs and metal plates, bearings, filter elements, suction strainer and hydraulic pump.
  • Rebuilding and testing of all subassemblies.
  • Assembly of the transmission according to the manufacturer’s service manual, always making sure that all tolerances and tightening torques are according to specifications.
  • We test the transmission in our test stand, checking all hydraulic pressures, speed, level and temperature sensors through our custom made software and we record the results for future reference.

We can offer the option to have your transmission ECU, joystick or pushbutton selector repaired. In case this is not feasible, we can offer new or rebuilt preprogrammed ECU’s in competitive prices.

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We stock a huge range of wire terminals for the wiring harnesses that DANA, ALLISON, ZF and VOLVO use, along with all the special tooling to have your wiring harness repaired at very low cost.

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The transmission, torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair or overhaul of one unit is performed, or a new unit is installed in the machine, the balance of the system must be considered before the job can be considered completed.

After the new or overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgment must be exercised as to the method employed. The following are considered the minimum steps to be taken:

  1. Drain entire system thoroughly.
  2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning.
  3. Replace oil filter elements, cleaning out filter cases thoroughly.
  4. The oil cooler must be thoroughly cleaned. The cooler should be "back flushed" with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes.
  5. Reassemble all components and use only recommended type oil. Fill transmission through filler opening until fluid comes up to LOW mark on transmission dipstick or until oil runs from LOWER check plug. Replace filler and level plug. Run engine two minutes at 500-600 rpm to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (500-600 rpm): add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level plug or dipstick. Recheck with hot oil (180-200 oF) [82.2-93.3 oC]. Add oil to FULL mark on dipstick or until it runs freely from UPPER oil level plug.
  6. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.
  7. Remember to replace oil filter element after 50 and 250 working hours and afterwards every 500 hours or when indicated on cartridge.
  8. Every 1000 hours, drain the system with oil at 150 - 200 oF [65.6-93.3 oC], clean sump screen, install a new filter element and refill as per above instructions.

Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions. Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination.

Use only approved type oil and GENUINE filters and parts, otherwise every kind of warranty will not applied.

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