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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates. |
- Park the machine on a smooth, level surface.
- Shift the rocker switch for the transmission direction control to the NEUTRAL position.
- Lower the work tool to the ground.
- Engage the parking brake.
- Place blocks in front of the wheels and behind the wheels.
- Install the steering frame lock.
- Remove the front axle shafts and rear axle shafts except for stall tests.
- Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.
Note: All tests and all adjustments must be made while the transmission oil is at normal operating temperature.
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Do not connect or disconnect hose fittings to or from the quick disconnect nipples when there is pressure in the system. This will prevent damage to the seals that are in the fitting. |
| Required Tools | ||
| Part Number | Description | Qty |
| 1U-5481 | Pressure Gauge Group | 1 |
| 1U-5482 | Pressure Adapter Group | 1 |
Diagnostic Testing of the Transmission Electronic Control
The electronic control module (ECM) for the transmission is located below the floor panel at the right rear of the cab. The main function of the ECM is shifting the transmission. The ECM receives information from the transmission controls and the auto/manual switch in order to shift the transmission to the desired speed and direction.
The ECM also controls the starting of the engine and the backup alarm. The ECM will not allow the engine to be started unless the direction control switch is in the NEUTRAL position. The backup alarm is activated when the direction control switch is in the REVERSE position.
The ECM has a built-in diagnostic system in order to detect faults in the electronic system of the transmission. The diagnostic information is displayed on the electronic display module, when the system is placed in the service mode. For information about system operation and testing and adjusting, refer to Service Manual, "Electronic Transmission Control System".
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| Illustration 1 | g00286809 |
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Transmission Hydraulic Control in the NEUTRAL position and with the Engine Stopped. (1) Clutch solenoid valve for the Number 2 clutch (2) Clutch solenoid valve for the Number 3 clutch (3) Oil cooler (4) Transmission lubrication passage (5) Clutch solenoid valve for the Number 6 clutch (6) Clutch solenoid valve for the Number 1 clutch (7) Clutch solenoid valve for the Number 5 clutch (8) Clutch solenoid valve for the Number 4 clutch (9) Torque converter outlet relief valve (10) Torque converter housing (11) Flow control orifice (12) Torque converter (13) Converter inlet ratio valve (14) Slug (15) Slug (16) Modulating relief valve (17) Direction selector spool (18) Transmission oil filter (19) Second speed and fourth speed selector spool (20) Oil pump (21) Pressure differential valve (22) Load piston (23) Orifice (24) First speed and third speed selector spool (25) Suction screen and magnet (26) Reservoir (A) Transmission lubrication pressure tap (B) Torque converter outlet pressure tap (C) P3 Torque converter inlet pressure tap (D) P1 Speed clutch pressure tap (E) Pump pressure tap (F) P2 Directional clutch pressure tap | |
| Transmission Pressures(1) | ||||
| Pressure | Pressure Tap | Position of Governor Control Lever | Adjustment | |
| Pressure at Low Idle | Pressure at High Idle(2) | |||
| Transmission Lubrication Oil (1AY1-up, ; 7WY1-up, ; B6E1-up, and ; 1RY1-up) | (A) | This pressure is a minimum of |
This pressure is |
- |
| Transmission Lubrication Oil (1WY1-up) | (A) | This pressure is a minimum of |
This pressure is |
- |
| Converter Outlet Pressure | (B) | - | This pressure is a minimum of |
Add spacers (28) or remove spacers (28).(3) |
| Converter Inlet Pressure "P3" | (C) | - | This pressure is a maximum of This pressure is a maximum of |
- |
| Direction Clutch "P2" | (D) | This pressure is |
This pressure is |
- |
| Oil Pump | (E) | - | This pressure is |
- |
| Speed Clutch "P1" (Initial Pressure) | (F) | The pressure is |
- | Add spacers (29) or remove spacers (29).(3) |
| Speed Clutch "P1" | (F) | This pressure must not be less than |
This pressure is a minimum of |
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| (1) | This data is taken when the following conditions are met: oil at normal operating temperature, parking brake engaged and installed axle shafts. |
| (2) | The data in this column is taken with the engine at high idle. The transmission lubrication pressure is not taken with the engine at high idle. |
| (3) | Refer to Table 3. |
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| Illustration 2 | g00287064 |
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Transmission (A) Transmission lubrication pressure tap. (D) Direction clutch pressure tap "P2". (F) Speed clutch pressure tap "P1". (G) Access plug for load piston plug. | |
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| Illustration 3 | g00287155 |
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Transmission Control Valve (C) Converter inlet pressure tap "P3". (D) Direction clutch pressure tap "P2". (F) Speed clutch pressure tap "P1". (G) Access plug for load piston plug. | |
Removal Procedure For Load Piston Plug
- Turn the engine start switch to the OFF position.
- Remove access plug (G).
- Install a 5/16-18 bolt into the end of load piston plug (H). Remove the plug.
- Install access plug (G).
Installation Procedure For Load Piston Plug
- Turn the engine start switch to the OFF position.
- Remove access plug (G).
- Install a 5/16-18 bolt into the end of load piston plug (H). Remove the bolt.
Note: Verify that the O-ring is installed on plug (H) and that the seal is in good condition.
- Install access plug (G).
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| Illustration 4 | g00287162 |
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Relief Valve (B) Torque converter outlet pressure tap. | |
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| Illustration 5 | g00287163 |
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Transmission Control Valve (C) Torque converter inlet pressure tap "P3". | |
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| Illustration 6 | g00287165 |
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Transmission Oil Filter (E) Pressure tap for transmission oil pump. | |
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| Illustration 7 | g00287171 |
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Torque Converter Outlet Relief Valve (9) Relief valve body. (27) Relief valve. (28) Spacers. | |
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| Illustration 8 | g00287176 |
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Transmission Selector and Pressure Control Valve (22) Load piston. (29) Spacers. | |
| Spacers | |||
| Pressure Change for the Valve(1) | |||
| Description | Thickness | Pressure Change | Location of Spacers |
| 4M-1751 Spacer (28) | |
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Outlet relief valve (9) |
| 5S-7001 Spacer (28) | |
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| 5M-9622 Spacer (29) | |
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Load Piston (20) |
| 5M-9623 Spacer (29) | |
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| 5M-9624 Spacer (29) | |
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| (1) | Result of the addition of one spacer or the removal of one spacer to the valve. |
| Speed Range and Direction | Engaged Clutches and Energized Solenoids |
| Fourth Speed Forward | 3 and 2 |
| Third Speed Forward | 4 and 2 |
| Second Speed Forward | 5 and 2 |
| First Speed Forward | 6 and 2 |
| Neutral | 3 |
| First Speed Reverse | 6 and 1 |
| Second Speed Reverse | 5 and 1 |
| Third Speed Reverse | 4 and 1 |
| Fourth Speed Reverse | 3 and 1 |