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