Sie sind auf Seite 1von 22

6002

Section
6002
POWERSHIFT TRANSMISSION SPECIFICATIONS,
PRESSURE CHECKS AND TROUBLESHOOTING

CNH America LLC.


700 State Street
Racine, WI 53404 U.S.A.

Bur 5-12130

Copyright 2008 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued March, 2008

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-12130

Issued 3-08

3
4
5
5
6
7
8
9
10
11
11
12
13
13
14
14
15
15
16
19
20
22

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

CAS-1804 PRESSURE FITTING KIT


CAS-10280 FLOWMETER

B797157M

CAS-1808 FLOWMETER FITTING KIT

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-5

TEST PORT AND COMPONENT LOCATIONS


1

8
7
6
5
4

3
BC08A224

LEFT SIDE VIEW


1.
2.
3.
4.

Bur 5-12130

VALVE BODY
OIL FILTER BYPASS VALVE
SPEED PICKUP
4TH CHECK PORT

5.
6.
7.
8.

2ND CHECK PORT


1ST CHECK PORT
LUBRICATION CHECK PORT
TORQUE CONVERTER INLET
PRESSURE TEST PORT

Issued 3-08

Printed in U.S.A.

6002-6

9
10

11

BC08A225

FRONT VIEW
9. SPIN ON FILTER
10. OIL PUMP

Bur 5-12130

11. DIP STICK PORT

Issued 3-08

Printed in U.S.A.

6002-7

13

12
14
15

16

18

17
BC08A226

RIGHT SIDE VIEW


12.
13.
14.
15.

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

19

24
20
23

21

22

BC08A227

REAR VIEW
19. BOOSTER PORT TO VEHICLE BRAKES
20. HYDRAULIC PUMP MOUNT
21. SAHR PARKING BRAKE HOUSING

Bur 5-12130

22. OIL RETURN PORT FROM VEHICLE BRAKES


23. PARK BRAKE PRESSURE TEST PORT
24. PARK BRAKE RELEASE SOLENOID

Issued 3-08

Printed in U.S.A.

6002-9

26

27

28

25

31

29
30

BC08A228

TOP VIEW
25.
26.
27.
28.

Bur 5-12130

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

HEATING THE OIL


1. Check the oil level and type before proceeding.
2. Activate the parking brake.
3. Start the engine.
4. Place the gear selector into 4th gear.
5. Put the FNR selector in forward position.

6. Run the engine up to 1500 to 1700 rpm for a


duration of 30 seconds.
NOTE: DO NOT exceed 30 seconds.
7. Reduce engine rpm to low idle and place the
FNR lever in neutral for 15 seconds.
8. Repeat this procedure until the oil temperature
reaches 78 to 82 C (172.5 to 176 F).
9. Refer to section 2002 and perform a stall test on
the engine before proceeding.

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

Machine Will Not Move


Is oil level correct? Add oil as required.
Is there still a problem.

No

Troubleshooting complete. Find cause for


loss of oil.

No

Check transmission oil pressure, check


electrical supply to the solenoid.

No

Troubleshooting complete.

No

Check electrical connections at transmission.


Is there power to the clutch solenoids?

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

Check pressure and pump flow.


Is flow in specified range?

No

Possible causes include:


1. Cold oil by-pass valve might be stuck or
damaged.
2. Pressure regulator could be bad.

Yes

There can be a problem in the transmission


control valve. Is the converter In pressure in
the specified range?

3. Pump could be bad. See Section 6007 to


repair or replace as required.

No

Check the transmission control valve.


Repair or replace as required.

Yes
Continued on next page.

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-12

There can be a problem in the


forward/reverse solenoid valve. Are the
clutch pressures for forward and reverse in
the specified range?

No

Check the transmission. See Section 6007.


Repair or replace as required.

No

Possible causes include:

Yes
Check clutch pressure.
Is the pressure in the specified range?

1. If pressure remains at zero in forward,


neutral and reverse the problem could be
in the control valve.

Yes
Check the transmission. See Section 6007.
Repair or replace as required.

2. If pressure is low, problem could be in


the control valve.
3. If pressure for forward and reverse are
d if fe r e n t, i n s p e c t i n d i v i d u a l c l u t c h
circuits. See Section 6007 for repair.

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

Repair engine as required.

No

See Section 6007 to repair as required.

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.

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-13

Transmission Oil Too Hot


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

See Machine will not Move on page 11.

No

If torque converter pressure is high and lube


pressure is low, possible causes include:

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?

1. The oil cooler is restricted. Replace the


oil cooler.

Yes
Troubleshooting complete.

2. The oil cooler circuit is restricted. Inspect


the oil cooler circ uit and repair as
required.

NOTE: The transmission oil cooler cannot be flushed or cleaned out, the transmission oil cooler must be
replaced if restricted or plugged.

Wheels Rotate When Vehicle is Raised


Is oil type correct? Change oil as required.
Is there still a problem?

No

Troubleshooting complete.

Yes

Wait for oil to reach operation temperature.

Yes

Replace control valve.

Yes
Is oil temperature low (high oil viscosity)
No
Control valve allowing pressure to clutches
while in neutral position.

Bur 5-12130

Issued 3-08

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

See Section 6007 and replace.

Yes

See Section 6007 and replace.

Yes

See Section 6007 and repair/replace as


required.

Yes
Damaged converter.
No
Damaged oil pump.
No
Seized or broken gears, shafts, bearing, etc.

Irregular Clutch Activation


Is oil level correct? Add oil as required.
Is there still a problem?

No

Troubleshooting complete.
Find cause for loss of oil.

No

Inspect modulation spool and piston for


sticking or damage.

No

Check the transmission clutches. See


Section 6007. Repair or replace as
required.

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.

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-15

Gear Remains Engaged


Is oil level correct? Add oil as required.
Is there still a problem?

No

Troubleshooting complete.
Find cause for loss of oil.

No

Inspect modulation spool and piston for


sticking or damage.

No

Check the transmission clutches. See


Section 6007. Repair or replace as
required.

No

Troubleshooting complete.

No

If the front drive shaft turned with the


directional control lever (FNR) in forward or
reverse, the problem is in the front axle. See
Section 5006. Repair as required.

No

Check the transmission 4WD clutch. See


Section 6007. Repair or replace as
required.

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.

4WD Does Not Work


Check for broken universal joint or front drive
shaft, and repair as required. Is there still a
problem?
Yes
Check to see if front drive shaft turns with
transmission direction control lever (FNR) in
forward or reverse, 4WD engaged, and the all
wheels off the ground. Does the front drive
shaft turn?
Yes
Check for TRAX fault codes
Are fault codes present
Yes
See section 4005 and this section for
troubleshooting procedures.

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-16

Problem in Parking Brake System


Does parking brake release.

No

Check the electrical and hydraulic circuits.


Hydraulic
Check differential lock
pressure, is pressure as
specified?
NOTE: Differential lock and
park brake are on the same
pressure circuit.

Electrical

No
Troubleshoot and repair
transmission as needed,
see section 6007.

Yes

Check fuses, replace as needed.

Check switch operation, replace as needed.

Check solenoid, 9.8 Ohm at 20 C (68 F),


replace as needed.

Test parking brake, see section 7002.


Does parking brake hold machine?

No

See section 7000 for brake disc


replacement.

Yes
Troubleshooting complete

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-17

NOTES

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-18

5
7

9
11

10
12

13

14

15

16
20

17
19

21

22

18

23

24

25
26
27

28

29
BS08A363

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

SAHR PARKING BRAKE


4WD SAHR CLUTCH
3RD GEAR CLUTCH
4TH GEAR CLUTCH
FORWARD CLUTCH
REVERSE CLUTCH
FORWARD CLUTCH PRESSURE CHECK PORT
REVERSE CLUTCH PRESSURE CHECK PORT
1ST GEAR CLUTCH
2ND GEAR CLUTCH
1ST GEAR CLUTCH PRESSURE CHECK PORT
2ND GEAR CLUTCH PRESSURE CHECK PORT
DIFFERENTIAL LOCK PORT
PARKING BRAKE SOLENOID VALVE
AUXILIARY PORTS

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

OIL FLOW DIVIDER/PRESSURE REGULATOR VALVE


SPIN-ON FILTER
OIL FILTER RELIEF VALVE
TRANSMISSION OIL PUMP
TORQUE CONVERTER
OIL COOLER
TEMPERATURE THERMOSTAT
AIR BREATHER
SUCTION FILTER
TORQUE CONVERTER PRESSURE RELIEF VALVE
BRAKE OIL PORT RETURN TO SUMP
OUTPUT SHAFTS LUBRICATION
PRIMARY SHAFT LUBRICATION
INPUT SHAFT LUBRICATION

HYDRAULIC COMPONENTS

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-20

BC08A418

CONTROL VALVE
1.
2.
3.
4.

PULSE- WIDTH MODULATION 2/4 SOLENOID, PORT A


REVERSE SOLENOID, PORT B
FORWARD SOLENOID, PORT C
PULSE- WIDTH MODULATION 1/3 SOLENOID, PORT D

5.
6.
7.
8.

4 WHEEL-DRIVE SOLENOID, PORT E


2ND/4TH SOLENOID, PORT F
DIFFERENTIAL LOCK SOLENOID, PORT G
3RD/4TH SOLENOID, PORT H

1
2

BD08B401-01

NOTE: Remove the floor plate to gain access to the connectors for the transmission, connector J1 (1) and
connector J2 (2).

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-21

DEU_DT04-12P

DEU_DT04-8P

CONNECTOR J1
CAV

TO CAV

COMPONENT

CONNECTOR J2
CAV

TO CAV

COMPONENT

PIN 2

S 1/3 AND S 2/4 SOLENOID

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

4WD AND HDL SOLENOID

PIN 2

REVERSE SOLENOID

PIN 1

4WD SOLENOID

PIN 1

PWM 1/3 SOLENOID

PIN 1

DIFFERENTIAL LOCK
SOLENOID

PIN 2

PWM 1/3 SOLENOID

PIN 1

PWM 2/4 SOLENOID

PIN 1

RPM SENSOR

PIN 2

PWM 2/4 SOLENOID

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

NOTE: Readings are taken at 20 C (68 F).


1. Take an Ohm reading from pin 1 to pin 2 on
connector J1 for the S 1/3 solenoid, a reading of
7.15 Ohm should be obtained.
2. Take an Ohm reading from pin 1 to pin 3 on
connector J1 for the S 2/4 solenoid, a reading of
7.15 Ohm should be obtained.
3. Take an Ohm reading from pin 4 to pin 5 on
connector J1 for the 4WD solenoid, a reading of
7.15 Ohm should be obtained.

NOTE: Readings are taken at 20 C (68 F).


1. Take an Ohm reading from pin 1 to pin 2 on
connector J2 for the forward solenoid, a reading
of 7.15 Ohm should be obtained.
2. Take an Ohm reading from pin 3 to pin 4 on
connector J2 for the reverse solenoid, a reading
of 7.15 Ohm should be obtained.
3. Take an Ohm reading from pin 5 to pin 6 on
connector J2 for the PWM 1/3 solenoid, a
reading of 7.25 Ohm should be obtained.
4. Take an Ohm reading from pin 7 to pin 8 on
connector J2 for the PWM 2/4 solenoid, a
reading of 7.25 Ohm should be obtained.

4. Take an Ohm reading from pin 4 to pin 6 on


connector J1 for the differential lock solenoid, a
reading of 7.15 Ohm should be obtained.

Bur 5-12130

Issued 3-08

Printed in U.S.A.

6002-22

ELECTRICAL SCHEMATIC
2
1
3
4
5

14
22

21

7
20
8
9

19

10

15
16

18

11
12
13

17

1.
2.
3.
4.
5.
6.

FNR SHIFTIER
7.
TRANSMISSION CONTROLLER 8.
FORWARD SOLENOID
9.
REVERSE SOLENOID
10.
PWM 1/3 SOLENOID
11.
PWM 2/4 SOLENOID
12.

1/3 SOLENOID
2/4 SOLENOID
4WD SOLENOID
DIFF LOCK SOLENOID
SPEED SENSOR
TEMP SENSOR

13.
14.
15.
16.
17.

PRESSURE SENSOR
J2 CONNECTOR
J1 CONNECTOR
BRAKE PRESSURE SWITCHES
AUTO/MANUAL SWITCH

18.
19.
20.
21.
22.

FRONT CONSOLE CAN


CHASSIS 4WD CONNECTOR
LOADER LEVER HARNESS
KICK DOWN SWITCH
TO FRONT CONSOLE

NOTE: See electrical schematic in rear pocket of manual for complete circuit.

Bur 5-12130

Issued 3-08

Printed in U.S.A.