Transmission & Transmission Hydraulic Control Valve, Testing and Adjusting

Usage:

Checking Transmission Supply Pressure

Instrument tests

(1) Transmission supply pressure tap.

(2) Transmission Pump

1. Stop the machine, engage the parking brake, turn off the machine.

2. The transmission oil pressure tap is located on the transmission pump.

3. Install a 6000 kPa (870 psi) pressure gauge on the pressure tap (1).

4. Start the engine, set the hand throttle at high idle. The transmission supply pressure should be
a minimum of 3300 kPa (479 psi) when the transmission oil is at an operating temperature of 50°
C (122° F).

Check Transmission Clutch Pressures

1. Stop the machine, engage the parking brake and turn the engine OFF.
 (1) Guard
(2) Transmission Control Valve

2. Remove the guard (1) from the transmission control valve (2), to provide access to the control.
Pressure Tap Test Ports

(3) Caps.

3. Put blocks in front of and behind the wheels of the machine. Remove the differential drive
shaft.

4. Remove caps (3) and install 6000 kPa (870 psi) pressure gauges on the pressure taps (D) and
(G).

5. Operate the engine at high idle either in PARK or NEUTRAL. Record the gauge pressures.
Pressure tap (D) is clutch number 8 and pressure tap (G) is clutch number 5. Remove the gauges
and replace the caps (3).
6. Remove caps (3) and install 6000 kpa (870 psi) pressure gauges on the pressure taps (B), (F)
and (H).

7. Operate the engine at high idle in FIRST/FORWARD. Record the gauge pressures. Pressure
tap (B) is clutch number 1, pressure tap (F) is clutch number 6 and pressure tap (H) is clutch
number 7. Remove the gauges and replace the caps (3).

8. Remove caps (3) and install 6000 kpa (870 psi) pressure gauges on the pressure taps (C) and
(E).

9. Operate the engine at high idle in SECOND/FORWARD. Record the gauge pressures.
Pressure tap (C) is clutch number 2 and pressure tap (E) is clutch number 4. Remove the gauges
and replace the caps (3).

10. Remove cap (3) and install 6000 kPa (870 psi) pressure gauge on pressure tap (A).

11. Operate the engine at high idle in FIRST/REVERSE. Record the gauge pressure. Pressure tap
(A) is clutch number 3. Remove the gauge and replace the cap (3).

12. Refer to the chart shown for the correct pressures. If an adjustment is needed, refer to "Initial
Pressure Adjustment Procedure".

Note All pressures are taken at 2000 rpm and 51° C (123° F) average.

13. Stop the engine, install the differential drive shaft and engage the parking brake. Replace all
covers and guard.

Initial Pressure Adjustment Procedure

1. Stop the machine, engage the parking brake and turn the engine OFF.
 (1) Guard
(2) Transmission control valve

2. Remove the guard (1) from the transmission control valve (2), to provide access to the control.

3. Put blocks in front of and behind the wheels of the machine. Remove the differential drive
shaft.

Transmission Control Valve

(3) Wiring harnesses.

(4) Bolts.
(5) Cover.
(6) Caps.

4. Disconnect the manual modulation cable and wiring harnesses (3) from the transmission
control valve.

5. Remove 33 mounting bolts (4). Remove the transmission control valve.

6. Place the transmission control valve on a clean surface. Remove cover (5). Install the 4C-8254
Test Cover and tighten the bolts to 30 ± 4 N·m (22 ± 3 lb ft).
7. Install the transmission control valve on the transmission and tighten the mounting bolts to 30
± 4 N·m (22 ± 3 lb in).

8. Connect the wiring harnesses (3) and the manual modulation cable.

9. Remove caps (6) and install 1000 kPa (145 psi) pressure gauges on the pressure taps (D) and
(G).

10. Operate the engine at high idle either in PARK or NEUTRAL. Record the gauge pressures.
Pressure tap (D) is clutch number 8 and pressure tap (G) is clutch number 5. Remove the gauges
and replace caps (3).

11. Remove caps (6) and install 1000 kpa (145 psi) pressure gauges on the pressure taps (B), (F)
and (H).

12. Operate the engine at high idle in FIRST/FORWARD. Record the gauge pressures. Pressure
tap (B) is clutch number 1, pressure tap (F) is clutch number 6 and pressure tap (H) is clutch
number 7. Remove the gauges and replace the caps (3).

13. Remove caps (3) and install 1000 kpa (145 psi) pressure gauges on the pressure taps (C) and
(E).

14. Operate the engine at high idle in SECOND/FORWARD. Record the gauge pressures.
Pressure tap (C) is clutch number 2 and pressure tap (E) is clutch number 4. Remove the gauges
and replace the caps (3).

15. Remove cap (3) and install 1000 kPa (145 psi) pressure gauge on pressure tap (A).

16. Operate the engine at high idle in FIRST/REVERSE. Record the gauge pressure. Pressure tap
(A) is clutch number 3. Remove the gauge and replace the cap (3).

17. Refer to the chart shown for the correct pressures. If an adjustment is needed, follow Steps 18
and 19.
Pressure Tap Test Ports
Note All pressures are taken at 2000 rpm and 51° C (123° F) average.

18. If the pressure does not agree with the chart, adjust the pressure using the following
procedure.
 (7) 4M-1751 Spacer and 5J-1036 Shim.
(8) Adjuster assembly.
(9) Locknut.
(10) Adjustment screw.

a. Loosen the locknut (9) on the adjuster assembly (8).

b. While monitoring the pressure, adjust by turning adjustment screw (10). To lower the
pressure, turn the adjustment screw clockwise. Total adjustment screw range is approximately
132 kPa (19 psi).

c. Tighten the locknut (9) to 25 ± 4 N·m (18 ± 3 lb ft). Shift the transmission to NEUTRAL for a
minimum of 15 seconds and then shift the transmission back to the gear specified in Steps 9
through 17. Confirm that the pressure agrees with the "Initial Pressures" chart.
d. If the pressure cannot be adjusted to within the acceptable limits with the adjusting screw (10),
stop the engine and remove the solenoid manifold to access the selector spool. Remove the
selector spool and add or remove shims and spacers as required.

5J-1036 Shim:

Outside diameter - 15.09 ± 0.25 mm (.594 ± .010 in)

Thickness - 0.80 mm (.031 in)

4M-1751 Spacer:

Outside diameter - 15.09 ± 0.25 mm (.594 ± .010 in)

Thickness - 0.4 mm (.02 in)

e. Install the solenoid manifold and adjust the initial pressure according to Steps a thru c in Step
18.

19. Continue the procedure until all the stations (pressure taps) are checked and adjusted.

20. Stop the engine, remove the transmission valve and install the original 8E-9474 Cover.

21. Use new 9P-9150 Washers and install the control group on the transmission. Tighten the
mounting bolts (4) to 30 ± 4 N·m (22 ± 3 lb ft).

22. Attachment the wiring harnesses (3) and the manual modulation cable.
23. To verify the clutch pressures, follow Steps 4 through 12 in "Check Transmission Clutch
Pressure".

24. Install guards and differential drive shaft.

NOTE: This procedure should be followed whenever a transmission control valve is repaired by
replacing any of the springs contained within the individual clutch stations.

NOTE: If the transmission clutch pressure (steady state) is out of range, the most likely cause of
the failure will be a failed modulation spring, debris in control valve or a seal failure within the
transmission.

Check Transmission Lubrication Pressure

1. Operate the machine until the transmission oil is at operating temperature of 51° C (122° F).

2. Stop the machine on a hard level surface. Engage the parking brake. Turn the engine OFF.

3. Remove plug (1) from the transmission case. Install a nipple and a 1000 kPa (145 psi) pressure
gauge into the pressure port.

4. Start the engine and operate the engine at low idle. The gauge pressure should read 80 ± 30
kPa (12 ± 4 psi).

5. Operate the engine at high idle. The pressure on the gauge should be a minimum of 340 kPa
(50 psi).
6. Remove the differential drive shaft. Operate the machine in FIRST/FORWARD at LOW idle.
The gauge pressure should be a minimum of 7 kPA (1psi).

7. Operate the machine in FIRST/FORWARD at HIGH idle. The gauge pressure should read 241
± 27 kPa (35 ± 4 psi).

8. Operate the machine in NEUTRAL at HIGH idle. The gauge pressure should read 558 ± 55
kPa (80 ± 8 psi).

9. Stop the machine, turn the engine OFF and install the differential drive shaft. Remove the
pressure gauge and install plug (1).

Differential Lock Valve Pressure Check

1. Operate the machine until the transmission oil is at operating temperature of 50° C (122° F).

2. Stop the machine on a hard level surface. Engage the parking brake. Turn the engine OFF.

Differential Lock Valve

(1) Plug

3. Remove plug (1) and install a nipple and a 6000 kPa (870 psi) pressure gauge.

4. Remove the differential drive shaft. Operate the machine in FIRST/FORWARD at HIGH idle
and engage the differential lock. The gauge should read 2620 kPA (380 psi) minimum.

5. Stop the machine. Turn the engine OFF and install the differential drive shaft. Remove the
pressure gauge and install plug (1).

Manual Modulation Pedal Check

 (1) Transmission.
(2) Modulation Pedal.
(3) Pedal Stop.
(4) Locknut.
(5) Locknut.
(6) Modulation Pedal Box.
(7) Rod.
(8) Transmission control valve.
(9) Modulation valve spool.
(10) Locknut.
(11) Modulation pedal cable
(A) 447 ± 3 mm (17.6 ± .1 in).

NOTE: Make sure there are no kinks or binds in the modulation pedal cable (11).

1. Modulation pedal cable (11) should be clasped to the modulation spool (9).

2. There should be three threads showing after the locknut (5) is tightened at the modulation
pedal box (6).

3. Distance (A) should be 447 ± 3 mm (17.6 ± .1 in). Distance (A) is centerline to centerline of
rod ends of rod (7).

4. Loosen the locknut (4) on the pedal stop (3) and turn the stop all the way in.

5. Put blocks in front of and behind the wheels of the machine. Remove the differential drive
shaft.
6. Start the engine. Press the modulation pedal (2) all the way down. Move the transmission
control lever to FIRST/FORWARD position and operate at half throttle. Slowly release the
modulation pedal until the transmission drive starts to turn.

7. Hold the pedal (2) at that position.

8. Turn the pedal stop (3) out until it touches the modulation pedal (2). The pedal stop should be
turned out approximately 9.52 mm (.375 in). Tighten locknut valve.

9. If the modulation does not work properly, check the modulation valve pressure at the
transmission control valve.

(8) Transmission control valve.

(12) Transmission control valve cover

a. Remove cover (12) from the transmission control valve (8).

(8) Transmission control valve.

(B) Test Port
b. Remove the cover on test port (B). Connect an 8T-0855 Pressure Gauge to the test port.

c. Press the modulation pedal (2) all the way down against the pedal stop (3). Move the
transmission control lever to FIRST/FORWARD position and operate at half throttle.

d. Let the modulation pedal (2) fully out. The transmission should be turning should be turning.
The pressure at test port (B) should read 2122 kPa (308 psi) minimum. Slowly press the pedal
down, (watching the gauge), and when the pressure reaches 0 kPa (.0 psi), adjust the pedal stop
(3) to touch the pedal. Tighten the locknut (4).

For a double check, use an ECAP service tool. Following the above procedure, the modulation
(inching) pedal status should go to OFF when the pedal hits the stop.

10. If the pressure is correct in Step 9, the modulation is working correctly. If the pressure is not
correct in Step 9, follow Step 11.

11. Disconnect the modulation pedal cable (11) from the modulation valve spool (9).

a. Operate the machine in FIRST/FORWARD at half throttle.

b. Manually pull the modulation valve spool (9) out. The pressure gauge should read 0.0 kPa (0
psi).

c. Push the spool into the valve body. The spool should move freely, but firm because of spring
resistance, and modulation (transmission drive starts to turn) should occur in the range of 0.0 kPa
(0 psi) to 834 kPa (121 psi).

d. If the spool does not move freely, the spool may need to be cleaned.

12. If the spool moves freely and the modulation occurs in Step 11, the cable may have drag and
needs to be replaced.