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Powershift S-type
Transmission
Neutral ...................................................................................................................................... 16
Torque from the engine is transferred into the gearbox by a conventional hydraulic torque
converter. Gear reduction is achieved by constant-mesh spur gear type of gear train.
Mechanically, the Powershift S-type transmission is very similar to the Power shuttle
transmission which has been successfully used in the Case loader backhoes for many years.
This transmission offers 4 forward and 3 reverse speeds, and all speed range gears are shifted
by dog type synchronizers with blocking rings. The synchronizers are shifted by two shift forks,
one for the 1st and 2nd gears, and the other for the 3rd and 4th gears. The forks are mounted
to shift rails which are positioned by hydraulic pressure. Forward and Reverse are hydraulically
engaged by multi-plate clutch packs.
The transmission oil to engage the clutches, shift, lubricate bearings, provide fluid for the
torque converter, and cool the transmission is supplied by a charge pump driven by tangs on
the torque converter. The fluid to move the shift rails and clutches is controlled by electric
solenoids at a control valve manifold mounted to the top of the transmission. The electric
solenoids are actuated by an electronic transmission controller (TRAX).
There is no automatic shifting mode with this transmission, and the transmission will shift gears
only as requested by input from the operator.
A hydraulic pump drive shaft engages splines in the front of the torque converter housing and
carries torque through the center of the hollow input shaft, engaging the machine hydraulic
pump at a mounting flange at the rear.
The Powershift S-type transmission uses the same Case Hytran Ultra fluid as used in the
hydraulic system, as well as the other two transmission options for the N series loader
backhoes.
Kickdown Button
Declutch Button
Differential Lock
6 HDL out
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REV PWM solenoid to ramp up pressure and engage the reverse clutch
FWD PWM solenoid to ramp up pressure and engage the forward clutch
S3 Engages 3rd gear by sending pressure to the 3rd piston and dumping the 4th piston
S1 Engages 1st gear by sending pressure to the 1st piston and dumping the 2nd piston
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4th shift 3rd gear 3rd/4th shift 4th gear 3rd shift 3N4 neutral
piston switch rail/fork assembly switch piston piston
2nd shift 1st gear 1st/2nd shift 2nd gear 1st shift 1N2 neutral
piston switch rail/fork assembly switch piston piston
When the machine is first started, the TRAX controller checks to make sure that the shift rails
are in a neutral position, then immediately shifts into the gear position requested by the FNR
lever input.
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If the shift cannot be completed, and the gear position switches do not indicate the expected
result within an allotted time, the transmission will attempt to complete the shift three times.
If after three attempts the shift still cannot be completed, a fault code is generated and the
transmission will not operate. Refer to the fault code information later in this section for more
information.
Be aware with transmission oil temperatures below freezing, the shifting process can take a
significant time to complete due to the thick oil viscosity, and the shift may not complete in
time. This can result in fault code(s) being generated by the TRAX controller. Operational
complaints and/or nuisance faults codes may be generated if the operator attempts to
immediately drive the machine after starting in very cold weather. However, driving the
machine for one to two minutes to provide warm-up will heat the oil sufficiently for the
transmission shifting to resume normal shifting times.
The following pages will show how the shifting takes place in the transmission.
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The 3rd/4th shift rail remains in the neutral position, with the 3N4 and 4th shift pistons
remaining under pressure. The 1N2 piston is also pressurized, but is not a factor as the piston
cannot move any farther to the left due to the machined step in the case.
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The 3rd/4th shift rail remains in the neutral position, with the 3N4 and 4th shift pistons
remaining under pressure.
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The 1st/2nd shift rail remains in the neutral position, with the 1N2 and 2nd shift pistons
remaining under pressure. The 3N4 piston is also pressurized, but is not a factor as the piston
cannot move any farther to the left due to the machined step in the case.
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The 1st/2nd shift rail remains in the neutral position, with the 1N2 and 2nd shift pistons
remaining under pressure.
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• Selected Gear: This is the gear which the TRAX controllers interprets that has been
specified by the operator through the FNR switch gear command 01 & 02.
• Current Gear: This is the gear that the TRAX controller sees the transmission is in.
• S-type – Gear 1 & 2 Analog voltage: input from the resistor network
• S-type – Gear 3 & 4 Analog voltage: input from the resistor network
• S-type – Gear Command 02 Status: input from FNR switch / Comfort Steer Cutout relay
• S-type – Gear SW1 logical status: TRAX interpretation of gear switch position based on
analog voltages from resistor network
• S-type – Gear SW2 logical status: TRAX interpretation of gear switch position based on
analog voltages from resistor network
• S-type – Gear SW3 logical status: TRAX interpretation of gear switch position based on
analog voltages from resistor network
• S-type – Gear SW4 logical status: TRAX interpretation of gear switch position based on
analog voltages from resistor network
• S-type – Solenoid valve 1 Status: TRAX controller is sending current to this solenoid.
• S-type – Solenoid valve 2 Status: TRAX controller is sending current to this solenoid.
• S-type – Solenoid valve 3 Status: TRAX controller is sending current to this solenoid.
• S-type – Solenoid valve 4 Status: TRAX controller is sending current to this solenoid.
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Following is an example EST screen shot showing these parameters being monitored:
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• A 5 V sensor supply voltage, ground, and the gear switches are connected to a “resistor
network” that converts the four switch states into two voltage signals.
• The 2 voltage signals should only be at distinct levels: 1V, 2V, 3V, or 4V.
• If the voltage signal is in between levels, like 3.55V for example, then look for
water/contamination in the harness especially in the 4 connectors for the gear position
switches.
2V Both 1st and 2nd gear switches are open, rail is between gears
3V Both 1st and 2nd gear switches are closed, rail is in neutral
2V Both 3rd and 4th gear switches are open, rail is between gears
3V Both 3rd and 4th gear switches are closed, rail is in neutral
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The TRAX controller always makes sure the transmission is shifted into neutral upon startup.
After this initial check for neutral, the transmission will shift into which ever gear is requested
by the FNR lever position.
The following table shows the gear switch logical status for each gear:
Neutral ON ON ON ON
1st OFF ON ON ON
2nd ON OFF ON ON
3rd ON ON OFF ON
4th ON ON ON OFF
1st 12V 0V
2nd 0V 0V
3rd 0V 12V
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1. Remove all four 2-pin connectors that go to the gear position switches.
2. Carefully Insert a jumper (piece of wire) into each connector, shorting the pins together
to simulate the gear switches being closed.
4. Remove one jumper at a time. If the 1stgear position switch jumper is removed then the
“gear 1 and 2 analog voltage” and “gear switch 1 logical status” should match the
expected values below, 1V and OFF.
5. The actual gear position switches can also be checked. If the unit is off, the shift rails
should be in neutral and all the switches will be closed. If one of the switches is
measured as open, either the switch is faulty or the shift rail is not in neutral.
6. The individual switches can be removed and manually cycled by pressing the plunger
while monitoring with the EST. Depressing the switch plunger should cause the switch
to go open, with an ‘OFF’ indication on the EST.
Following is a diagram of the switch locations as facing the right side of the transmission:
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Measure the
rail depth here
Measurement Interpretation
If the piston is out of position, then transmission hydraulic pressure tests should be performed
to determine whether the correct hydraulic pressures are being sent to the shift rail positioning
pistons to center the shift rails into neutral. The pressures to be checked should be determined
by which shift rail is out of position.
If the pressure tests show correct, then the shift piston or rail is physically jammed in position,
requiring transmission disassembly to correct.
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The following table shows which ports have pressure applied in each gear:
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2nd gear
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4th gear
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• For example, the TRAX pilots 2nd gear, but the gear position switches indicate that the
transmission is in 1stgear.
• Two possibilities, either the shift rail is actually in a position that it should not be or the
gear switches are giving a false indication of the shift rail position.
• This code is seen when the SPS fails to make a shift and then returns to the gear that
was previously selected. For example, the customer shifts the FNR from 2ndto 3rd, but
the SPS fails to make the shift and returns to 2nd.
• If the gear position switches are malfunctioning the transmission may be making the
shift, but the TRAX is receiving false information from the switches, like in the case of
the water in the connector.
• The length of each shifting attempt is based on the temperature of the transmission,
and can be up to 6 seconds.
• 4206 is the same as 4205, but the transmission is unable to make it back to the
previously selected gear.
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• Verify that the gear position switch giving the fault is open. If the switch reads closed,
then check for a harness/resistor network issue.
• If the switches and harness are functioning correctly, then the shift rail is out of position
at start-up.
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5 19ED Orange TRAX key on 12V when key on From fuse F-009
8 19EC Orange TRAX key on 12V when key on From fuse F-009
16 21C7 Yellow Neutral Input 12V when in neutral From FNR lever
17 0401 Blue Sensor Ground Ground at all times For sensors and resistor network
18 25A5 Light Blue Forward Input 12V when in forward From FNR lever
19 1902 Yellow Gear Command 1 12V in 1st and 4th From FNR lever
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22 25C2 Yellow 4wd Input 12V when 4wd From 4wd switch
29 G101 Black TRAX Ground Ground at all times Chassis Ground at loader handle stud
34 19EB Orange TRAX key on 12V when key on From fuse F-009
39 25X3 White 4wd Coil pos 12V in 2wd Solenoid energized in 2wd
44 3441 Yellow Pressure Sensor Ground > 9.5 bar Check using EST
45 3451 yellow 3rd/4th Analog V 1,2,3,or 4 Volts Depending on gear position switches
46 25B6 Light Blue Reverse Input 12V in Reverse From FNR lever
47 3223 Yellow Gear Command 2 12 V in 3rd and 4th From FNR lever
49 3214 Yellow Kickdown Input 12V to kickdown to 1st Active only when in 2nd gear
51 25S1 Yellow HDL Input 12V when diff lock From HDL button on loader handle
54 3541 Yellow 1st/2nd Analog V 1,2,3,or 4 Volts Depending on gear position switches
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Item Pressure
Control valve supply pressure 13 bar (189 psi) MIN @ 900 rpm
1N2, 3N4, 1st, 2nd, 3rd, 4th, HDL, 4WD 13 bar (189 psi) MIN @ 900 rpm
Torque converter inlet 1.5 bar (22 psi) MIN @ 900 rpm
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