D5R2 and D6R2 Track-Type Tractors Transmission Caterpillar

Before you complete any procedure, read Troubleshooting, "Machine Preparation for Troubleshooting" in this module.

Transmission Controls

Illustration 1	g01110111
D6T View From the Top Side of the Transmission (1) Transmission Modulating Valves (2) Modulation Valve (No. 1 Clutch for Reverse Direction) (3) Modulation Valve (No. 2 Clutch for Forward Direction) (4) Modulation Valve (No. 3 Clutch for NEUTRAL and THIRD GEAR) (5) Modulation Valve (No. 4 Clutch for SECOND GEAR) (6) Modulation Valve (No. 5 Clutch for FIRST GEAR) (7) Transmission Relief Valve

Problem List

• "The Transmission Does Not Operate in Any Gear"

• "Harsh Shifting of Transmission"

• "The Machine Makes an Abrupt Stop When You Shift into the NEUTRAL Position"

• "The Transmission Does Not Change Gear but the Machine Moves"

• "The Transmission Operates in FORWARD Gear Only"

• "The Transmission Operates in REVERSE Gear Only"

• "The Transmission Does Not Operate in FIRST GEAR FORWARD or REVERSE"

• "The Transmission Does Not Operate in SECOND GEAR in FORWARD or REVERSE"

• "The Transmission Does Not Operate in THIRD GEAR FORWARD or REVERSE"

The Transmission Does Not Operate in Any Gear

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Illustration 2	g03726495
Typical Cat ET screen

1. Use Cat ET To Check The FNR Signal From The Transmission Lever.

   1. Look for the following parameters:
      • "Transmission Level Position Sensor"

   2. These parameters should correspond to the values in Table 2.

      Expected Results

      Show/hide table

      Table 2

      FORWARD	69.1% to 95%
      NEUTRAL	41% to 59.5%
      REVERSE	5% to 30.9%

      Results

      • OK: The transmission lever is within tolerance. Proceed to Step 2.

      • NOT OK: Contact the technical communicator for your Dealer for possible consultation with AVSpare.

2. Operate The Machine.

   The two primary causes of this symptom are the transmission and the brakes. This step guides the diagnosis of the problem to the brakes or to the transmission.

   1. Start the engine.

   2. Operate the engine at high idle.

   3. Attempt to operate the machine. Shift the transmission into third gear forward. Observe the engine speed during shifts.

      Expected Results

      • The engine speed decreases. The engine is near stall condition during shifts.

      Results

      • NEAR STALL: Proceed to Step 3.

      • NO SIGNIFICANT DECREASE: The engine speed does not decrease significantly. Therefore, check the transmission first. Proceed to Step 4.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check The Brake Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Brake Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Brake Pressure - Test".

   Expected Results

   • The pressure is correct.

   Results

   • OK: The brake pressure is correct but the original problem is not resolved. Therefore, the transmission is the probable cause of the problem. Proceed to Step 6.

   • NOT OK: Proceed to Step 5.

4. Check For Transmission Drag.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".

   Expected Results

   • The maximum pressure for a clutch that is disengaged is less than138 kPa (20 psi).

   Results

   • OK: Proceed to Step 7.

   • NOT OK: Proceed to Step 8.

5. Follow The Procedure In This Reference.

   Refer to "The Machine Does Not Move or the Machine Moves Slowly" in this module under Troubleshooting, "Machine Movement".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: Proceed to Step 9.

6. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: Proceed to Step 9.

7. Eliminate Other Possible Causes.

   The condition can be caused by several other components. Eliminate the following components as possible causes of the problem.

   1. Torque divider (converter)

   2. Transfer or bevel gears

   3. Final drives

   4. Drive shaft

   5. Axle shafts

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: The cause of the problem is unknown. Use the information from the original problem to troubleshoot.

8. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

9. Inspect The Transmission.

   1. Disassemble the transmission. Inspect the transmission for damage.
      

      ReferenceFor D5R2 models, refer to the latest revision of Disassembly and Assembly, UENR4118, "Transmission".

      ReferenceFor D6R2 models, refer to the latest revision of Disassembly and Assembly, UENR4108, "Transmission".

   2. Replace components or repair components that are not functioning correctly, if necessary.

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

Harsh Shifting of Transmission

Follow this procedure if harsh shifts occur. Harsh shifting can occur when the transmission shifts into certain gears or when the transmission shifts from certain gears.

1. Operate The Machine.

   1. Operate the machine. Determine the shift or shifts that are harsh shifts.

   2. Determine the clutches that are used. Refer to Table 1 in "Transmission Controls" in this topic. The table shows the clutches that are used for the corresponding gears.

      Expected Results

      • One clutch is common for all harsh shifts.

      Results

      • YES: Proceed to Step 6.

      • NO: Proceed to Step 2.

2. Check The System Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Relief Valve (Transmission) - Test and Adjust".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Relief Valve (Transmission) - Test and Adjust".

   Expected Results

   • The system pressure is correct.

   Results

   • OK: Proceed to Step 6.

   • NOT OK: The cause of the problem may be the adjustment of the transmission relief valve. The transmission relief valve maintains the system pressure in the control section of the power train oil pump. Proceed to Step 3.

3. Check The Accumulator Charge Pressure.

   Correct accumulator precharge can improve shift quality and extend the service life of the power train. Ensure that the power train accumulator is functioning correctly and is not undercharged or overcharged. Low charge will cause harsh engagement.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Accumulator - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Accumulator - Test".

   Expected Results

   • The accumulator is functioning correctly.

   Results

   • OK: Proceed to Step 4

   • NOT OK: Adjust the precharge or if needed, replace the accumulator. Check the function of the accumulator again. If harsh shifting continues, proceed to Step 4

   Reference Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

4. Adjust The Transmission Relief Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Relief Valve (Transmission) - Test and Adjust".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Relief Valve (Transmission) - Test and Adjust".

   Results

   • REPAIRED, OK: Proceed to Step 6.

   • NOT OK: Proceed to Step 5.

5. Follow The Procedure In This Reference.

   Refer to "System Pressure Is Low" in this module under Troubleshooting, "Power Train Oil".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

6. Calibrate The Transmission Modulating Valves.

   1. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".

   2. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Proceed to Step 7.

7. Replace The Transmission Modulating Valves.

   1. Replace the modulating valves for the shifts that are harsh.
      

      ReferenceFor D5R2 models, refer to the latest revision of Disassembly and Assembly, UENR4118, "Transmission Hydraulic Control Valves".

      ReferenceFor D6R2 models, refer to the latest revision of Disassembly and Assembly, UENR4108, "Transmission Hydraulic Control Valves".

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Disassemble the transmission and inspect the transmission for failure. Repair the components and/or replace the components, if necessary. Check the operation of the machine for the original problem.

      
      

      ReferenceFor D5R2 models, refer to the latest revision of Disassembly and Assembly, UENR4118, "Transmission".

      ReferenceFor D6R2 models, refer to the latest revision of Disassembly and Assembly, UENR4108, "Transmission".

The Machine Makes an Abrupt Stop When You Shift into the NEUTRAL Position

The machine functions correctly when the transmission is engaged. However, the machine stops when the transmission is placed in the NEUTRAL position.

1. Check For The Symptom.

   1. Determine that the symptom is active.

   2. Follow this procedure only if the symptom is active.

      Results

      • ACTIVE: Proceed to Step 2.

      • NOT ACTIVE: The symptom is intermittent. Follow this procedure when the problem is active. Stop.

2. Check The Brake Pedal.

   1. Inspect the brake pedal. Determine if the pedal is returning to the original position.

   2. Repair the components or replace the components, if necessary.

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Proceed to Step 3.

3. Check The Brake Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Brake Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Brake Pressure - Test".

   Expected Results

   • The pressure is correct.

   Results

   • OK: Proceed to Step 7.

   • NOT OK: Proceed to Step 4.

4. Check The System Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Relief Valve (Transmission) - Test and Adjust".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Relief Valve (Transmission) - Test and Adjust".

   Expected Results

   • The system pressure is correct.

   Results

   • OK: Proceed to Step 8.

   • NOT OK: The cause of the problem may be the adjustment of the transmission relief valve. The transmission relief valve maintains the system pressure in the control section of the power train oil pump. Proceed to Step 5.

5. Adjust The Transmission Relief Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Relief Valve (Transmission) - Test and Adjust".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Relief Valve (Transmission) - Test and Adjust".

   • The pressure setting of the transmission relief valve is correct.

   • The original problem is resolved.

   Results

   • OK: Stop.

   • NOT OK: Proceed to Step 6.

6. Follow The Procedure In This Reference.

   Refer to "System Pressure Is Low" in this module under Troubleshooting, "Power Train Oil".

   Results

   • REPAIRED OK: The system pressure is correct but the original problem exists. Proceed to Step 8.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

7. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

8. Follow The Procedure In This Reference.

   Refer to "The Machine Does Not Move or the Machine Moves Slowly" in this module under Troubleshooting, "Machine Movement".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Change GEARS but the Machine Moves

Follow this procedure if the machine operates in both directions, but the machine only operates in a single speed.

1. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • YES: The Clutch is repaired.

   Proceed to Step 6.

   • NO: Proceed to Step 2.

2. Identify The Operation.

   1. Determine the operation of the machine.

      Results

      • AUTOSHIFT: Proceed to Step 3.

      • MANUAL SHIFT: Proceed to Step 4.

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Illustration 3	g03720881
Bidirectional Autoshift Selector Dial (1) Off (2) 1F1R (3) 1F2R (4) 2F1R (5) 2F2R

3. Test The Autoshift Operation.

   1. Turn the start switch key to the ON position. Do not start the engine.

   2. Fully disengage the parking brake.

   3. The dial for the autoshift function is located on the left B-post of the cab. The available modes are "1F1R", "1F2R", "2F1R" and "2F2R".
      

   4. Turn the Dial to #2 for the Autoshift function "1F1R".

   5. Move the transmission control from the FORWARD position to the REVERSE position. Then, move the transmission control back to the FORWARD position. The speed display progresses through the following sequence: "1F", "N", "1R", "N" and "1F".

   6. Turn the Dial to #3 for the Autoshift function "1F2R".

   7. Move the transmission control from the FORWARD position to the REVERSE position. Then, move the transmission control back to the FORWARD position. The speed display progresses through the following sequence: "1F", "N", "2R", "N" and "1F".

   8. Turn the Dial to #4 for the Autoshift function "2F1R".

   9. Move the transmission control from the FORWARD position to the REVERSE position. Then, move the transmission control back to the FORWARD position. The speed display progresses through the following sequence: "2F", "N", "1R", "N" and "2F".

   10. Turn the Dial to #5 for the autoshift function until the feature is OFF.

       Expected Results

       • The autoshift function operates properly.

       Results:

       • OK: Proceed to Step 4.

       • NOT OK: The autoshift function does not operates properly.

       Repair: Check these components: the wiring, the electrical connectors, the circuit boards and the electronic control module (ECM).

       Proceed to Step 6.

   11. Move the transmission control from the FORWARD position to the REVERSE position, then move the transmission control back to the FORWARD position. The speed display progresses through the following sequence:"2F","N","2R","N" and "2F"

4. Check The Operation Of The Upshift/Downshift Shifter Control.

   1. Check the operation of the Shifter Control by actuating the control in both directions to verify that proper transmission shifting occurs.

      Expected Results

      • The Shifter Control functions properly.

      Results:

      • OK: Proceed to Step 5.

      • NOT OK: The Shifter Control does not operate properly.

      Repair: Repair or replace the Shifter Control.

      Proceed to Step 6.

5. Check The Bidirectional Autoshift Selector Dial.

   1. Check the Bidirectional Autoshift Selector Dial, Illustration 3, to determine whether the gear is available. The AVSpare Electronic Technician ET service tool is required.

      Expected Results

      • SECOND and THIRD GEARS are not available.

      Results

      • YES: The transmission does not operate in second or third gear because the Bidirectional Autoshift Selector Dial is in the wrong position.

      Repair: Place the Bidirectional Autoshift Selector Dial in the proper position.

      Proceed to Step 6.

      • NO: Proceed to Step 6.

6. Check the operation of the machine for the original problem.

   Expected Results

   • The original problem is resolved.

   Results

   • OK: The original problem is resolved. Return the machine to service.

   • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

The Transmission Operates in FORWARD Gears Only

Follow this procedure if the machine shifts freely between all forward gears. However, the machine does not move when the transmission is shifted into any reverse gears.

Illustration 4	g03726495

1. Use Cat ET To Check The FNR Signal From The Transmission Lever.

   1. Look for the following parameters:
      • "Transmission Level Position Sensor"

   2. These parameters should correspond to the values in Table 3.

      Expected Results

      Show/hide table

      Table 3

      FORWARD	69.1% to 95%
      NEUTRAL	41% to 59.5%
      REVERSE	5% to 30.9%

      Results

      • OK: The transmission lever is within tolerance. Proceed to Step 2.

      • NOT OK: Contact the technical communicator for your Dealer for possible consultation with AVSpare.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

Note: Ensure that these tests are conducted with the transmission shifted into the REVERSE position.

2. Check The Pressure For The No. 2 Transmission Clutch.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".

   Expected Results

   • The pressure is less than 138 kPa (20 psi).

   Results

   • OK: The pressure to the No. 2 clutch is not preventing disengagement of the clutch. Proceed to Step 3.

   • NOT OK: The No. 2 clutch is not disengaging correctly. The engagement of the No. 2 clutch may be preventing the reverse movement of the machine when REVERSE is selected. Proceed to Step 6.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check The Pressure At The No. 1 Transmission Clutch.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   Expected Results

   • The pressure is equal to the main relief.

   Results

   • OK: The modulating valve is receiving the correct pressure. Proceed to Step 7.

   • NOT OK: Proceed to Step 4.

4. Interchange The Modulating Valves.

   1. Interchange the transmission modulating valve for the No. 1 clutch with the transmission modulating valve for the No. 2 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS: Proceed to Step 6.

      • DOES NOT FOLLOW: Proceed to Step 5.

5. Restore The Modulating Valves.

   1. Restore the modulating valves to the original locations.

   2. Note the suspect valve.

   3. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: An obstruction in the control valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valves.

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".

      • NOT OK: Proceed to Step 7.

6. Replace The Transmission Modulating Valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Perform the following test for the No. 1 clutch only. Proceed to Step 7.

7. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OK: Calibrate the transmission modulating valves.

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Operates in REVERSE Gears Only

Follow this procedure if the machine shifts freely between all reverse gears. However, the machine does not move when the transmission is shifted into any forward gears.

Illustration 5	g03726495

1. Use Cat ET To Check The FNR Signal From The Transmission Lever.

   1. Look for the following parameters:
      • "Transmission Lever Position Sensor"

   2. These parameters should correspond to the values in Table 4.

      Expected Results

      Show/hide table

      Table 4

      FORWARD	69.1% to 95%
      NEUTRAL	41% to 59.5%
      REVERSE	5% to 30.9%

      Results

      • OK: The transmission lever is within tolerance. Proceed to Step 2.

      • NOT OK: Contact the technical communicator for your Dealer for possible consultation with AVSpare.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

Note: Ensure that these tests are conducted with the transmission shifted into the FORWARD position.


2. Check The Pressure At The No. 1 Transmission Modulating Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   Expected Results

   • The pressure is less than 138 kPa (20 psi).

   Results

   • OK: The pressure to the No. 1 clutch is not preventing disengagement of the clutch. Proceed to Step 3.

   • NOT OK: The No. 1 clutch is not disengaging correctly. The engagement of the No. 1 clutch may be preventing the forward movement of the machine when a FORWARD speed is selected. Proceed to Step 6.

3. Check The Pressure At The No. 2 Transmission Modulating Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   • The pressure is equal to the main relief.

   Results

   • OK: The pressure to the No. 2 clutch is correct. Proceed to Step 7.

   • NOT OK: The transmission modulating valve is the probable cause of the problem. Proceed to Step 4.

4. Interchange The Modulating Valves.

   1. Interchange the transmission modulating valve for the No. 2 clutch with the transmission modulating valve for the No. 1 clutch.

   2. Determine whether the problem follows the valve.

      Expected Results

      • The original problem is resolved.

      Results

      • FOLLOWS: Note the suspect valve. Proceed to Step 6.

      • DOES NOT FOLLOW: Proceed to Step 5.

5. Restore The Modulating Valves.

   1. Restore the transmission modulating valves to the original locations.

   2. Note the suspect valve.

   3. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valves.

      
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

      • NOT OK: Proceed to Step 7.

6. Replace The Transmission Modulating Valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Perform the following tests for the No. 2 clutch only. Proceed to Step 7.

7. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OK: Calibrate the transmission modulating valves.

   
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
   

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Operate in FIRST GEAR FORWARD or REVERSE

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

1. Operate The Machine.

   The following steps guide the diagnosis of the problem to the transmission clutches or to the transmission modulating valves.

   1. Start the engine.

   2. Operate the engine at high idle.

   3. Shift the transmission into FIRST GEAR FORWARD.

   4. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • YES: First, check the transmission clutches. An engaged clutch may be preventing the transmission from operating properly. Proceed to Step 2.

      • NO: Check the pressure at the transmission modulating valve first. Proceed to Step 3.

2. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Stop.

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check The Pressure At The Transmission Modulating Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   Expected Results

   • The pressure is approximately 2240 kPa (325 psi).

   Results

   • OK: The pressure to the No. 5 clutch is correct but the No. 5 clutch may not be engaging properly. Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

   • NOT OK: Check the transmission modulating valve. Proceed to Step 4.

4. Interchange The Modulating Valves.

   1. Interchange the transmission modulating valve for the No. 5 clutch (first gear) with the transmission modulating valve for the No. 4 clutch (second gear).

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 5.

      • DOES NOT FOLLOW: Proceed to Step 6.

5. Replace The Modulating Valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: Stop.

      • NOT OK: Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

6. Restore The Modulating Valves.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valves.

      
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

      • NOT OK: Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

7. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Calibrate the transmission modulating valves.

   
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
   

   • NOT OK: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Operate in SECOND GEAR in FORWARD or REVERSE

1. Operate The Machine.

   The probable cause of the problem is the transmission or the brakes. The following step helps you determine a starting point for troubleshooting.

   1. Start the engine.

   2. Operate the engine at high idle.

   3. Shift the transmission into SECOND GEAR in the FORWARD direction.

   4. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • OK: Check the brake pressure first. If the brake pressure is low, then the brake does not release. Proceed to Step 2.

      • NOT OK: Check the pressure to the transmission modulating valve first. Proceed to Step 3.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

2. Check The Brake Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Brake Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Brake Pressure - Test".
   

   Expected Results

   • The pressure is correct.

   Results

   • OK: If the symptom is not resolved, an engaged transmission clutch could be preventing the transmission from operating properly. Proceed to Step 5.

   • NOT OK: A brake that is engaged could be preventing the movement of the machine. Proceed to Step 4.

3. Check The Pressure At The Transmission Modulating Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   Expected Results

   • The pressure is equal to the main relief.

   Results

   • OK: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

   • NOT OK: Proceed to Step 7.

4. Follow The Procedure In This Reference.

   Refer to "The Brake Does Not Release" in this module under Troubleshooting, "Brake Troubleshooting".

   Results

   • REPAIRED OK: The Brake Does Release.

   STOP.

   • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

5. "Check The Bidirectional Autoshift Selector Dial."

   1. Check the Bidirectional Autoshift Selector Dial, Illustration 3, to determine whether the gear is available. The AVSpare Electronic Technician ET service tool is required.

      Expected Results

      • SECOND GEAR and THIRD GEAR are not available.

      Results

      • YES: The transmission does not operate in second or third gear because the Bidirectional Autoshift Selector Dial is in the wrong position.

      Repair: Place the Bidirectional Autoshift Selector Dial in the proper position.

      STOP.

      • NO: Proceed to Step 6.

6. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Calibrate the transmission modulating valves.

   
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
   

   STOP.

   • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

7. Interchange The Modulating Valves.

   1. Interchange the transmission modulating valve for the No. 4 clutch with the transmission modulating valve for the No. 5 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 8.

      • DOES NOT FOLLOW: Proceed to Step 9.

8. Replace The Modulating Valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      STOP.

      • NOT OK: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

9. Restore The Modulating Valves.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: An obstruction in the control valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valves.

      
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

      STOP.

      • NOT OK: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

10. Follow The Procedure In This Reference.

    Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch".

    Results

    • REPAIRED OK: Calibrate the transmission modulating valves.

    ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

    ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
    

    STOP.

    • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

    STOP.

The Transmission Does Not Operate in THIRD SPEED FORWARD or REVERSE

1. Operate The Machine.

   The probable cause of the problem is the transmission or the brakes. The following step helps you determine a starting point for troubleshooting.

   1. Start the engine.

   2. Operate the engine at high idle.

   3. Shift the transmission into THIRD GEAR FORWARD.

   4. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • OK: Check the brake pressure first. If the brake pressure is low, then the brake does not release. Proceed to Step 2.

      • NOT OK: Check the pressure to the transmission modulating valve first. Proceed to Step 3.

2. Check The Brake Pressure.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Brake Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Brake Pressure - Test".
   

   Expected Results

   • The pressure is correct.

   Results

   • OK: If the symptom is not resolved, an engaged transmission clutch could be preventing the transmission from operating properly. Proceed to Step 5.

   • NOT OK: A brake that is engaged could be an interference in the movement of the machine. Proceed to Step 4.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check The Pressure At The Transmission Modulating Valve.
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Transmission Clutch Pressure - Test".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Transmission Clutch Pressure - Test".
   

   Expected Results

   • The pressure is equal to the main relief.

   Results

   • OK: Perform the following tests for only the No. 3 clutch. Proceed to Step 4.

   • NOT OK: Proceed to Step 7.

4. Follow The Procedure In This Reference.

   Refer to "The Brake Does Not Release" in this module under Troubleshooting, "Brake System".

   Results

   • REPAIRED OK: The Brake Does Release.

   STOP.

   • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

5. Check The Bidirectional Autoshift Selector Dial.

   1. Check the Bidirectional Autoshift Selector Dial, Illustration 3, to determine whether the gear is available. The AVSpare Electronic Technician ET service tool is required.

      Expected Results

      • THIRD GEARS are not available.

      Results

      • YES: The transmission does not operate in third gear because the Bidirectional Autoshift Selector Dial is in the wrong position.

      Repair: Place the Bidirectional Autoshift Selector Dial in the proper position.

      STOP.

      • NO: Proceed to Step 6.

6. Follow The Procedure In This Reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch".

   Results

   • REPAIRED OK: Calibrate the transmission modulating valves.

   
   

   ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

   ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
   

   STOP.

   • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

7. Interchange The Modulating Valves.

   1. Interchange the transmission modulating valve for the No. 3 clutch with the transmission modulating valve for the No. 5 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 8.

      • DOES NOT FOLLOW: Proceed to Step 9.

8. Replace The Modulating Valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: The original problem is resolved.

      STOP.

      • NOT OK: Perform the following tests for only the No. 3 clutch. Proceed to Step 9.

9. Restore The Modulating Valves.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OK: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valves.

      
      

      ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

      ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
      

      STOP.

      • NOT OK: Perform the following tests for only the No. 3 clutch. Proceed to Step 10.

        
        

10. Follow The Procedure In This Reference.

    Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch".

    Results

    • REPAIRED OK: Calibrate the transmission modulating valves.

    
    

    ReferenceFor D5R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4119, "Calibration".

    ReferenceFor D6R2 models, refer to the latest revision of Specifications, Systems Operation/Testing, and Adjusting, UENR4109, "Calibration".
    

    STOP.

    • NOT OK: The cause of the problem is uncertain. Inform your dealer Technical Communicator (TC) with the information that has been gathered for possible consultation with AVSpare. This consultation will provide instructions on the action that must be taken to resolve this problem.

    STOP.