T12000 Powershift Transmission Maintenance Service Manual

T12000 Powershift Transmission Maintenance Service Manual

DANA T12000 Powershift Transmission 3, 4 & 6 SPEED INTERMEDIATE DROP Maintenance and Service Manual

1. SAFETY PRECAUTIONS
2. CLEANING, INSPECTION AND LEGEND SYMBOLS
2.1 CLEANING ……………………………………………………………………………………………………………… 2-1
2.1.1 Bearings …………………………………………………………………………………………………………. 2-1
2.1.2 Housings ………………………………………………………………………………………………………… 2-1
2.2 INSPECTION …………………………………………………………………………………………………………… 2-1
2.2.1 Bearings …………………………………………………………………………………………………………. 2-1
2.2.2 Oil Seals, Gaskets, Etc. ……………………………………………………………………………………. 2-2
2.2.3 Gears and Shafts …………………………………………………………………………………………….. 2-2
2.2.4 Housing, Covers, etc. ……………………………………………………………………………………….. 2-2
2.3 LEGEND SYMBOLS…………………………………………………………………………………………………. 2-2
3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OF THE UNIT ………………………………………………………………………………… 3-1
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY…………………………………………………………………….. 3-1
3.3 TIGHTENING TORQUES ………………………………………………………………………………………….. 3-2
3.3.1 Torque specifications for lubricated or plated screw threads ………………………………….. 3-2
3.3.2 Pipe plug torque chart ………………………………………………………………………………………. 3-3
3.3.3 Permanent metric plug torque chart ……………………………………………………………………. 3-3
3.3.4 Coil and cartridge torque …………………………………………………………………………………… 3-3
3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS …………………………………………………. 3-4
3.5 ELECTRICAL SPECIFICATIONS ……………………………………………………………………………….. 3-5
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS……………………………………….. 3-5
4. MAINTENANCE
4.1 OIL SPECIFICATION ……………………………………………………………………………………………….. 4-1
4.1.1 Recommended lubricants …………………………………………………………………………………. 4-1
4.2 MAINTENANCE INTERVALS …………………………………………………………………………………….. 4-3
4.2.1 Daily ………………………………………………………………………………………………………………. 4-3
4.2.2 Normal drain period………………………………………………………………………………………….. 4-3
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL ……………………………………….. 4-4
4.4 INSTRUCTIONS FOR LINING REPLACEMENT AND
ADJUSTMENT OF PARKING BRAKE ASSEMBLY……………………………………………………….. 4-5
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING ……………………………………………………………………………… 5-1
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE ……………………………………….. 5-2
5.3 EXTERNAL PLUMBING ……………………………………………………………………………………………. 5-3
5.3.1 Optional remote filter ………………………………………………………………………………………… 5-3
5.3.2 Cooler & filter lines specifications ………………………………………………………………………. 5-3
5.4 SPEED SENSOR INSTALLATION ……………………………………………………………………………… 5-4T12000 ID 04/99 I-ii
6. OPERATION OF THE TRANSMISSION
6.1 THE TRANSMISSION ASSEMBLY …………………………………………………………………………….. 6-1
6.1.1 The converter, pump drive section and pressure regulating valve …………………………… 6-2
6.1.2 The input shaft and directional clutches ………………………………………………………………. 6-3
6.1.3 The range clutches ………………………………………………………………………………………….. 6-4
6.1.4 The output section …………………………………………………………………………………………… 6-4
6.1.5 The transmission controls (refer to hydraulic diagram) ………………………………………….. 6-5
6.2 ELECTRIC SOLENOID CONTROLS ………………………………………………………………………….. 6-6
6.2.1 3-Speed transmission …………………………………………………………………………………….. 6-6
6.2.2 4-speed transmission ……………………………………………………………………………………… 6-6
6.2.2.1 Standard 4-speed transmission ………………………………………………………………. 6-6
6.2.2.2 Alternative 4-speed transmission,……………………………………………………………. 6-7
6.2.3 6-Speed transmission ………………………………………………………………………………………. 6-7
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT ……………………….. 6-8
6.3.1 3-Speed transmission …………………………………………………………………………………….. 6-8
6.3.1.1 Neutral and 3rd clutch engaged ……………………………………………………………… 6-8
6.3.1.2 Forward 1st speed ………………………………………………………………………………. 6-10
6.3.1.3 Forward 2nd speed……………………………………………………………………………… 6-12
6.3.1.4 Forward 3rd speed ……………………………………………………………………………… 6-14
6.3.1.5 Reverse 1st speed………………………………………………………………………………. 6-16
6.3.2 4-Speed transmission …………………………………………………………………………………… 6-18
6.3.2.1 Standard 4-speed transmission …………………………………………………………….. 6-18
6.3.2.1.1 Neutral and 3rd clutch engaged ………………………………………………… 6-18
6.3.2.1.2 Forward 1st speed …………………………………………………………………… 6-19
6.3.2.1.3 Forward 2nd speed …………………………………………………………………. 6-21
6.3.2.1.4 Forward 3rd speed ………………………………………………………………….. 6-24
6.3.2.1.5 Forward 4th speed ………………………………………………………………….. 6-26
6.3.2.1.6 Reverse 1st speed ………………………………………………………………….. 6-28
6.3.2.2 Alternative 4-speed transmission…………………………………………………………… 6-30
6.3.2.2.1 Neutral and 3rd clutch engaged ………………………………………………… 6-30
6.3.2.2.2 Forward 1st speed …………………………………………………………………… 6-32
6.3.2.2.3 Forward 2nd speed …………………………………………………………………. 6-34
6.3.2.2.4 Forward 3rd speed ………………………………………………………………….. 6-36
6.3.2.2.5 Forward 4th speed ………………………………………………………………….. 6-38
6.3.2.2.6 Reverse 1st speed ………………………………………………………………….. 6-40
6.3.3 6-Speed transmission …………………………………………………………………………………… 6-42
6.3.3. 1Neutral and 3rd clutch engaged…………………………………………………………………….. 6-42
6.3.3.2 Forward 1st speed ………………………………………………………………………………. 6-44
6.3.3.3 Forward 2nd speed……………………………………………………………………………… 6-46
6.3.3.5 Forward 4th speed………………………………………………………………………………. 6-50
6.3.3.6 Forward 5th speed………………………………………………………………………………. 6-52
6.3.3.7 Forward 6th speed………………………………………………………………………………. 6-54
6.3.3.8 Reverse 1st speed………………………………………………………………………………. 6-56
6.4 GEAR AND CLUTCH LAY-OUT (3-SPEED) ……………………………………………………………….. 6-58
6.4 GEAR AND CLUTCH LAY-OUT (4-SPEED AND 6-SPEED) …………………………………………. 6-59
7. TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION
7.1 T12000 TRANSMISSION ………………………………………………………………………………………….. 7-1
7.2 TROUBLESHOOTING PROCEDURES ………………………………………………………………………. 7-1
7.2.1 Stall Test…………………………………………………………………………………………………………. 7-1
7.2.2 Transmission pressure checks …………………………………………………………………………… 7-2
7.2.3 Mechanical and electrical checks ………………………………………………………………………. 7-2
7.2.4 Hydraulic checks ……………………………………………………………………………………………… 7-2T12000 ID 04/99 I-iii
7.3 TROUBLESHOOTING GUIDE …………………………………………………………………………………… 7-3
7.3.1 Low clutch pressure …………………………………………………………………………………………. 7-3
7.3.2 Low charging pump output ………………………………………………………………………………… 7-3
7.3.3 Overheating ……………………………………………………………………………………………………. 7-3
7.3.4 Noisy converter ……………………………………………………………………………………………….. 7-3
7.3.5 Lack of power ………………………………………………………………………………………………….. 7-3
7.4 CHECK POINTS ………………………………………………………………………………………………………. 7-4
7.5 ELECTRICAL WIRING ……………………………………………………………………………………………… 7-7
7.5.1 3-Speed transmission ………………………………………………………………………………………. 7-7
7.5.2 Standard 4-Speed transmission …………………………………………………………………………. 7-8
7.5.3 Alternative 4-Speed transmission ………………………………………………………………………. 7-9
7.5.4 6-Speed transmission …………………………………………………………………………………….. 7-10
7.6 SPEED SENSOR – STATIC STANDALONE TEST ………………………………………………………..7-11
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION
GROUP – CONVERTER HOUSING …………………………………………………………………………………… 8-2
GROUP – TRANSMISSION CASE AND PLATE …………………………………………………………………… 8-4
GROUP – TORQUE CONVERTER …………………………………………………………………………………….. 8-6
GROUP – PUMP DRIVE …………………………………………………………………………………………………… 8-8
GROUP – CHARGING PUMP ………………………………………………………………………………………….. 8-10
GROUP – REVERSE IDLER ……………………………………………………………………………………………. 8-12
GROUP – FORWARD AND REVERSE SHAFT ………………………………………………………………….. 8-14
GROUP – 3RD SHAFT (FOR 3-SPEED TRANSMISSION ONLY) ……………………………………….. 8-16
GROUP – HIGH (4TH) AND 3RD SHAFT ………………………………………………………………………….. 8-18
GROUP – 1ST AND 2ND SHAFT ……………………………………………………………………………………… 8-20
GROUP – OUTPUT SHAFT (REAR ONLY) ……………………………………………………………………….. 8-22
GROUP – OUTPUT SHAFT (FRONT ONLY) ……………………………………………………………………… 8-24
GROUP – OUTPUT SHAFT (FRONT & REAR) ………………………………………………………………….. 8-26
GROUP – DISC BRAKE ………………………………………………………………………………………………….. 8-28
GROUP – CALIPER ASSEMBLY ……………………………………………………………………………………… 8-30
GROUP – ELECTRIC CONTROL …………………………………………………………………………………….. 8-32
GROUP – DRIVE PLATE ………………………………………………………………………………………………… 8-34
9. ASSEMBLY INSTRUCTIONS
10. DISASSEMBLY AND REASSEMBLY OF THE T12000 TRANSMISSION
11. OPTIONS
11.1 ELECTRIC CONTROL-SINGLE MODULATION HYDRAULIC ACTUATED INCHING ……….11-1
11.1.1 Sectional views and parts identification ……………………………………………………………11-1
11.1.2 Single modulation and hydraulic inching removal ………………………………………………11-6
11.1.3 Disassembly single modulator assembly ………………………………………………………….11-8
11.1.4 Reassembly single modulator assembly…………………………………………………………11-10
11.1.5 Disassembly hydraulic inching actuator ………………………………………………………….11-12
11.1.6 Reassembly hydraulic inching actuator ………………………………………………………….11-14
11.1.7 Single modulation and hydraulic inching installation…………………………………………11-16
11.2 MT SECTION…………………………………………………………………………………………………………11-19
11.2.1 Sectional views and parts identification ………………………………………………………….11-19
11.2.2 Assembly instructions ………………………………………………………………………………….11-21

Reviews

You must log in and be a buyer of this download to submit a review.

0 sales

0 sales

Download Category:
Download Tag:

Copyright 2018

repairguid