DANA VDT12000, MAINTENANCE SECTION, from April 2011
Contents
1. ccc aa 43 GROUP PUMP DRIVE dais 44 GROUP CHARGING ARTE 45 GROUP REVERSE IDLER did 46 GROUP FORWARD AND REVERSE SHAFT 0 0 0 2 cece cc cec a 47 GROUP 3RD SHAFT FOR 3 SPEED TRANSMISSION ONLY ula 49 GROUP HIGH 4TH AND SRD SHAFT EE 51 GROUP 1ST AND 2ND SHAFT css ai dd ica 53 GROUP OUTPUT SHAFT REAR ONLY eege EE Eet 55 GROUP OUTPUT SHAFT FRONT ON 56 GROUP OUTPUT SHAFT FRONT 8 REAR REENEN RENE 57 GROUP DISK BRAKE oun ccc cece aa 58 GROUP CALIPER ASSEMBLY usina AN aa Eaa a Eaa aaia radan ainia 59 GROUP ELECTRIC CONTROL ue cece cece ccececcececeeaececeenececeeaeceeaeaeceeaeaecueaeaecueaeaecueaesesueaeeneunsneaeass 61 GROUP DRIVE PLATE usina di 63 YOI Z000 EE 64 TRANSMISSION CASE amp PLATE GROUP sisescscssissivacastievinairasicancalinaciasasidiodutaundidveraenke a ei 64 3 SHAFT DROP BOX elef 66 AOHAFT DOROP BOX GROUP ira edita ca eae eens 67 T12000 INSTALLATION DETAILS 0 0 cccccecececececececececececececececececececececenecenecececeeeceneneneneaes 69 CONVERTER DRIVE COUPLING ANEN ENNEN 69 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE c00ccccccncnnononononcncncononononcncncnconononons 70 3 Maintenance and Repair manual and installation guide T12000 VDT amp 17 ana EXTERNAL PLUMBINO a AA ee N 71 OPTONAL eebe 12 COOLER amp FILTER LINES SPECIE ICA EHNEN 12 SPEED SENSOR INSTALLATION AE 73 OPERATION OF THE 112000 TRANSMISSION Uu 75 THE TRANSMISSION ASSEMBEY Hana root 75 THE CONVERTER PU2. lt pana gt SPICER Off Highway Products service Manual Transmission 112000 3 4 4 6 speed Intermediate Drop VDT12000 VDT 17 TSM 0022 April 201 1 RANA T12000 VDT amp 17 1 Maintenance and Repair manual and installation guide T12000 VDT amp 17 ana NOTICE AA AA AA 1 PORE WORD geet 1 TOWING OR PUSHING E 1 ARETY PRECAUTIIN E 1 CLEANING AND INSPECTION ssstessteccccicesendsasrnscdasondaaienescdaamentsacecenacescdasasrcanaearsenaseesdeansnmnccs 2 CEEANIN OS tee 2 BE RINGO aaa eee AA AA Aa 2 PEDE E AA AA ANA ee ee 2 INSPECTION PAA HA 2 Sie e 2 JIE EALS CGA KETS EDO sionista ee ee 2 GEAR E NO AP q 3 POU INGO COVERS ETO sorento cota E tte eee 3 TECHNICAL SPECIFICATION WT 4 F200 E ee WEE 4 PES INIT Te 29016 OF TRE H lr IN RE 4 WEIGH DIMENSIONS OIL CAPACITY GE 4 PRESSURE AND TEMPERATURE SPECIFICATIONS cooccccccccnnnnoccnncccnnnnccncnnnnnnnnancnnnnnnnnnnnccnncnnnnnnncnnos 5 ELECTRICAL SPEGIPIGA TIONG sanas GA AA LA 5 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS cee ceeeeee eee eeee nananana eeeeeeeeeaaaeneeeeees 5 NOT 12000 EE 6 IDENTIFICATION OF THE UNIT assistant iris 6 WEIGHT DIMENSIONS OIL CAPACITY corras ios 6 TRANSMISSION WITH A 3 SHAFT DROP BOX ccccccooccccnccnnnnnncnnnnnnnnnnnnncnnnnnnnnnrrnnncnnnnnnnrnnnnnnnnncrnnnncnnnnnes 6 TRANSMISSION WITH A A SHAFT DROP BOX ccccccooccccnccnnnnoncnnnccnnnnnnccnncnnnnnnnrnnnncnnnnnnnnnnnnnnnnncrnnncnnnnnnes 7 VOL I DEGREES E 8
3. 119 Nm Maintenance and Repair manual and installation guide o MAINTENANCE EE INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PAR DANA 05042011 MOT12000T20 d BRAKE PADS BACKLASH ADJUSTMENT Loosen and remove the brake pads 4 outer adjustment nut 1 Tighten the inner adjustment nut 2 until firm contact is made with the disc by the pads 4 Using a dynamometric wrench tighten the nut to a tightening torque of 11 Nm Loosen the inner adjustment nut 2 by 4 5 surfaces Check the correct working of the brake caliper 7 Screw the outer nut 1 on the adjustment bolt 6 Keeping the inner nut 2 in position torque the outer nut 1 to a tightening torque of 60 75 Nm Maintenance and Repair manual and installation guide 21 ana MON 346 spoed TROUBLESHOOTING GUIDE T12000 3 4 6 speed The following information is presented as an aid to isolating and determining the specific problem area in a transmis sion 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 components Proper operation of the transmission depends on the condition and cor rect functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter trans
4. IDENTIRICATON OF THE El TN WE 8 WEIGHT DIMENSIONS al e CR GE 8 HGFELENING LOROJES za GUAN E AA AAO 9 COIL AND CARTIDGETOROUE anna nna ANA ee ener ee eee a aaa e aaa a aaa aa 10 MAINTE NANCE cuina 11 OIL SPECIFICA HON Sita 11 RECOMMENDED LUBRICANTS seta copio 11 WALID FOR VDTI2000 amp ELE 12 VACC FOR T OUO Ree AA aia 12 Toe E O P O A ios 13 MAINTENANCE TR AE 13 DAILY paa E E e 13 NORMAL DRAIN PERIOD EE 13 SERVICING MACHINE AFTER COMPONENTS OVERHAUL 0 0 0 ccc ce eee cece ee teeee eres eee e eee eeeeeeaaeeeeeeeeeaaas 14 AB ZOO RE 15 MAINTENANCE INTERVALS FOR THE 3 8 4 SHAFT DROP BOX ioccccccccnocccccnconnnnnncnnnncnnnnnnncncnononanccnnos 15 PPP Saco Sn oe eae cc ae tosis egg eee hs eee ese 15 NORMAL DRAIN PERIOD aaa AA ee AA eee 15 MAINTENANCE INTERVALS FOR THE TRANSMISSION 000 0 ce cece cece ee tere ee eee ee eeeeeeeeeaaeeeeeeeeeaaaaneeeeees 15 INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PARKING BRAKE ASSEM A see pec aceo ube sds li Co al A 16 lll DIA GRAN NEE 16 DI A AA e 17 Al EE 18 Maintenance and Repair manual and installation guide RANA T12000 VDT amp 17 TROUBLESHOOTING GUIDE oui ice HA 22 112000 3 4 0 SPS80 EE 22 TI12000 TRANSMISSION scudo olaaa asap setae 22 TROUBLESHOOTING PROCEDURES occccnoncnconononnonononno aaa 22 STALL TEST AA 22 TRANSMISSION PRESSURE CHECKS cccsccscsscsessssscsesscsscsesucsscscsussssecsrssssusssssssussessesusetsatsessesseatesesssessesetesee 22 MECHANICAL AN
5. T12000 3 4 6 speed de een SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 O BELGIUM O MODEL L SERIAL pe IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number WEIGHT DIMENSIONS OIL CAPACITY Weight dry 174 6 kg 385 Ib Maximum length 623 1 mm 24 53 623 1 mm 24 53 Maximum width 477 0 mm 18 78 477 0 mm 18 78 Maximum height 701 1 mm 27 60 701 1 mm 27 60 OIL CAPACITY 12 9 3 4 US Gallon without cooler and hydraulic lines Consult operator s manual on applicable machine for system capacity 4 Maintenance and Repair manual and installation guide o TECHNICAL SPECIFICATION ll 2000 VDT amp 17 WEIGHT DIMENSIONS OIL CAPACITY RING PRESSURE AND TEMPERATURE SPECIFICATIONS e Normal operating temperature 70 120 C 158 248 F measured at temperature check port converter out port 71 7 e Maximum allowed transmission temperature 120 C 248 F e Transmission regulator pressure neutral port 31 7 At600 RPM min 12 76 bar 185 PSI minimum At2000 RPM 19 31 bar 280 PSI maximum e Pump flow At 2000 RPM in neutral 53 l min minimum 14 GPM e Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 Forward High clutch port 44 Forward clutch port 45 Reverse clutch port 46
6. AND PARTS IDENTIFICATION 0 0 2 0 ccc eee cece errr eee ANAN AS tener reer eee NANANA AASA kkkkkknnnnnna nan anONG 284 ASSEMBLY INSTRUCTIONS aa access ctw esate eee 284 MT CROSS SECTION AND ASSEMBLY INSTRUCTIONS 0 0 0 e cece cece ee reer eee a eter teste aaaeeeeeeeeeaaaees 286 VOT T2000 RN 287 JOHAR TOROF BOX A o A 287 A BOA A E AA 288 SOART AA e o A 289 PA nen 290 d4 Sha DROP gt AAA Un e AA PAGA A 291 BM ET E 291 jaa my A PP o ee 300 YOT I DESREES eee ee en ee ee AA 308 GENERAL BEARING INSTALLATION PROCEDURE cocccccccnnncccncccnnnnncncnnnnnnnncccnnnnonnnnnnncnnnnnnnncncnnnnnnnnnnnenos 309 TAPER BEARING ADJUSTMENT sorprendo 309 INPUT SHAFT TAPER BEARING ADJUSTMENT 0 0 cece cece cccceeee cece cece etter eee ee ea eee eeeeeeeeaaeeeeeeeesaaaaeeeeeeeaaas 312 Katie 313 RE aca E 313 AAA PP A 320 INPUISS HART E 330 DGA E NAA AA AA AA AA AA r 330 A y ip CO AA A A 331 5 Maintenance and Repair manual and installation guide o NOTICE T12000 VDT 8 17 FOREWORD ana NOTICE All information mentioned in the and Service manual T12000 Powershift Transmission 3 4 amp 6 Speed Intermediate Drop is valid unless otherwise specified in this 17 Drop Box and VDT FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instruc tions on the maintenance and repair of the SPICER OFF HIGHWAY PRODUCTS product Extreme care has been exercised in th
7. O e O REAR VIEW LEFT VIEW Maintenance and Repair manual and installation guide 15 MAINTENANCE o lt lt INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PAR 112000 VDT amp 17 05042011 MOT12000T20 INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PARKING BRAKE ASSEMBLY ASSEMBLY DIAGRAM 16 Maintenance and Repair manual and installation guide o MAINTENANCE gt Y 112000 VDT amp 17 INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PAR DANA 05042011 MOT12000T20 DISASSEMBLY Undo the lock nuts 9 securing the runner pins 10 Remove the runner pins 10 holding the lock nuts 9 in position Remove the brake calliper 8 With a plier press and remove the spring flat Remove the pads 4 Maintenance and Repair manual and installation guide 17 HANS ASSEMBLY 18 MAINTENANCE o INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PAR T12000 VDT amp 17 05042011 MOT12000T20 Install the brake pads 4 Install the spring flat 5 and fit it in the pads holes Insert the fixing screws 9 trough the sleeves 3 in the brake caliper 7 Screw the lock nuts 8 on the fixing screws 9 and leave a gap of 2 mm between the lock nuts 8 and the sleeves 3 Spread the threaded portion of the screws 9 with LOC TITE 243 Maintenance and Repair manual and installation guide o MAINTENANCE EE INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF
8. Recheck level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to FULL mark on dipstick or runs from oil level check plug hole Install oil level plug of dipstick Recheck with hot oil 82 2 93 3 C 180 200 F Adjust oil level to FULL mark on dipstick or runs freely from oil level plug 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary 14 Maintenance and Repair manual and installation guide o MAINTENANCE 112000 VDT 4 17 EEN ana VDT12000 MAINTENANCE INTERVALS FOR THE 3 amp 4 SHAFT DROP BOX DAILY Check oil level daily Maintain oil level at full mark Middle of oil level glass NORMAL DRAIN PERIOD Normal drain period is every 1000 hours for average environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination For extreme conditions judgement must be used to determine the required change intervals MAINTENANCE INTERVALS FOR THE TRANSMISSION TO DRAIN THE TRANSMISSION BOTH DRAIN PLUGS A 8 B NEED TO BE REMOVED e 3 shaft drop box REAR VIEW LEFT VIEW e 4 shaft drop box X0 O 0 3 Nov o O l o 3 4 A Q l A SO OOO 6 PAGA AB eS oN a 7 2 logro 2 A
9. e At1800 RPM 16 5 19 3 bar 240 280 PSI clutch activated 0 0 2 bar 0 3 PSI clutch released e Filter bypass valve set at 2 1 3 5 bar 30 50 PSI e Lube pressure port 33 2 9 4 0 bar 42 58 PSI at 49 l min 13 GPM pump flow 1850 RPM e Safety valve cracking pressure 8 27 10 20 bar 120 148 PSI measured at port 32 with convertor out shut off e Transmission out pressure port 32 2 9 6 41 bar 42 93 PSI at 49 l min 13 GPM pump flow 1850 RPM and max 8 27 bar 120 PSI at no load governed speed SAI pressures and flows to be measured with oil temperature of 82 93 C 180 200 F Refer to section 7 Troubleshooting for check port identification ELECTRICAL SPECIFICATIONS e Solenoid forward reverse 1st 2nd and splitter e Coil resistance 12V 9 79 Q 0 5 O 24V 393022 0 e Speed sensor Type magneto resistive sensor Sensing distance O 1 8 mm 0 0 07 Sensor signal generates a square current with a fixed amplitude changing between 7 and 14 mA HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS e Minimum 19 mm 75 internal diameter for lines and fittings e Suitable for operation from ambient to 120 C 248 F continuous operating temperature e Must withstand 20 bar 290 PSI continuous pressure and with 40 bar 580 PSI intermittent surges e Conform SAE J1019 and SAE J517 100RI Maintenance and Repair manual and installa
10. of one unit is performed the balance of the system must be considered before the job can be considered complete 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 judge ment must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cle aning 3 Replace oil filter element The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and 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 5 Reassemble all components and use only type oil See chapter 4 1 1 Recommended lubricants Fill the tran smission through filler opening until fluid comes up to FULL mark on transmission dipstick NOTE IF THE DIPSTICK IS NOT ACCESSIBLE OIL LEVEL CHECK PLUGS ARE PROVIDED Remove check plug fill until oil runs from oil hole Relift filler and level plug Run engine two minutes at 500 600 RPM to prime torque convertor and hydraulic lines
11. D ELECTIRCAL CHECKS o cccccccscsssscssssesesesessessesssessssusssseesssesseseessseatesearssearsisstesesteseaceseeeees 23 HYDRAULIC CHECKS 2k 23 TROUBLESHOOTING RECH IR 24 LOW CLUTCH PRESSURE ici a 24 LOW CHARGING PUMP OUTPUT cccccccccscssesccsescssescssescsesessessssesssesessesessesessesearsseateseateseatereatesestsseasestereeeeseees 24 OVERHEATING oncccccccocsscocsscscsscscsscscssessucsssucsssucsssucassucassucassucassucassucassucassucasstsasstcassusssarcasanssusssassasacsasacereavareavaseaes 24 NOISY CONVERTER rn 24 LACICOP POWER EEN 24 CHECI el KEE 25 ELECTRICAL WIRING ovina e diia 28 3 SPEED TRANSMISSION mms 28 STANDARD 4 SPEED TRANSMISSION 1 3 5 6 SPEED ccccccccssssssessescsessssecsessesesessussessestsstsesesetsessesateeees 29 ALTERNATIVE 4 SPEED TRANSMISSION 1 3 4 5 6 SPEED ccccccccccscssessesecsesecsesecsuesessesscsesecsessesseseeeesneevee 30 6 SPEED TRANSMISSION mms 30 SPEED SENSOR STATIC STANDALONE TEST 31 BA AA a a a 32 CHECK POINT eeaeee EE eee AE TEE 32 TRANSMISSION WITH A 3 SHAFT DROP BOX ccssccscsssecsesscsesssssssessesscecsussusecsuesessessssesetsessesssatesessstsatsessteee 32 TRANSMISSION WITH A 4 SHAFT DROP BOX ccssccscssssecsesucsesesssssessesvcsesussusscsuesessestssesatsessesestssessssesststesteeess 35 VDT 17 DEGREES Uu 38 CHECK DONT 38 SECTIONAL VIEWS AND PARTS IDENTIFICATION NNN 39 IKA a a E 39 GROUP CONVERTER HOUSING Uu aa 39 GROUP TRANSMISSION CASE AND DATE 41 GROUP TORQUE CONVERTER 0 0
12. HAUSTIVE BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL THE POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS Maintenance and Repair manual and installation guide 1 CLEANING AND INSPECTION o Bana SPECTION 742000 VDT amp 17 CLEANING AND INSPECTION CLEANING 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 CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES FIRE HAZARDS AND INHALATION OF VA POURS WHEN USING SOLVENT TYPE CLEANERS 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 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 evapor
13. MP DRIVE SECTION AND PRESSURE REGULATING VALVE uman 76 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES 00 inna nn 77 THE RANGE CLOTHE patito toba 78 TAROT SECTION E 78 THE TRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM AAA 79 Seat ee E e lee el WR el 80 Ce id ol OM Elle WE 80 SN KREE WEE 80 STANDARD 4 SPEED TRANSMISSION 1 3 5 6 6 SPEED c scsseeseeseeseesteseeseeeeesteteeneeeeteeneaneneeneeneeeeess 80 ALTERNATIVE 4 SPEED TRANSMISSION MODEL T12496 ONLY 1 3 4 5 6 SPEED i is 80 6 5 EED TRANSMISSION E 81 POWERFLOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT umaani 82 3 SPEED TRANSMISSION siniseen eee kn GRE RILES PESTE NN 82 BERGERE 82 FORWARD ST SPEED pando isis 84 FORWARD 2ND SPEED conc 86 FORWARD ORO ee eet 88 REVER OGIST PEED E 90 PEER TREN SW IS SION sto 92 STANDARD 4 SPEED TRANSMISSION espuelas ooo aala 92 ALTERNATIVE 4 SPEED TRANSMISSION cinco 105 BREED TRANSMISSION WE 117 NEUTRAL AND 3RD CLUTCH ENGAGED issue datan 117 FORWARD IST SPEED ca AA AN PADA AA AA 119 WEI 121 FORWARD 3RD SPEED D 123 FORWARDATH O een 125 FORWARD OTH PEED panteon 127 SIE E 129 REVERSE SS EE 131 GEAR AND CLUTCH LAY OUT G SPEED A 133 GEAR AND CLUTCH LAY OUT 4 SPEED AND 6 SPEED 0 0 0 ee ee naan 134 ASSEMBLY INSTRUCTION simiente iia 135 P2000 85O E 135 TRANSMISSION COMPLETE AANEREN 141 DIS RS SEI Pe o o 141 AE aa ips 155 Lol COC AA E C00U 0 ee 172 BS a A re EE Ro ro Oe 172 AOSPNPIN ras 176 2NG CUNG WE 182 D A
14. PAR DANA 05042011 MOT12000T20 d Move towards the external part of the brake caliper 7 the screws 9 complete with sleeves 3 and lock nuts 8 to fa cilitate the brake caliper 7 installation Insert the brake caliper 7 in the braking disc and install it in its seat fasten the fixing screws 9 Remove the backlash between screws 9 and sleeves 3 working on the lock nuts 8 Send the screws 9 to end stro ke complete with sleeves 3 and lock nuts 8 BRAKE CALIPER BACKLASH REGULATION Repeat the operation on both screws Holding the lock lock nut in position unloose the screw of about 1 turn Maintenance and Repair manual and installation guide 19 20 INSTRUCTIONS FOR LINING REPLACEMENT AND ADJUSTMENT OF PAR 108 119 Nm MAINTENANCE T12000 VDT amp 17 05042011 MOT12000T20 Repeat the operation on both screws Using a screwdriver adjust the sleeve 3 as shown in pictu re Repeat the operation on both screws Insert a 0 7 mm shim between the sleeve 3 and the lock nut 8 to check the brake caliper 7 backlash NOTE Check that the lock nut 8 is at end of stroke Repeat the operation on both screws Keeping the shim in position insert the screw 9 to regulate the backlash betwe en sleeve 3 and lock nut 8 GN Repeat the operation on both screws Keeping the screws 9 in position torque the lock nuts 8 to a tightening torque of 108
15. S RECOMMENDED LUBRICANTS CUSTOMER OIL TYPE JOHN DEERE J20 C D MILITARY MIL PRF 2104G DEXRON Il Equivalent See note below DEXRON II EQUIVALENT IS ACCEPTABLE HOWEVER IT IS NOT COMPATIBLE WITH TORQUE CON VERTERS OR TRANSMISSIONS EQUIPPED WITH GRAPHITIC FRICTION MATERIAL CLUTCH PLATES DEXRON Ill ENGINE OIL OR GL 5 OILS ARE NOT RECOMMENDED PREFERRED OIL VISCOSITY It is recommended that the highest viscosity monograde lubricant available be used for the anticipated ambient tem perature Typically this will be a CAT TO 4 qualified lubricant When large swings in ambient temperature are proba ble J20 C D multigrades are recommended Multigrade lubricants should be applied at the lower viscosity rating for the prevailing ambient temperature i e a 10W20 should be used where a 10W monograde is used If a C 4 multigra de is used in stead of J20 lubricant it is recommended that the viscosity span no more than 10 points i e 10W20 SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OF THE ABOVE SPECIFICATIONS OIL VISCOSITY GUIDELINES APPLY BUT SYNTHETIC MULTIGRADES MAY SPAN MORE THAN 10 POINTS FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER OFF HIGHWAY PRO DUCTS Recommended SAE J300 Viscosity Grade Based on Prevailing Ambient Temperature Celsius 40 30 20 10 0 10 20 30 40 50 Fahrenheit 40 22 4 14 32 50 68 88 104 122 Maintenance and Repair manual and installation guid
16. S EMBE maa ANAN AA AA AA AA 182 ASSEMBE EE 187 A aaa AA EEE OOO AA 194 DISASSEMEL E 194 A ENIDE EE 199 A p E A me e eu A AA AA 206 DISASSEMBE E 206 Maintenance and Repair manual and installation guide RANA T12000 VDT amp 17 e OT a GE 210 REYERSECLUTOR nn A 216 A E PA 216 pA E E PA o A E E o A 220 FORWARD AA PP o AA 225 Bio A A A PP A 225 PPP A eee 229 REGULATOR VALVE oct idad roots tte 234 PI SPOS pai ici 234 Ae PP e 235 DUAL MODULATEDVELVEASSEMBLY csi ia 236 BISA A EE 236 A AAPP A EO e 237 SPACER PEATE E 241 RE E E ee 241 Ao ap merne AA AA A a a 246 FRONT OUTPUT EE 252 a AA to e A E 252 a AP e A 204 CONVERTER e E LEE 256 A EP A e Ae 256 AO TE ios 259 SINGLE MODULATION AND HYDRAULIC REMOVAL cccccceeeeee cece ee eee eee eeeeeeeeeeeeeeaaeeeeeeeeeaaaneneeees 262 SINGLE MODULATED VALVE ASSEMBLY 00007702000000000ananana cette ee etter reese ea ANN eee ee ees aaaeeeeeeeaaaeeeeeeeeeaaaneeeeees 265 DIO E E 265 ASSEMBL aa AA AA o ee ee ee 268 HYDRAULIC INCHING REMOVAL cosita iii das 270 Mo AA A S E ere e 270 Sl AA AA AA 273 SINGLE MODULATION AND HYDRAULIC INCHING INSTALLATION cece eeeee sees teeeeeeeeeaaeneeeeees 2 6 OPTIONS corneal ee cee 279 ELECTRIC CONTROL SINGLE MODULATION HYDRAULIC ACTUATED INCHING coooocccccccccccccncnnnnancncnnncnnnos 279 SECTIONAL VIEWS AND PARTS IDENTIFICATION AAA 279 MI SECLION EE 284 SECTIONAL VIEWS
17. allation guide 7 TECHNICAL SPECIFICATION o gt lt a VDT 17 DEGREES 112000 VDT 8 17 VDT 17 DEGREES Ka SPICER OFF HIGHWAY lt gt TEN BRIELE 3 8200 B O BELGIUM MODEL SERIAL IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number WEIGHT DIMENSIONS OIL CAPACITY Weight dry 249 kg 9 Lbs 730 7 mm 77 803 4 mm 63 619 9 mm 40 OIL CAPACITY e Transmission 13 516 US gallon without cooler and hydraulic lines Consult Operator s Manual on applicable machine for system capacity e 17 Drop Box 0 25 0 07 US gallon NOTE THE OIL OF THE DROP BOX IS COMPLETELY SEPARATED FROM THE OIL OF THE TRANSMIS SION 8 Maintenance and Repair manual and installation guide o TECHNICAL SPECIFICATION 112000 VDT 8 17 TIGHTENING TORQUES No TIGHTENING TORQUES COARSE PITCH SIZE OF BOLT TORQUE WRENCH rome wna ON astelle eremm FINE PITCH SIZE OF BOLT TORQUE WRENCH mmm Dn mn zeen tos scene eremm Maintenance and Repair manual and installation guide 9 TECHNICAL SPECIFICATION DANA TIGHTENING TORQUES 112000 VDT amp 17 05042011 MOT12000T20 COIL AND CARTIDGE TORQUE A tighten cartridge to 22 27 N m 16 20 LBF FT B tighten cartridge nuts to 5 7 N m 4 5 LBF FT 10 Maintenance and Repair manual and installation guide OIL SPECIFICATIONS No MAINTENANCE OIL SPECIFICATION
18. and operating temperatures for the engine and transmission Air clean the radiator if necessary e The engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and ma ximum no load governed speed specifications HYDRAULIC CHECKS 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 Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the con verter and its fluid circuit lines must be fully charged filled at all times 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 CHECKS WITH COLD OIL 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 Refer to 7 2 1 Stall test BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGI NE AND CONVERTER AT STALL RPM Maintenance and Repair manual and installation guide 23
19. ation 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 CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lintless absor bent wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound INSPECTION 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 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 OIL SEALS GASKETS ETC Replacement of spring load oil seals O 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 o
20. e 11 MAINTENANCE A gt lt a OIL SPECIFICATIONS 112000 VDT 8 17 VALID FOR VDT12000 amp 112000 NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hours for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contami nation Judgement must be used to determine the required change intervals for extreme conditions EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metal analysis can provide useful information but a transmission should not be removed from service based solely on this analysis VALID FOR T12000 SUMP PREHEATERS Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up FILTERS Service oil filters element every 1000 hours under normal environmental and duty cycle conditions Dexron is a registered trademark of GENERAL MOTORS CORPORATION 12 Maintenance and Repair manual and installation guide o MAINTENANCE 112000 VDT amp 17 T12000 3 4 6 speed Lana T12000 3 4 6 speed MAINTENANCE INTERVALS DAILY Check oil level daily with engine running at idle 600 RPM and oil at 82 93 C 180 200 F Maintain oil level at full
21. e 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 studies the instructions in this manual carefully and uses it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAY PRODUCTS appro ved 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 PRODUCTS 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 PRODUCTS TOWING OR PUSHING 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 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 CORPORATION All rights res
22. erved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instruction must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced by a spare part which has the same part number or with an equivalent part Do not use a spare part of lesser quality The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare part service procedure or tool which is not recommended by SPI CER OFF HIGHWAY PRODUCTS must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the spare part service procedure or tool selected NOTE IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTI CES THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL IN JURY DURING SERVICE OR REPAIR OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE NOT EX
23. f the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lip of seal seriously impairs its ef ficiency When assembling new metal type sealing rings these should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recom mended type Automatic Transmission Fluid before assembly 2 Maintenance and Repair manual and installation guide o CLEANING AND INSPECTION 112000 VDT 4 17 WEIER ana GEARS AND SHAFTS 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 HOUSINGS COVERS ETC Inspect housings covers and bearing caps to ensure that 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 conditions which would cause subsequent oil leaks or failures Maintenance and Repair manual and installation guide 3 TECHNICAL SPECIFICATION 8 ee T12000 3 4 6 speed 112000 VDT amp 17 TECHNICAL SPECIFICATION
24. mark NORMAL DRAIN PERIOD Normal drain period and oil filter element change are for average environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterio ration and contamination For extreme conditions judgement must be used to determine the required change intervals EVERY 1000 HOURS Change oil filter element Drain and refill system as follows Drain with oil at 65 93 C 150 200 F 1 Drain transmission Remove and discard filter Install new filter Refill transmission to FULL mark Run engine at 500 600 RPM to prime convertor and lines Recheck level with engine running at 500 600 RPM and add oil to bring level to FULL mark When oil temperature is hot 82 2 93 3 C 180 200 F make final oil level check and adjust if necessary to bring oil level to FULL mark Hi P U N NOTE IT IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION ON NEW REBUILT OR REPAIRED UNIT Maintenance and Repair manual and installation guide 13 MAINTENANCE a gt lt a T12000 3 4 6 speed 112000 VDT amp 17 SERVICING MACHINE AFTER COMPONENTS 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
25. mission as sembly oil cooler filter connecting lines and controls including the engine as a complete system By analysing 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 112000 TRANSMISSION 112000 power shift with torque converter transmission troubles fall into three general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning correctly the correct functioning of the hydraulic circuit 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 en sure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working com ponents TROUBLESHOOTING PROCEDURES STALL TEST A stall test to identifies transmission converter or engine problems Use following 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 3 Select the highest speed With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission converter outle
26. t oil temperature reaches the operating range DO NOT OPERATE THE CONVERTER AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TI ME SHIFT TO NEUTRAL FOR 15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPE RATURE IS REACHED EXCESSIVE TEMPERATURE 120 C 250 F MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES FLUID CONVERTER AND SEALS 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 transmission lubrication pressure can also be measured 22 Maintenance and Repair manual and installation guide o TROUBLESHOOTING GUIDE 112000 VDT amp 17 T12000 3 4 6 speed Lana MECHANICAL AND ELECTIRCAL CHECKS Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and elec trical checks should be made e Check the parking brake and inching pedal for correct adjustment e Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points e The controls are actuated electrically Check the wiring and electrical components e Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling
27. tion guide 5 TECHNICAL SPECIFICATION o Bana CATION 112000 VDT amp 17 VDT12000 ang SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 O BELGIUM O MODEL SERIAL IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number WEIGHT DIMENSIONS OIL CAPACITY TRANSMISSION WITH A 3 SHAFT DROP BOX Weight dry 255 kg 562 Lbs Max lenght 529 3 mm 20 84 Max Width 872 0 mm 34 33 Max Heigth 619 2 mm 24 38 OIL CAPACITY Transmission 13 5 I 3 6 US gallon without cooler and hydraulic lines Consult Operator s Manual on applicable machine for system capacity Drop Box 0 75 I 0 2 US gallon 6 Maintenance and Repair manual and installation guide o TECHNICAL SPECIFICATION ll 2000 VDT amp 17 WEIGHT DIMENSIONS OIL CAPACITY RING TRANSMISSION WITH A 4 SHAFT DROP BOX Weight dry 255 kg 562 Lbs TRANSMISSION WITH A 4 SHAFT DROP BOX Weight dry 272 kg 600 Lbs 4 SHAFTS DROP BOX Max lenght 529 3 mm 20 84 Max Width 1007 2 mm 39 66 Max Heigth 619 2 mm 24 38 OIL CAPACITY Transmission 13 5 3 6 US gallon without cooler and hydraulic lines Consult Operator Drop Box 1 0 0 26 US gallon NOTE THE OIL OF THE DROP BOX IS COMPLETELY SEPARATED FROM THE OIL OF THE TRANSMIS SION Maintenance and Repair manual and inst
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