Section 6002

POWERSHIFT TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS AND TROUBLESHOOTING

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

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Copyright 2008 CNH America LLC. All rights reserved. Printed in U.S.A. Issued March, 2008

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

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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).

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SPECIAL TOOLS

B877558U

CAS-1804 PRESSURE FITTING KIT CAS-10280 FLOWMETER

B785789M

B797157M

CAS-1808 FLOWMETER FITTING KIT

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TEST PORT AND COMPONENT LOCATIONS

1 2

8 7 6 5 4

3
BC08A224

LEFT SIDE VIEW 1. 2. 3. 4. 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

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9 10

11

BC08A225

FRONT VIEW 9. SPIN ON FILTER 10. OIL PUMP 11. DIP STICK PORT

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13

12 14 15

16

18

17
BC08A226

RIGHT SIDE VIEW 12. 13. 14. 15. THERMOSTAT 16. 3RD CHECK PORT OIL RETURN FROM COOLER 17. DRAIN PLUG OIL PORT TO COOLER 18. ID PLATE SUCTION FILTER

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19

24 20 23 21

22

BC08A227

REAR VIEW 19. BOOSTER PORT TO VEHICLE BRAKES 20. HYDRAULIC PUMP MOUNT 21. SAHR PARKING BRAKE HOUSING 22. OIL RETURN PORT FROM VEHICLE BRAKES 23. PARK BRAKE PRESSURE TEST PORT 24. PARK BRAKE RELEASE SOLENOID

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26 25

27

28

31

29 30

BC08A228

TOP VIEW 25. 26. 27. 28. 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

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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.

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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. 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 transmission oil pressure, check electrical supply to the solenoid. No Troubleshooting complete. Find cause for loss of oil.

No

Troubleshooting complete.

No

Check electrical connections at transmission. Is there power to the clutch solenoids? 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

3. Pump could be bad. See Section 6007 to repair or replace as required.

There can be a problem in the transmission control valve. Is the converter In pressure in the specified range? Yes Continued on next page.

No

Check the transmission control valve. Repair or replace as required.

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There can be a problem in the forward/reverse solenoid valve. Are the clutch pressures for forward and reverse in the specified range? Yes Check clutch pressure. Is the pressure in the specified range? Yes Check the transmission. See Section 6007. Repair or replace as required.

No

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

No

Possible causes include: 1. If pressure remains at zero in forward, neutral and reverse the problem could be in the control valve. 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? 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. No See Section 6007 to repair as required. No Troubleshooting complete. Find cause for loss of oil.

No

Troubleshooting complete.

No

Repair engine as required.

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Transmission Oil Too Hot

Is oil level correct? Add oil as required. Is there still a problem? 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. No If torque converter pressure is high and lube pressure is low, possible causes include: 1. The oil cooler is restricted. Replace the oil cooler. 2. The oil cooler circuit is restricted. Inspect the oil cooler circ uit and repair as required. No See Machine will not Move on page 11. No Troubleshooting complete. Find cause for loss of oil.

No

Troubleshooting complete.

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? Yes Is oil temperature low (high oil viscosity) No Control valve allowing pressure to clutches while in neutral position. Yes Replace control valve. Yes Wait for oil to reach operation temperature. No Troubleshooting complete.

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Transmission Noisy
Is oil level correct? Add oil as required. Is there still a problem? Yes Damaged converter. No Damaged oil pump. No Seized or broken gears, shafts, bearing, etc. Yes See Section 6007 and repair/replace as required. Yes See Section 6007 and replace. Yes See Section 6007 and replace. No Troubleshooting complete. Find cause for loss of oil.

Irregular Clutch Activation

Is oil level correct? Add oil as required. Is there still a problem? 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. Check the transmission clutches. See Section 6007. Repair or replace as required. No Inspect modulation spool and piston for sticking or damage. No Troubleshooting complete. Find cause for loss of oil.

No

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Gear Remains Engaged

Is oil level correct? Add oil as required. Is there still a problem? 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. Check the transmission clutches. See Section 6007. Repair or replace as required. No Inspect modulation spool and piston for sticking or damage. No Troubleshooting complete. Find cause for loss of oil.

No

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. Check the transmission 4WD clutch. See Section 6007. Repair or replace as required. 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 Troubleshooting complete.

No

No

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

Electrical

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? Yes Troubleshooting complete

No

See section 7000 for brake disc replacement.

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NOTES

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3 9

5 7

6 8 13

10 12

11 14

15

16 17 19 18 20 21 22

23

24

25 26 27 28 29
BS08A363

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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

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7
CONTROL VALVE

8
BC08A418

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).

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DEU_DT04-12P

DEU_DT04-8P

CONNECTOR J1 CAV 1 2 3 4 5 6 7 8 9 10 11 12 TO CAV PIN 2 PIN 1 PIN 1 PIN 2 PIN 1 PIN 1 PIN 1 PIN 3 PIN 1 PIN 3 PIN 1 PIN 2 COMPONENT S 1/3 AND S 2/4 SOLENOID S 1/3 SOLENOID S 2/4 SOLENOID 4WD AND HDL SOLENOID 4WD SOLENOID DIFFERENTIAL LOCK SOLENOID RPM SENSOR RPM SENSOR TEMP SENSOR TEMP SENSOR PRESSURE SENSOR RPM/TEMP/PRESS SENSORS CAV 1 2 3 4 5 6 7 8 TO CAV PIN 1 PIN 2 PIN 1 PIN 2 PIN 1 PIN 2 PIN 1 PIN 2

CONNECTOR J2 COMPONENT FORWARD SOLENOID FORWARD SOLENOID REVERSE SOLENOID REVERSE SOLENOID PWM 1/3 SOLENOID PWM 1/3 SOLENOID PWM 2/4 SOLENOID PWM 2/4 SOLENOID

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.

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. 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.

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ELECTRICAL SCHEMATIC
2 1 3 4 14 22 21 20 8 19 15 18 17 16 11 12 13 9 10 5 6 7

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.

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