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Service Manual Powershift Transmission T12000 3, 4, & 6-Speed Long Drop TSM-0023 April 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the Spicer OffHighway Product. Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, troubleshooting, and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Spicer Off-Highway approved parts as listed in the applicable parts manual should be used. Use of "will-fit" or non-approved parts may endanger proper operation and performance of the equipment. Spicer Off-Highway does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Spicer Off-Highway. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts. TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing. NOTE : If the transmission has 4 wheel drive, disconnect both front and rear drivelines. Because of the design of the hydraulic system, the engine cannot be started by pushing or towing ©Copyright Dana Spicer Off-Highway Products Division Unpublished Material – All rights reserved Limited Distribution No part of this work may be reproduced in any form Under any means without direct written permission of Dana Spicer Off-Highway Products Division Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD TABLE OF CONTENTS T12000 TRANSMISSION ASSEMBLY HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Transmission Case and Plate Group.................................................................Fig. A Converter Group................................................................................................ Fig. B Forward -Reverse, 3rd and 4th -High Clutch Group. ......................................... Fig. C Low (1st), 2nd and Output Shaft Group............................................................. Fig. D Output Shaft Group with Disconnect. ................................................................ Fig. E Control Valve Group-Dual Modulation.................................................................Fig. F Control Valve Group-Single Modulation, Mechanical Inching...................................................................................Fig. G Assembly Instructions ....................................................................................Fig. H, I, J, K, L, M DISASSEMBLY OF TRANSMISSION.............................................................................. REASSEMBLY OF TRANSMISSION.................................................................................... 58 CLUTCH ENGAGEMENT (POWER FLOW) 3 SPEED. ........................................................ 72 CLUTCH ENGAGEMENT (POWER FLOW) 4 AND 6 SPEED. ............................................ 73 DRIVEPLATEINSTALLATION .............................................................................................. 74 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE. ........................................... 75 SPECIFICATIONSANDSERVICEDATA ............................................................................... 76 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL. .......................................... 77 EXTERNAL PLUMBING AND PRESSURE CHECK POINTS............................................. 78, 79 CLEANINGANDINSPECTION .............................................................................................. 80 PARKINGBRAKESERVICE................................................................................................ 81 TROUBLESHOOTINGGUIDE............................................................................................. 82 CONVERTERSTALLPROCEDURE.................................................................................... 83 ELECTRIC SOLENOID CONTROL WIRING DIAGRAM..................................................... 84, 85 NOTE: Metric Dimensions Shown in Brackets [ ]. Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 TRANSMISSION ASSEMBLY The transmission and hydraulic torque converter portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate. The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation. The electric shift control valve is located in the vehicle's operator compartment, The function of the control is to energize the selected solenoid valves thus directing the oil under pressure to the selected directional and range (gear) clutches. The purpose of the range or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. An axle disconnect is optional and is located on the output shaft. The drive to the front axle can be disconnected or connected by manual, pneumatic, or hydraulic shifting. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector solenoid to the oil sump. The same procedure is used in the speed selector. The direction or speed clutch assembly consists of a drum with slots and a bore to receive a hydraulically actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external tangs is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted, Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with O.D. splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the electric shift control lever is placed in the desired position. This energizes the selected direction and range (gear) solenoids allowing the oil under pressure to flow through tubes and passages to the selected clutch shafts. Oil sealing rings are located on the clutch shaft. These rings direct oil under pressure through a drilled passageway in the shaft to a desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs with tangs on the outer diameter clamping against discs with teeth on the inner diameter enables the hub and clutch shaft to be locked together and allows them to drive as a unit. There are bleed balls in the clutch piston or clutch drum which allow quick escape for oil when the pressure to the piston is released. Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD HOW THE UNITS OPERATE With the engine running, the transmission charging pump draws oil from the transmission sump through the oil suction tube and screen and directs it through the pressure regulating valve and oil filter. The pressure regulating valve maintains pressure to the transmission solenoid valves for actuating the direction and speed clutches. This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in the closed position. When a specific pressure is achieved, the valve spool works against the spring until an exhaust port is exposed along the side of the bore. This sequence of events provides the proper system pressure. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed out through an external oil cooler and into the lube inlet port. From the lube inlet port oil goes through the forward-reverse shaft, lubricating the forward and reverse clutches, with the remainder going to the torque converter. After entering the converter, the oil is directed through the converter blade cavity and exits in the passage between the turbine shaft and impeller hub. The oil then lubes the impeller hub bearing with the remainder going to the 3rd-4th clutch shaft and 1st-2nd clutch shaft to lubricate those clutches and shaft bearings. The oil then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero R.P.M. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing. With the engine running and the electric shift control lever in neutral position, oil pressure from the regulating valve is blocked at the solenoid control valves, and the transmission is in neutral. Movement of the control lever will energize the forward or reverse solenoid valves and selected range (gear) solenoid, directing oil under pressure to the selected direction and range (gear) clutches. Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure A Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 TRANSMISSION CASE AND PLATE GROUP ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION AR -As Required Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure B Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 CONVERTER GROUP Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure C Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 FORWARD-REVERSE, 3RD AND 4TH-HIGH CLUTCH GROUP ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure D Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 LOW (1ST), 2ND, AND OUTPUT SHAFT GROUP (WITH BRAKES) ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure E Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 OUTPUT SHAFT GROUP (WITH HYDRAULIC OR MECHANICAL DISCONNECT) ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure F Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 CONTROL VALVE GROUP DUAL MODULATION ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure G Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 CONTROL VALVE GROUP WITH SINGLE MODULATION, INCHING ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION Date : Apr 2000 QUANTITY Maintenance & Service Manual T12000 3,4 & 6 Speed LD 3 SPEED ASSEMBLY INSTRUCTIONS Figure H Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD 4-6SPEED ASSEMBL Y INSTRUCTIONS Figure I Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure J Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure K Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure L Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Figure M Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Note: The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack. Service replacement assemblies are banded together and must be replaced as assembly. Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD CLUTCH ENGAGEMENT -72 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD CLUTCH ENGAGEMENT -73 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD DRIVE PLATE INSTALLATION Measure the '"A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below. Note two (2) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits with three intermediate drive plates. " A " Dimension (Bolt Circle Diameter) "" A " Dimension (Bolt Circle Diameter) 11.380" 1288,900 mm] Diameter Kit No.802501 11.380" [288,900 mm] Diameter Kit No.802543 13.125" [333,38 mm ] Diameter Kit No.802424 13.125" 1333,38 mm] Diameter Kit No.802426 13.500" [342,90 mm] Diameter Kit No.802425 13.500" [342,90 mm] Diameter Kit No.802427 Each Kit will include the following parts: Kit will include the following parts: 2 Intermediate Drive Plates. 1 Drive Plate and Weld Nut Assembly. 1 Backing Ring. 3 Intermediate Drive Plates. 1 Backing Ring. 6 Mounting Screws. 6 Mounting Screws. 6 Lock Washers. 1 Instruction Sheet. 6 Lock Washers. 1 Instruction Sheet. TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES -SEE ILLUSTRATION ABOVE -ALIGNMENT HOLES Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align intermediate drive plates and backing ring with holes in torque converter assembly. NOTE: Two dimples 180 ° apart in backing ring must be out (toward engine flywheel). Install capscrews and washers. Tighten 26 to 29 ft Ibs. torque [35 -39 N.m]. -74 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1.Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. 2. Check engine flywheel & housing for conformance to standard SAE No.3 per SAE J927 and J1033 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play. 3. Install two 2.50 [63,500 mm] long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole. * 4. Install a 4.00 [101,60 mm] long drive plate locating stud .3750 24 fine thread in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. 5. Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No.3. Locate transmission on flywheel housing. Aligning drive plate to flywheel and transmission to flywheel housing guide studs, install transmission to flywheel housing screws. Tighten screws to specified torque. Remove transmission to engine guide studs. Install remaining screws and tighten to specified torque. *6. Remove drive plate locating stud. 7. Install drive plate attaching screw and washer. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. After all eight (8) screws are installed torque each one 26 to 29 Ibf.ft torque [35 -39 N.m]. This will require tightening each screw and rotating the engine flywheel until the full amount of eight (8) screws have been tightened to specified torque. 8. Measure engine crankshaft end play after transmission has been completely installed on engine flywheel. This value must be within .001 [0,025 mm] of the end play recorded in step No.2. * Does not apply to units having 3 intermediate drive plates. See Fig. 4. -75 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD SPECIFICATIONS AND SERVICE DATA-POWER SHIFT TRANSMISSION AND TORQUE CONVERTER TRANSMISSION With transmission outlet oil temperature, 180° OUT PRESSURE -200° F. [82,3° -93,3° C] and transmission in NEUTRAL. Operating specifications: 25 P .S.I. [173 kPa] minimum pressure at 2000 R. P -M .engine speed AND a maximum of 100 P-S-I. [690 kPa] outlet pressure with engine operating at no-load governed speed. CONTROLS Speed Selection -Electric. CLUTCH TYPE OIL FILTRATION CLUTCH PRESSURE Multiple discs, hydraulically actuated, spring released, automatic wear compensation, and no adjustment. All clutches oil cooled and lubricated. Normal operating pressure 240-280 P.S.I. [1654,8 -1930,5 kPa] at 2000 R.P.M. NOTE: Never use service brakes while making CLUTCH INNER DISC CLUTCH OUTER DISC Full flow oil filter safety by-pass, also strainer screen in sump at bottom of transmission case. 185 P.S.I. [1275,5 kPa] minimum -With parking brake set (see note), oil temperature 180° 200° F. [82,2° -93,3° C], engine at idle (400 to 600 R.P .M-), shift thru direction and speed clutches. All clutch pressure must be equal within 5 P.S.I., [34,5 kPaJ. If clutch pressure varies in anyone clutch more than 5 P.S.I., [34,5 kPa] repair clutch. clutch pressure checks. Units having brake ac Friction. tuated declutching in torward and/or reverse will not give a true reading, ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS. Steel. LUBRICA TION RECOMMENDED LUBRICANTS FOR CLARK-HURTH POWER SHIFTED TRANSMiSSION AND TORQUE CONVERTERS Prevailing Ambient Temperature TYPE OF OIL See Lube Chart. CAPACITY Consult Operator's Manual on applicable machine model for system capacity. Torque Converter, Transmission, and allied hydraulic system must be considered as a whole to determine capacity. Temperature Range "1" CHECK PERIOD Check oil level DAIL Y with engine running at 500 -600 R.P.M. and oil at 180° to 200° F. [82,2° 93,3°C]. Maintain oil level to FULL port. * *NORMAL DRAIN PERIOD Every 1000 hours, change oil filter Every 1000 hours, drain and refill system as follows: Drain with oil at 150° to 200°. [65,6°-93,3° C]. Temperature Range (a) Drain transmission. (b) Oil filter, remove and discard. Install new oil filter. (c) Refill transmission to LOW port. (d) Run engine at 500-600 R.P.M to prime con verter and lines (e) Recheck level with engine running at 500 -600 R.P.M. and add oil to bring level to LOW port. When oil temperature is hot (180° 200° F.) [82,2° 93,3° C] make final oil level check BRiNG OIL LEVEL TO FULL PORT . NOTE: it is recommended that oil filter be changed after 50 and 100 hours of operation on newand rebuilt or repaired units. "2" , --, - v vv (b) C-3 Grade 30 (c) Engine Oil-Grade 30 API-CD/SE or CD/SF (d) MIL-L-2104C-Grade 30 (e) MIL-L-2104DGrade 30 (a) MIL-L-2104C-Grade 10 (b) MIL-L-21040-Grade 10 (c) C-2 Grade 10 (d) C-3 Grade 10 (e) Engine Oil-Grade 10 API-CD/SE or CD/SF (f) Quintolubric 822-220 (Non Phosphate Ester Fire Resistant Fluid Temperature "3" (a) .Dexron Range (b) .Dexron II D See Caution Below Temperature "4" (a) MIL-L-46167 Range (b) MIL-L-46167 A Temperature "5" (a) Conoco High-Performance Range Synthetic Motor Oil Spec No 6718 *Dexron is a registered trademark of Generai Motors Corporation. PREFERRED OiL VISCOSiTY: Select highest oil viscosity compatible with prevailing ambient temperatures and oil application chart. Temperature ranges "2" and "3" may be used to lower ambient temperatures when sump preheaters are used. Temperature range "4" should be used only in ambient temperature range shown .*Normal drain periods and oil filter change intervals are for average environmental and duty-cycle conditions. Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause acclerated deterioration and contamination, For extreme conditions judgment must be used to determine the required change intervals. MODULATED SHiFT TRANSMISSIONS: T12000, 18000,24000,28000, & 32000 series transmissions with modulated shift use only C-3 or temperature range 3 items (a) & (b) .Dexron or .Dexron II D SEE CAUTiON BELOW 3000, 4000,5000,6000,8000, 16000 & 34000 series transmission with modulated shift use only C-3 or temperature range 3 item (a) only .Dexron. Do NOT use .Dexron II D SEE CAUTION BELOW. CAUTiON: *Dexron II D is not compatible with graphitic clutch plate friction materiai UNLESS iT MEETS THE APPROVED C-3 SPECIFiCATiONS. *Dexron II D cannot be used in the 3000,4000, 5000,6000, 8000, 16000, or 34000 series power shift transmissions, or the HR28000 & HR32000 series having converter lock-up, or the C270 series converter having lockUP UNLESS iT MEETS THE APPROVED C-3 SPECiFICATiONS. Any deviation from tnis cnart must nave written approval from tne application department of the Clark-Hurth Components Engineering and Marketing Department. -76 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its allied hydraulic system are important links in the driveline between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered complete. compressed air until all foreign material has been removed, Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air, and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes, After the overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned, This can be accomplished in several manners and a degree of judgment must be exercised as to the method employed, 5. Reassemble all components and use only type oil recommended for lubrication section. Fill transmission through filler opening until fluid comes up to LOW port on transmission. The following are considered the minimum steps to be taken: Remove LOWER check plug, fill until oil runs from LOWER oil hole, Replace filler and level plug, Run engine two minutes at 500-600 R.P.M, to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (500-600 R.P,M,). 1. Drain entire system thoroughly, 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning, Add quantity necessary to bring fluid level to run freely from LOWER oil level check plug hole, Install oil level plug, Recheck with hot oil (180200o F,) [82, 2-93, 3° C]. 3, Replace oil filter elements, cleaning out filter cases thoroughly, Bring oil level to FULL port to run freely from UPPER oil level plug hole. 4. The oil cooler must be thoroughly cleaned, The cooler should be .'back flushed" with oil and 6. Recheck all drain plugs, lines, connections, etc" for leaks and tighten where necessary. -77 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD PORT 71 -"TO COOLER" TEMPERATURE PORT IS TO BE USED FOR "OIL TO COOLER" TEMPERATURE PICK-UP. GAUGE IS TO BE LOCATED IN THE OPERATOR COMPARTMENT. SEE OIL TEMPERATURE GAUGE SPECIFICATION. TEST CONDITIONS: 1. "TO COOLER" OIL TEMPERATURE 180-220°F [82-104°C] 2. TRANSMISSION IN NEUTRAL OPERATING SPECIFICATION S: 1 25 psi [173 kPa] MINIMUM PRESSURE AT 2000 rpm ENGINE SPEED AND A MAXIMUM OF 100 PSI [690 kPa] OUTLET PRESSURE AT NO LOAD GOVERNED SPEED PORT 31 -CLUTCH PRESSURE IT IS RECOMMENDED THAT CLUTCH PRESSURE BE MONITORED BY A GAUGE LOCATED IN THE OPERATOR COMPARTMENT. NORMAL OPERATING PRESSURE 240-280 PSI [1655 1930 kPa] at 2000 RPM. PORT 45 and 46 -BACKUP WARNING THIS PORT IS PROVIDED FOR INSTALLATION OF BACK-UP PRESSURE SWITCH FOR WARNING LIGHT OR HORN. OIL TEMPERATURE GAUGE SPECIFICATIONS: 1. NORMAL OPERATING TEMPERATURE: 180 250°F [82-121°C] 2. RED LINED TEMPERATURE: 250°F [121°F] -78 Date : Apr 2000 Maintenance & Service Manual 3, 4 & 6 Speed T12000 3,4 & 6 Speed LD FRONT VIEW Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD CLEANING AND INSPECTION CLEANING INSPECTION Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned. The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. Bearings CAUTION: Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapors when us ing solvent type cleaners. Carefully inspect all rollers: cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed. Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process. Oil Seals, Gaskets, Etc. Replacement of spring load oil seals, "0" rings, metal sealing rings, gaskets, and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply a thin coat of Permatex No.2 on the outer diameter of the oil seal to assure an oil tight fit into the retainer. When assembling new metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all "0" rings and seals with recommended type Automatic Transmis sion Fluid before assembly. Housings Clean interior and exterior of housings, bearing caps, etc. , thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner. CAUTION: Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners. Gears and Shafts All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound. If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. Housing, Covers, etc. Inspect housings, covers, and bearing caps to be certain they are thoroughly clean and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oilleaks or failures. -80 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T12000 CALIPER BRAKE ASSEMBLY ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY 1 2 3 4 5 6 Housing...............................................................................1 Lining...................................................................................2 Spring..................................................................................1 Cam Plate............................................................................1 Ball. .....................................................................................1 Capscrew ............................................................................1 8 9 10 11 12 13 Lever. .................................................................................1 Nut. .....................................................................................1 BellevilleSpring....................................................................1 Retainer ..............................................................................1 Retainer Ring. .....................................................................1 Piston..................................................................................1 7 Body (Module).....................................................................1 14 Capscrew ...........................................................................1 PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE DISASSEMBL Y 1 , Loosen and remove lever retaining nut (item 9) from brake module and piston assembly (item 13). Remove lever (item 8). 2. Depress retainer (item 11) and remove retaining ring (item 12) from lever end of brake module (item 7). 3. Remove retainer (item 11) and five (5) belleville springs (item 10) from piston (item 13). 4. Remove piston (item 13), two cam plates (item 4), and three balls (item 5) from brake module (item 7). 11. Position lever (item 8) in a convenient location for actuation rod, Install lever (item 8) and lever retaining nut (item 9) on brake module assembly (item 7). Snug lever retaining nut (item 9). 12. Adjust brakes per instructions. PARKING BRAKE ADJUSTMENT (Mechanical Applied) With the brake assembled on the transmission with a free floating operation of the caliper, adjust caliper as follows: REASSEMBLY 5. Lubricate three new balls (item 5) with high compres sion grease and place in ramps of new cam plates (item 4). 6. Install new cam plates (item 4) in brake module (item 7) making sure locking lugs are aligned properly in brake module (item 7). 7. Install piston (item 13) in brake module (item 7) making sure piston aligns properly on cam plates (item 4). 8. Install five (5) belleville springs (item 10) and retainer (item 11) on lever end of piston (item 13). 9. Depress retainer (item 11) and install retaining ring (item 12) in groove on piston (item 13), 1 0. Install brake module assembly (item 7) on housing (item 1 ). NOTE: Do not use operating lever (item 8) as a means to turn the module body (item 7). To use the lever will cause the piston to extend and cause a false setting. Module capscrews (item 14) must be loose before brake adjustment. 1, Screw brake module (item 7) in until linings contact disc. Back module (item 7) off until a flat on module lines up with capscrew (item 14). Torque capscrews (item 14) 8-10 Ibf.ft [11-14 N.m]. 2, Remove lever retaining nut (item 9). Remove lever (item 8). 3. Reposition lever (item 8) to desired angle of operation. 4, Install retaining nut (item 9) and tighten to 10 Ibfft torque [13,6 N,m]. -81 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine, as a complete system. The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a "transmission" problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain com ponents. Proper operation of the transmission depends on the condition and correct functioning of the other com ponents of the group. Therefore, to properly diagnose By analyzing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system. T12000 TRANSMISSION T12000 (powershift with torque converter transmission troubles fall into two general categories: mechanical problems and hydraulic problems). is most important. Transmission fluid is the "life blood" of the transmission. It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and Iubricate the working components. In addition to the mechanical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit TROUBLESHOOTING PROCEDURES Stall Test: Use a stall test to identify transmission, converter, or engine problems. radiator must be clean to maintain the proper cooling and operating temperatures for the engine and trans mission. Air clean the radiator, if necessary. Transmission Pressure Checks: Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmis sion lubrication pressure may also be measured. The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications. Hydraulic Check: Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check: Mechanical Checks: Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical checks should be made: Check oil level in the transmission. The transmission fluid must be at the correct (fulllevel). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. See NOTE below. There are only two mechanical linkages available on the transmission. 1. Mechanical inching from brake pedal to inching valve on transmission. NOTE: The transmission fluid must be at operating temperature of [82-93° C] 180-200° F to obtain correct fluid level and pressure readings. DO NOT ATTEMPT TO MAKE THESE CHANGES WITH COLD OIL. 2. Linkage from axle disconnect to disconnect actuator. Check the parking brake and inching pedal for correct adjustment and travel. Be sure the pedal moves freely and returns fully. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at "stall." Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. CAUTION: Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall R.P.M. The controls are actuated electrically. Check the wiring and electrical components. Be sure that all components of the cooling system are in good condition and operating correctly. The -82 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD CONVERTER STALL PROCEDURE 1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels. 2. Put the directional control lever in FORWARD (or REVERSE, as applicable). speed to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range. CAUTION: Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature ([120° C] 250° F maximum) will cause damage to transmission clutches, fluid, converter, and seals, 3. Put the speed control lever in 3rd (3 speed) (HIGH) or 6th (6 speed). With the engine running, slowly increase engine TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles. REMEDY CAUSE LOW CLUTCH PRESSURE 1. Low oil level. 1. Fill to proper level, 2. Clutch pressure regulating valve stuck open. 2, Clean valve spool and housing. 3. 3. Faulty charging pump. Replace pump. 4. Broken or worn clutch shaft or piston sealing rings. 5, 4. Replace sealing rings. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly. LOW CHARGING PUMP OUTPUT 1. Low oil level. 1. Fill to proper level. 2. Clean suction pump. 3. Replace pump. 1, Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem bly, 2, Worn charging pump. 3. Low oil level. 2. Replace. 4, Dirty oil cooler. 4, Clean cooler. 2. Suction screen plugged, 3, Defective charging pump. OVERHEATING 3. Fill to proper level. 5. Change cooler lines. 5, Restriction in cooler lines. NOISY CONVERTER 1. Worn charging pump. 1. Replace. 2. Worn or damaged bearings, 2. A complete disassembly will be necessary to deter mine what bearing is faulty. LACK OF POWER 1. Low engine R.P.M. at converter stall. 1. Tune engine check governor. 2. See "Overheating" and make same checks. 2. Make corrections as explained in "Overheating." -83 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD -84 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD -85 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD -94 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T-12000 3 SPEED HYDRAULIC DIAGRAM WITH MODULATION AND INCHING -94 -95 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T-12000 4&6 SPEED HYDRAULIC DIAGRAM WITH DUAL MODULATION -96 Date : Apr 2000 Maintenance & Service Manual T12000 3,4 & 6 Speed LD T-12000 4&6 SPEED HYDRAULIC DIAGRAM WITH MODULATION AND INCHING -97 Date : Apr 2000 Copyright 2010 Dana Holding Corporation All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means, electronic or otherwise, without prior written approval. 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