Professional Documents
Culture Documents
Section
6002
POWERSHIFT TRANSMISSION SPECIFICATIONS,
PRESSURE CHECKS AND TROUBLESHOOTING
Bur 5-12130
6002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST PORT AND COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATING THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels Rotate When Vehicle is Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Irregular Clutch Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Remains Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Printed in U.S.A.
6002-3
SPECIFICATIONS
Forward and reverse clutch pressures
At 2200 rpm............................................................................... 13.5 to 16.5 bar (196 to 240 psi), clutch activated
0 to 0.3 bar (0 to 4.3 psi), clutch released
Filter bypass valve .........................................................................................................8 to 11 bar (116 to 159.5 psi)
Lube pressure...................................................................................................................1 to 5 bar (14.5 to 72.5 psi)
Torque converter inlet pressure ......................................................................................3 to 9 bar (43.5 to 130.5 psi)
Differential lock ............................................................................................................14 to 17 bar (203 to 246.5 psi)
Brake booster port .......................................................................................................14 to 17 bar (203 to 246.5 psi)
Park brake pressure switch.........................................................................................9 to 11 bar (130.5 to 159.5 psi)
Park brake check port.........................................................................................13.5 to 15.5 bar (195.8 to 217.6 psi)
IMPORTANT: Vehicle may move during park brake pressure check, check park brake pressure from inside of cab
by removing floor plate.
Pump flow
At 900 rpm bench test before filter ............................................................................... 19 l/min. minimum (5 gpm)
1st gear clutch
At 900 rpm......................................................................................................11.5 to 14.5 bar (166.8 to 210.3 psi)
At 2200 rpm....................................................................................................13.0 to 15.5 bar (188.5 to 224.8 psi)
2nd gear clutch
At 900 rpm......................................................................................................14.0 to 16.5 bar (203.0 to 239.3 psi)
At 2200 rpm....................................................................................................15.5 to 18.0 bar (224.8 to 261.0 psi)
3rd gear clutch
At 900 rpm......................................................................................................14.0 to 16.5 bar (203.0 to 239.3 psi)
At 2200 rpm....................................................................................................15.5 to 18.0 bar (224.8 to 261.0 psi)
4th gear clutch
At 900 rpm......................................................................................................14.0 to 16.5 bar (203.0 to 239.3 psi)
At 2200 rpm....................................................................................................15.5 to 18.0 bar (224.8 to 261.0 psi)
4 Wheel drive check port
At 900 rpm......................................................................................................13.5 to 15.0 bar (195.8 to 217.6 psi)
At 2200 rpm....................................................................................................14.5 to 16.5 bar (166.8 to 239.3 psi)
Forward/Reverse clutch solenoids...................................................................................... 7.15 Ohm at 20 C (68 F)
Four wheel drive solenoid................................................................................................... 7.15 Ohm at 20 C (68 F)
Park brake solenoid .............................................................................................................. 9.8 Ohm at 20 C (68 F)
S 1/3 solenoid..................................................................................................................... 7.15 Ohm at 20 C (68 F)
S 2/4 solenoid..................................................................................................................... 7.15 Ohm at 20 C (68 F)
PWM 1/3 solenoid .............................................................................................................. 7.25 Ohm at 20 C (68 F)
PWM 2/4 solenoid .............................................................................................................. 7.25 Ohm at 20 C (68 F)
NOTE: All pressures and flows to be measured with oil temperature of 80 C (175 F).
Bur 5-12130
Issued 3-08
Printed in U.S.A.
6002-4
SPECIAL TOOLS
B877558U
B785789M
B797157M
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Printed in U.S.A.
6002-5
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BC08A224
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VALVE BODY
OIL FILTER BYPASS VALVE
SPEED PICKUP
4TH CHECK PORT
5.
6.
7.
8.
Issued 3-08
Printed in U.S.A.
6002-6
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10
11
BC08A225
FRONT VIEW
9. SPIN ON FILTER
10. OIL PUMP
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6002-7
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BC08A226
Bur 5-12130
THERMOSTAT
16. 3RD CHECK PORT
OIL RETURN FROM COOLER 17. DRAIN PLUG
OIL PORT TO COOLER
18. ID PLATE
SUCTION FILTER
Issued 3-08
Printed in U.S.A.
6002-8
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BC08A227
REAR VIEW
19. BOOSTER PORT TO VEHICLE BRAKES
20. HYDRAULIC PUMP MOUNT
21. SAHR PARKING BRAKE HOUSING
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6002-9
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BC08A228
TOP VIEW
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PRESSURE SENSOR
29. REVERSE CLUTCH TEST PORT
BREATHER
30. OIL CHECK PORT
LUBE PRESSURE TEST PORT
31. DIFFERENTIAL LOCK TEST PORT
FORWARD CLUTCH TEST PORT
Issued 3-08
Printed in U.S.A.
6002-10
Bur 5-12130
Issued 3-08
Printed in U.S.A.
6002-11
TROUBLESHOOTING PROCEDURE
NOTE: All troubleshooting procedures must be done with oil at operating temperature.
e
No
No
No
Troubleshooting complete.
No
Yes
Is the SAHR parking brake releasing.
Yes
Check for broken universal joint or drive
shaft and repair as required. Is there still a
problem?
Yes
Check to see if drive shaft turns with
transmission directional control lever (FNR)
in forward or reverse and rear wheels off the
ground. Does the drive shaft turn?
No
Check the fuse panel.
Yes
No
Yes
No
Yes
Continued on next page.
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Printed in U.S.A.
6002-12
No
No
Yes
Check clutch pressure.
Is the pressure in the specified range?
Yes
Check the transmission. See Section 6007.
Repair or replace as required.
Loss of Power
Is oil level correct? Add oil as required.
Is there still a problem?
No
Troubleshooting complete.
Find cause for loss of oil.
No
Troubleshooting complete.
No
No
Yes
Is there a build up of mud or other foreign
material on inside of wheel wells or along
drive train? Clean or remove material.
Is there still a problem?
Yes
Do stall test according to instructions in
Section 2002.
Is the engine good?
Yes
Check pressure. Is the pressure as specified?
Yes
See Machine will not Move on page 11.
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6002-13
No
Troubleshooting complete.
Find cause for loss of oil.
No
Troubleshooting complete.
No
No
Yes
Check transmission oil cooler for air flow
restriction. Clean exterior of transmission oil
cooler as required.
Is there still a problem?
Yes
Check converter in pressure.
Is the pressure and flow as specified?
Yes
Check lube pressure. See page 9. Is the
pressure as specified?
Yes
Troubleshooting complete.
NOTE: The transmission oil cooler cannot be flushed or cleaned out, the transmission oil cooler must be
replaced if restricted or plugged.
No
Troubleshooting complete.
Yes
Yes
Yes
Is oil temperature low (high oil viscosity)
No
Control valve allowing pressure to clutches
while in neutral position.
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Printed in U.S.A.
6002-14
Transmission Noisy
Is oil level correct? Add oil as required.
Is there still a problem?
No
Troubleshooting complete.
Find cause for loss of oil.
Yes
Yes
Yes
Yes
Damaged converter.
No
Damaged oil pump.
No
Seized or broken gears, shafts, bearing, etc.
No
Troubleshooting complete.
Find cause for loss of oil.
No
No
Yes
Check clutch pressure
Is the pressure in the specified range?
Yes
Check for TRAX fault codes
Are fault codes present
Yes
See section 4005 and this section for
troubleshooting procedures.
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Issued 3-08
Printed in U.S.A.
6002-15
No
Troubleshooting complete.
Find cause for loss of oil.
No
No
No
Troubleshooting complete.
No
No
Yes
Check clutch pressure in neutral position
Is the pressure in the specified range?
Yes
Check for TRAX fault codes
Are fault codes present
Yes
See section 4005 and this section for
troubleshooting procedures.
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Printed in U.S.A.
6002-16
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Electrical
No
Troubleshoot and repair
transmission as needed,
see section 6007.
Yes
No
Yes
Troubleshooting complete
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6002-17
NOTES
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HYDRAULIC COMPONENTS
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6002-20
BC08A418
CONTROL VALVE
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BD08B401-01
NOTE: Remove the floor plate to gain access to the connectors for the transmission, connector J1 (1) and
connector J2 (2).
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6002-21
DEU_DT04-12P
DEU_DT04-8P
CONNECTOR J1
CAV
TO CAV
COMPONENT
CONNECTOR J2
CAV
TO CAV
COMPONENT
PIN 2
PIN 1
FORWARD SOLENOID
PIN 1
S 1/3 SOLENOID
PIN 2
FORWARD SOLENOID
PIN 1
S 2/4 SOLENOID
PIN 1
REVERSE SOLENOID
PIN 2
PIN 2
REVERSE SOLENOID
PIN 1
4WD SOLENOID
PIN 1
PIN 1
DIFFERENTIAL LOCK
SOLENOID
PIN 2
PIN 1
PIN 1
RPM SENSOR
PIN 2
PIN 3
RPM SENSOR
PIN 1
TEMP SENSOR
10
PIN 3
TEMP SENSOR
11
PIN 1
PRESSURE SENSOR
12
PIN 2
RPM/TEMP/PRESS SENSORS
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Issued 3-08
Printed in U.S.A.
6002-22
ELECTRICAL SCHEMATIC
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5.
6.
FNR SHIFTIER
7.
TRANSMISSION CONTROLLER 8.
FORWARD SOLENOID
9.
REVERSE SOLENOID
10.
PWM 1/3 SOLENOID
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PWM 2/4 SOLENOID
12.
1/3 SOLENOID
2/4 SOLENOID
4WD SOLENOID
DIFF LOCK SOLENOID
SPEED SENSOR
TEMP SENSOR
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PRESSURE SENSOR
J2 CONNECTOR
J1 CONNECTOR
BRAKE PRESSURE SWITCHES
AUTO/MANUAL SWITCH
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22.
NOTE: See electrical schematic in rear pocket of manual for complete circuit.
Bur 5-12130
Issued 3-08
Printed in U.S.A.